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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to an automated placket shirt front forming machine and method for sewing placket shirts applicable to chain stitch, lock stitch and other types of sewing machines to provide a completely automatic apparatus and method which allows the machine operator to sew placket shirt fronts without having to master the art of sewing. More particularly, the present invention pertains to apparatus and method which requires the operator only to properly line up the placket shirt front, the placket and liner before activating the machine which then automatically completes all sewing, mitre and thread cutting and stacking of the finished placket shirt front.
The apparatus includes means for clamping and transferring the properly aligned parts to a means for sewing and slitting the placket shirt front, means for mitre cutting, thread cutting and stacking finished placket shirt fronts. The method of the invention includes the automatic sewing, mitring and stacking of placket shirt fronts by initiating the sewing of the placket shirt front, placket and liner intermediate the ends of the placket shirt front and sewing to one end of the placket shirt front.
The present method and apparatus of the invention provides for the automatic positioning of the material under the sewing machine and automatically sewing and incrementally advancing the placket shirt front maintained by the sew clamp through the sewing machine in coordination with the movement of the needle and slitting operation from a point intermediate the ends of the placket shirt front to one end of the placket shirt front. The invention provides an inexpensively formed placket shirt front that reduces labor and waste of placket shirt material components while increasing the precision and quality of the finished garment.
2. Description of the Prior Art
The prior art includes a variety of patents pertaining to semi-automatic sewing machines for sewing or providing assistance in the formation of garments such as placket shirt fronts. It is well recognized in the prior art and the placket shirt industry that the formation of placket shirt fronts involves considerable time, labor and skill of the placket sewing machine operator in not only positioning the placket shirt front, placket and liner but also in maintaining the position of the components during sewing so that the seams are straight and the placket shirt front when turned is not crooked, puckered or otherwise of an unacceptable quality. It is also recognized by those skilled in the art that formation of placket shirt fronts having buttoned fronts are generally even more difficult to produce as the tolerances in properly laying out and sewing the components of placket shirt are more demanding. For example, if stitching on either side of the placket or the slitting is not exact, the placket shirts formed may have a non-aligned front producing a "seconds" quality shirt. The skill of the sewing machine operator has heretofore been extremely important in lining up and sewing up the placket from the top or neck portion of the shirt down to the center or chest portion of the shirt. The traditional method of sewing placket and improvements in the prior art method of sewing placket shirts type shirts from the neck down has been the subject of various patents.
One such patent, Scott U.S. Pat. No. 3,871,307 pertains to a placket forming machine which employs a chain stitch sewing machine and provides a fabric workpiece clamp which is employed to clamp the garment and thereafter advance along a track at a regulated speed employing a hydraulic cylinder to advance the garment and clamp in the sewing operation. After completion of the sewing machine, a pair of knives are automatically engaged to pick up the stitch forming threads and to sever the threads. After the threads are severed, the clamp returns to the start position.
The operation of the chain stitch machine in Scott et al, U.S. Pat. No. 3,871,307 at best provides a semi-automated placket forming machine that requires considerable attention of the sewing machine operator and does not position, mitre, remove, or sew placket shirt fronts utilizing either the apparatus or method of the present invention to form the placket shirt front and also stack the finished product. In U.S. Pat. No. 3,871,307 the clamp assists the placket machine operator by guiding the aligned placket shirt parts through the machine. The apparatus and method disclosed in U.S. Pat. No. 3,871,307 is materially different than provided by the present invention since in the prior art patent the operator still begins sewing of the placket shirt and thereafter sews downward from the neck to the center of the shirt. Thereafter a chain stitch cutting apparatus engages the thread and cuts the thread so that the placket shirt front may thereafter be removed by the operator.
The operation of the placket shirt forming machine as described in U.S. Pat. No. 3,871,307 requires the operator to still operate the machine in coordination with the guidance of the placket clamp and necessitates the mitre cutting and stacking of the placket shirt front before beginning work on the formation of a second placket shirt which similarly requires the operator to line up the shirt front, placket and liner.
The present invention by way of contrast is not limited to any particular type of sewing machine and is completely automatic in that it only requires the operator to layer the garment materials. Once the materials are properly layered, the apparatus of the present invention automatically positions the garment under a sew clamp which then positions the garment under the sewing machine, sews, mitre cuts, cuts sewing threads and stacks the shirt front without further attention or skill of the operator. The fully automatic process of the invention is aided by a novel method in which the traditional method of sewing placket shirts starting from the neck of the shirt and sewing down to the center of the placket shirt is replaced by a method in which the placket shirt is sewn starting from the center portion of the shirt up to the neck or top of the shirt while the machine is slitting the liner, placket and shirt front. The method of the present invention allows the construction of a fully automated placket shirt forming machine that is not subject to the disadvantages and limitations in prior art placket sewing machines.
In Dorosz, U.S. Pat. No. 3,814,038 a sewing machine is provided having a pallet for supporting a workpiece for movement relative to the tool. The pallet is mounted on a moving means that is synchronized for movement with respect to the operation of the sewing machine needles. U.S. Pat. No. 3,814,038 does not pertain to placket forming machines. Dorosz does not suggest or contemplate the utilization of the present combination of elements and new and useful result provided by the transfer clamp, sew clamp and the mitring, cutting, and stacking operation of the finished product that is achieved by the present invention. Furthermore, the provision for the timed motion of the pallet utilizes apparatus that is entirely different from the present invention as the timed motion for the movement of the rack and pinion in relation to the penetration of the needle utilizes a nipple and eccentric cam arrangement.
The present invention unlike the prior art begins the sewing of the placket shirt front, placket and liner by initiating the slitting and sewing of the placket shirt front at a point at the lowest point of the placket shirt and thereafter sewing up to the top or neck position of the placket shirt thereby eliminating much of the labor, attention and skill heretofore required of sewing machine operators to not only increase productivity but also the accuracy and quality of the placket shirt fronts sewn in accordance with the method and apparatus of the present invention.
As a result of the method and apparatus the present invention provides an enormous economic advantage in the production of high quality placket shirt fronts without having to rely upon the skill of the placket sewing machine operator. One of the distinguishing features of the present invention is the utilization of a transfer clamp and sew clamp to increase productivity and to initiate the sewing operation of the placket shirt from the center or mid portion of the placket to the top or the neck portion of the shirt to provide a method and apparatus for increasing not only productivity and accuracy of the placket sewn shirt but also assist in the cutting, mitring and removal of the placket shirt front and the subsequent stacking of the finished placket shirt fronts.
SUMMARY OF THE INVENTION
The disadvantages and limitations of prior art apparatus and methods for automating sewing machines and placket shirt front forming machines is obviated by the present invention which provides a fully automated, placket shirt front sewing machine and method of sewing placket shirt fronts that eliminates the labor and skill heretofore required in the formation of the placket shirt front and increases accuracy and productivity. The method and apparatus of the invention employs a high speed-type operation capable of producing about six shirts a minute or over 360 placket shirt fronts per hour if the operator could layer the components at least as fast as the present machine can sew, mitre and stack the finished product. In experimental operations of machines constructed in accordance with the invention well over 1,800 placket shirt fronts per day were produced and required only the attention of the automated placket sewing machine operator in layering and lining up the placket shirt front, placket and liner and thereafter starting the machine.
Apparatus constructed in accordance with the broadest aspects of the invention automatically engages garments and guides them to a sewing machine which initiates the sewing of the garment at a point intermediate the ends of the garment and sews from that point to one of the ends of the garment. In the preferred embodiment of the invention a transfer clamp is utilized to guide a properly layered garment to a sew clamp which automatically clamps the layered placket shirt front components and positions the components under the sewing machine thereafter activating the sewing machine to slit and sew the components together.
Upon completion of the sewing and slitting of the placket shirt components the machine automatically mitres, cuts the thread and stacks the finished placket shirt front while the operator of the apparatus is free to properly layer and line up a second placket shirt front, placket and liner so that upon completion of the stacking operation the sew clamp returns to automatically engage the placket shirt components and transfer them to the sew clamp of the placket machine for subsequent sewing and stacking.
The advantages incumbent in the present apparatus for forming placket shirt fronts stem in part from the method of sewing placket shirts which initiates the sewing operation at a point corresponding to the fullest length of the placket shirt opening and sews from that point, which is generally about the chest portion of the shirt, up to the top or neck portion of the placket shirt. Placket shirt fronts sewn in accordance with the invention not only assist in reducing "seconds" quality shirts but also increases the accuracy of shirts produced while providing means for readily and mechanically removing the placket shirt front from the placket sewing machine without requiring the attention and time of the placket shirt sewing machine operator to remove the garment from the machine.
The placket machine operator is consequently free to again line up the components while the machine is sewing, mitring and stacking the previous garment. In the preferred embodiment two guides are employed to assist the operator in properly lining up the placket shirt components of placket shirt front, placket and placket liner. The first guide device may conveniently consist of a marked positioning area or index on the placket machine work table to assist in the positioning and centering of the placket shirt front with the placket and liner.
A second guide for assisting in the positioning of the layers of the garment may be provided in the form of a light having a cross hair shining on the work table surface or other positioning means to assure the proper lining up of the components of the placket shirt front. In this embodiment all that is required is the lining up of the neck of the placket shirt body with the first guide means and thereafter lining the placket with the neck of the placket shirt body and the second guide means. Thereafter the liner is aligned with the neck of the placket shirt body and the second guide means to assure that the placket shirt front, placket and liner will be slit, sewn and properly mitred by the automated placket sewing machine of the present invention.
The activation of the present apparatus requires only that the operator depress the placket sewing machine start button to thereafter result in the placket machine automatically sewing the placket shirt without further attention of the placket machine operator. It will be recognized the advantages of this system allows the operator's attention to be directed to aligning an additional placket shirt front, placket and liner without having to divert attention to the operation of the sewing machine, stacker or any other aspect of the sewing of the placket shirt front and thereby increases production by at least 600 shirts per day over current production methods since the completion of the cycle takes about sixteen hundreths of a minute from the time they are slit, sewn, mitred and stacked at the back end of the machine.
The activation of the start button activates a transfer clamp which moves from a rest position to a position above the layered placket shirt components, at which time a second switch is activated causing the transfer clamp to clamp the layered garment composed of the placket shirt liner, placket and placket shirt front. The transfer clamp upon clamping the components activates a further switch which transports the clamped layers of cloth from the work area portion of the machine to the sew clamp by the activation of a transfer clamp cylinder which positions the layers of cloth underneath the sew clamp. As soon as the transfer clamp has positioned the layered garment under the sew clamp a further switch is activated resulting in the disengagement of the transfer clamp and its movement to a rest position which is a position intermediate the sew clamp and work area where the operator may be stacking a further shirt front, placket and liner.
The movement of the transfer clamp to the rest position activates a switch causing the sew clamp to drop down and positively clamp the placket shirt front, placket and liner which in turn initiates the travel of the sew clamp toward the foot of the sewing machine which as a result of the configuration of the sew clamp allows slitting of the garment prior to the initiation of the sewing operation. Preferably, one or more air jets are employed to blow the layered material past the foot of the sewing machine to assist in the positioning of the garment under the foot of the sewing machine prior to the lowering of the modified sewing machine foot and activation of the sewing machine. It will be recognized that the function of the transfer clamp and sew clamp may be combined so that the transfer clamp and sew clamp may be effectively combined into a single means for transferring a placket shirt front, placket and liner to the sewing machine.
Once the placket shirt front, placket and liner are positioned under the sewing machine and the foot of the sewing machine is lowered on the sew clamp over layered garment at a point corresponding to the center of the placket shirt front or the lowest part of the shirt from the neck at which the placket shirt front is designed to extend, the slitting and sewing is initiated. Once sewing is initiated, the movement of the sew clamp is thereafter advanced the length of a single stitch and only when the sewing needles are not engaged in the garment.
The advancement of the garment may be provided by for example a rack and pinion which may be driven by the hand wheel of the sewing machine by the connection of an eccentric arm to provide a one way ratcheting through an indexing clutch that preferably advances the rack for movement of the sew clamp in a timed relationship to the operation of the needles of the sewing machine. It will be recognized that at whatever the speed at which the sewing machine is operated will similarly control the speed of the sew clamp which is geared through the one way indexing clutch to ratchet the sew clamp through the sewing machine until the sewing machine has completed sewing the placket from a point intermediate the ends of the garment to one end of the garment.
In operation of the air clutch the rack and pinion mechanism is indexed to reach a predetermined position which corresponds to the neck portion of the shirt at which point the sewing machine stops. At this point a switch is activated which positions the sewing needles out of the cloth, actuates cylinder to lift the foot, and releases the thread tension and thereafter advances the sewclamp and sewn and slit garment to the proper position for the mitre cut. The mitre cutting cylinder is activated to automatically provide the mitre cut which may occur before or after but preferably after the shirt tail is clamped in the stacker unit.
After the mitre is cut the pressure on the sewing machine foot is released after the shirt is clamped the sew clamp is returned to the rest position to there after activate a cylinder connected to the raker bar which pulls the shirt and sewn layered parts from the sewing machine which places the threads in a taunt state for cutting. During the extension of the raker bar the threads are severed by a novel impact cutter. At the end of travel of the raker bar in the stacker unit the clamp is disengaged and the transfer clamp is free to move from its rest position to clamp a second shirt set up on the work table on the placket sewing machine if the start button of the machine has been again been activated by the operator signifying the completion of the task of layering the placket shirt front, placket and liner prior to the cycling of the machine.
It will be recognized that the present method and apparatus constructed in accordance therewith may be adapted to not only utilize a lock stitch machine as heretofore described, but also chain stitch machines and other forms of sewing machines. The method of sewing the placket shirt from a position at or near the center of the shirt to the top or the neck of the placket shirt allows the placket shirt to be more quickly and accurately sewn and removed from the shirt front machine. In contrast to the prior art it will be further recognized that the present placket sewing machine is completely automated with the attention of the operator being required only to stack the placket shirt front, placket and liner and engage the machine. Thereafter, the automatic placket sewing maching transfers, sews, cuts and stacks the final product at the back end of the machine.
Among the many advantages incumbent in the present invention is that the automated placket sewing machine of the present invention eliminates much of the time, skilled labor and error of prior art operations. Furthermore, the sewing of the placket from the center of the shirt to the top of the shirt eliminates many of the problems involved in the removal of the placket shirt front from the sewing machine and allows a wide variety of mechanisms to be utilized to perform the positioning, slitting, sewing, mitring and stacking of a finished placket shirt or other garment. Moreover, as a consequence of the design and construction of the invention, the present invention is far less expensive to operate and provides a more precisely formed placket shirt front at a higher rate of production than has heretofore been accomplished by prior art apparatus.
DESCRIPTION OF THE DRAWINGS
Other advantages of the invention will become apparent to those skilled in the art from the following detailed description of the invention in conjunction with the appended drawings in which:
FIG. 1 is a perspective view of a placket shirt front forming machine constructed in accordance with the invention;
FIG. 2 is a front elevation view of a portion of a placket machine utilizing the present invention;
FIG. 3 is a top plan view illustrating a portion of the work table of the automated placket forming machine of the invention;
FIG. 4 is a top plan view of a liner illustrating a guide means provided in accordance with the invention;
FIG. 5 is a top plan view illustrating the transfer clamp and placket aligning guide means;
FIG. 6 is a perspective view of a portion of a placket forming machine of the present invention;
FIG. 7 is a side elevation view from the right side of a fully automated placket sewing machine in accordance with the invention;
FIG. 8 is a rear elevational view of the means for driving the placket forming machine of the present invention;
FIG. 9 is a portion of a left side elevation view of a portion of the placket forming machine in accordance with the present invention;
FIG. 10 is a perspective view of the mitre positioning engagement mechanism;
FIG. 11 is a partial side elevational view of the mitre, thread cutter and a portion of the sewing machine of the automated placket forming machine;
FIG. 12 is an elevational view from the rear of one form of the placket forming machine of the invention;
FIG. 13 is a right side elevational view of the stacker portion of the placket forming machine; and
FIG. 14 is a left side elevational view of the stacker of FIG. 13.
DETAILED DESCRIPTION OF THE INVENTION
Referring now to FIGS. 1 and 2 a placket shirt forming machine 20 constructed in accordance with the invention is provided having a flat smooth table 22. Table 22 may be conveniently divided into areas 24, 26, and 28. Area 24 may be utilized for receiving placket shirt bodies 30 which can be layered in work area 26 along with placket 32 and liner 34 in a manner well known in the art. To facilitate production a work box 36 may be attached to a work table 22 utilizing a support structure 38, although it will be recognized that alternative configurations and utilization of the work area 26 and work box 36 are possible to suit particular requirements. Work area 26 may conveniently include a first alignment means such as marker 40 for centering and positioning the top or neck areas of body 30, placket 32 and liner 34 on work area 26.
Work box 36 provides a support for the attachment of a second alignment means such as positioning and alignment of placket shirt body 30, placket 32 and liner 34 on the work table 22. First guide means or marker 40 may be adjustable or include markings to accomodate the positioning of a variety of styles of placket shirt fronts. Second guide means 42 is preferably adjustable along with the travel of the sew clamp to accomodate variations in desired length of placket shirt front openings. Work table 22 is preferably smooth and provides little friction to the sliding of cloth across the surface from areas 26 to 28 for reasons that will become apparent.
With reference now to FIGS. 1, 2, 3, 4 and 5 it will be appreciated that the operator of the fully automated placket machine has only to properly layer placket shirt body 30, placket 32 and liner 34 in work area 26. To assist the operator in the proper alignment of the shirt body 30, placket 32, and liner 34 a first guide means 40 is provided in work area 26 of table 22. The operator thereafter aligns the placket 32 and liner 34 by utilizing the shirt body 30 and guide means 40 in conjunction with a second guide means 42 to assure the proper positioning of the garment on table 22 so that the automatic placket sewing machine of the invention may thereafter sew, mitre, cut and stack the sewn placket shirt front without requiring further labor or attention of the operator of the placket machine.
In the alignment and layering of the garment the operator lines up the center of the neck portion 46 in alignment with the first guide means 40 and then takes a placket 32 and similarly aligns it with guide means 40 and the light provided by second guide means 42 so that the cross hair 48 (FIG. 4) is directed down to a T-shaped cut in the placket to assist in the alignment of the placket shirt parts in the manufacture of placket shirts. The operator then takes a liner 34 and similarly aligns it at the neck portion 46 on the placket 32 in alignment with the first guide means 40 and the second guide means 42 so that cross hair 48 is similarly in alignment with the notched out portion 52 of the bottom portion 50 of the liner 34 (FIG. 4).
Once the alignment and layering of the garment components is complete, the operator of the automatic placket sewing machine has only to depress start switch 54 to complete not only the placket sewing, but also the cutting, mitring and stacking of the finished placket shirt front. As is understood by those skilled in the art of placket shirt construction the proper positioning and maintenance of layers during the sewing operation is the most critical part in the process of making placket shirts. This aspect of the construction of placket shirt fronts is achieved with a great deal of precision in the present invention by the utilization of clamps to align and maintain the position of the layers of cloth in the fully automated operation of slitting, sewing, mitring and stacking of the garment. While the present automatic placket machine in the preferred embodiment utilizes air driven cylinders to actuate the various mechanical movements it will be understood by those skilled in the art that the present invention may be utilized by employing other fluid, electrical or other driving means.
Once switch 54 is depressed the operation of the automated placket forming machine is provided by the triggering of additional switches by the mechanical motion and timed inter-relationship of the functions of transferring the cloth to the sewing machine, slitting, sewing, mitring, cutting the threads and the ultimate stacking of the finished placket shirt front. In this manner, errors resulting from inadvertence, inattention or fatigue can be eliminated by the provision of the present completely automated placket shirt forming machine. Actuation of switch 54 results in transfer clamp assembly 56 moving from its rest position as illustrated in FIG. 1 to work area 26 on table 22 to a position above the layers of cloth forming the placket shirt front. Transfer clamp assembly 56 is positioned over the layered shirt front by the actuation of a transfer clamp cylinder 58 extending rod 60 which may be conveniently actuated by air pressure, hydraulic pressure or other fluid or electrical impulses. Lower frame 62 of transfer clamp assembly may be of a rectangular configuration which may travel on rails 64 and 66 designed to span work areas 26 and 28 of table 22. Upon completion of travel to a position above the placket shirt body lower frame 62 of transfer clamp assembly 56 contacts a switch 68 which causes the top portion 70 of transfer clamp assembly 56 to clamp down on placket shirt front 30, placket 32 and liner 34 which in clamping down (FIG. 5) results in the activation of switch 72.
Once switch 72 is activated rod 60 is retracted in cylinder 58 thereby transferring clamp assembly 56 and placket shirt body 30, placket 32 and liner 34 across the surface of table 22 to area 28 and position the transfer clamp assembly under sew clamp or sew clamp assembly 74. At the end of the travel of rod 60 switch 76 is closed which releases air pressure in both cylinder 58 and cylinder 78 which as a result of the action of spring 80 raises transfer clamp portion 70 to release the placket shirt body, placket and liner in the alignment position for subsequent clamping and sewing under sew clamp assembly 74. The release of pressure in cylinder 78 and the action of spring 80 lifts the top portion 70 of transfer clamp assembly 56 to clear the raised sew clamp assembly 74 and raised sewing machine foot assembly 82 and at the same time activates a further switch 86. The activation of switch 86 energizes cylinder 57 to result in the travel of transfer clamp assembly 56 back to its rest position as illustrated in FIG. 1.
A particularly advantageous aspect of the present invention is that transfer clamp assembly 56 places the placket shirt body, placket and liner directly under the sew clamp assembly 74 so that the center portion 84 (FIG. 4) of liner 34 which is layered over placket and shirt body and which may be partially pre-slit, is positioned directly under sew clamp assembly 74 so that the center slot 90 (FIG. 6) of sew clamp 74 is in direct alignment with the partially perforated center portion 84 of the liner 34 (FIG. 4). It will be recognized that center portion 84 of the liner which is layered over the placket and shirt body is in slot 90 of sew clamp 74 and is in direct alignment with slitter knife 94 also disposed on the sewing needle assembly 96 of sewing machine 98. As heretofore described the sewing machine employed is for the purposes of illustration a lock stitch machine made by one of the commercial manufacturers such as Singer but it will also be understood that the present invention is applicable to a variety of machines such as chain stitch and other types of sewing machines.
Needles 100 and 102 are in direct alignment with slots 104 and 108 of sew clamp assembly 74 so that upon actuation of sewing machine 98 the liner, placket and shirt body are automatically both slit and sewn during the operation of sewing machine 98. The method of the present invention along with the efficient sew clamp assembly 74 allows the cloth to be slit and sewn at about the same time during the operation of the sewing machine. As heretofore been described the activation of switch 86 results in the activation of cylinder 57 resulting in the return of transfer clamp assembly 56 to its rest position as illustrated in FIG. 1. Once transfer clamp assembly 56 has moved to the rest position, switch 110 is activated (FIG. 2) which activates cylinder 112 and causes the sew clamp assembly 74 to firmly clamp the placket shirt body, placket and liner. The clamp of sew clamp assembly 74 on the placket shirt body, placket and liner results in lowering of the sew clamp on guide rods 114 and 116 resulting in the activation of a switch 120 (FIG. 6).
Activation of switch 120 results in the activation of air jets 122 and 124 which are directed toward sewing machine 98 and assist in blowing the tail of the shirt out and under the sewing machine foot assembly 82. In this manner, the tail portion of shirt body 30 is guided toward the stacker unit 126 for subsequent slitting, sewing, mitring, thread cutting and stacking. Switch 120 also may activate sew clamp cylinder 128 to advance the sew clamp to the start sew position under sewing machine foot assembly 82. The advancement of the sew clamp assembly 74 by cylinder 128 to the start sew position, lines up the needles 100 and 102 and the slitter knife 94 with slots 104, 108 and 90 of the sew clamp assembly 74. Upon the advancement of sew clamp 74 to its start sew position under foot assembly 82 of sewing machine 98 a switch 130 is activated causing cylinder 132 to drop foot assembly 82 on top of sew clamp 74. Foot assembly may conveniently include four rollers 134 for rolling on the top of sew clamp assembly 74 which further assists in the operation of the slitter knife 94 so that slitting of the garment can occur either before or simultaneously with the sewing operation. It will be recognized that sewing of the placket shirt begins at the center or a point intermediate the ends of the garment such as at position 136 and sews from there to the top of the neck portion of the shirt to provide the advantages of the present invention.
The activation of switch 130 may also be utilized to activate air clutch 138 which may be a suitable air clutch model such as Horton model BW air clutch. Sew clamp assembly 74 which is supported by arm 118 is pushed to sew position by cylinder 128 and is associated with air clutch 138 through a pinion 140 which is associated with rack 142. Rack 142 is operatively connected to sew clamp 74 by supports 144 and 146 at one end and arm 118 at the other end which are adapted for slideable engagement on rods 148 and 150 and which when engaged at the start sew position is thereafter controlled by the action of air clutch 138 and the drive of rack 142 by pinion 140.
Activation of switch 130 can also result in starting the operation of sewing machine 98 which is connected to air clutch 138 by means of a cam assembly 152 which results in an incremental ratcheting of pinion 140 in rack 142 resulting in sew clamp assembly 74 being incrementally advanced in coordination with the length of the stitches sewn by needles 100 and 102 and the speed of the sewing machine in the advancement of the sew clamp 74.
Referring now to FIGS. 6, 7, 8, 9 and 10 the operation of sewing machine 98 in coordination with the advancement of sew clamp 74 will be briefly examined. Cam assembly 152 provides for the incremental advancement of sew clamp 74 by employing an arm 154 which is connected to air clutch 138 by a shaft 156 having a slotted arm member 158 having a slot 160 for adjustment of the cam assembly 152 which is attached to the sewing machine handwheel 162. Cam assembly 152 is eccentrically mounted to center shaft 164 of sewing machine handwheel 162 by a bearing assembly 166 of arm 154 so that once in every revolution rack 142 advances when needles 100 and 102 are withdrawn from the garment.
The function of slot 160 is to adjustably position a pin 168 in the slot so that upon each revolution of the sewing machine handwheel the rack 142 is advanced in accordance with the length of each stitch sewn by needles 100 and 102 of the sewing machine 98. The air clutch 138 and a one directional clutch, housed in the shaft area of arm 158 is utilized for incrementally advancing pinion 140 in rack 142. After dropping of sewing machine foot assembly 82 by cylinder 132 switch 130 or preferably a further switch 169 which causes the machine to begin sewing and advancing as pinion 140 incrementally advances along rack 142. The sewing, slitting and movement of the sew clamp 74 past the sewing machine 98 continues until the sewing machine and sew clamp 74 has advanced a predetermined distance which corresponds to the length of the placket shirt opening from the center of the shirt to the top or neck portion of the shirt.
The method of the present invention unlike prior art methods and apparatus for sewing placket shirts, starts at the center of the shirt and sews up to the top or neck portion of the shirt. The present method consequently is conveniently adaptable to chain stitch, lock stitch and other types of sewing machines to provide an easy method for removing the sewn, slit and mitred placket shirt front from sewing machine 98.
Indexing of the rack 142 and operation of the sewing machine continues until the machine has reached the end of travel. The length of travel of the rack 142 may be conveniently set by the positioning of a stop guage 170 in a slotted member 172 so that as soon as rack 142 has traveled the predetermined distance a switch 176 is contacted which corresponds to the predetermined point 180 on sew clamp assembly 74. This position may be conveniently altered by modifying the position of the stop guage 170 in slot 184 of slotted member 172. As soon as switch 176 is contacted sewing machine motor 190, located underneath the sewing machine 98 is stopped and air clutch 138 is deactivated so that pinion 140 is free to rotate and travel in rack 142.
Referring now to FIG. 8, the switches on sewing machine motor 190 are illustrated wherein a switch 192 is activated as soon as sewing machine motor 190 is deactivated to prevent further operation of the machine in the sewing operation. As soon as switch 192 is activated, the handwheel position locking assembly 198 is allowed to engage a notched out portion 204 in sewing machine handwheel 162. Handwheel 162 is connected to pulley 196 of the motor 190 via a belt 202 which assures the braking of sewing machine handwheel 162 as pressure is applied to cylinder 212 forcing a stop mechanism 214 into the corresponding notch or notched out portion 204 in handwheel 162.
In the preferred embodiment of the invention a small positioning motor illustrated as 220 on motor 190 may be employed to turn motor 190 slowly until stop mechanism 214 is locked into the notch 204 on sewing machine handwheel 162. Once stop mechanism is engaged in notch 204 on handwheel 162 the needles 100 and 102 along with slitter knife 94 are removed from the material. The activation of cylinder 212 and the locking of stop mechanism in notch 204 of handwheel 162 actuates switch 222 which extends cylinder 132 of foot assembly 82 of sewing machine 98 and thereby raises foot assembly from the sew clamp assembly 74 and the sewn placket shirt front, sewn placket liner and placket.
The activation of switch 222 may also be utilized to activate a mitre positioning cylinder 236 (FIGS. 6 and 10) which advances the sew clamp 74 to the mitring position for the mitre cut. Mitre positioning cylinder is associated with sew clamp by suitable means such as a pinion and rack assembly associated with sew clamp assembly 74. Sew clamp assembly includes a positioning bar 228 suitably attached to sew clamp 74. Positioning bar 228 which includes a series of holes 230 that are designed to be engaged by cylinder rod 232 having a cone shaped tip 234 to assist in the engagement of one of the predetermined holes 230 or bar 228. The advancement of tip 234 into one of the holes 230 is assisted by cylinder 236 which when extended activates a further switch 238.
Activation of the mitre positioning cylinder 236 in combination with the mitre positioning means 226 operates to precisely position the sewn placket shirt front for the mitre cut. As will be appreciated by those skilled in the art the engagement of one of the holes 230 by the activation of mitre positioning tip 234 is preset according to the length of the placket portion of the placket shirt and is a critical aspect in the manufacture of placket shirts. More particularly, the positioning of the mitre of the mitre cut must be within a few stitch lengths in order for the mitre cut to be properly oriented and positioned on the shirt to provide a quality placket shirt.
Once mitre positioning means 226 has locked sew clamp 74 into proper position for the mitre cut switch 238 is activated energizing cylinder 240 (FIG. 11) forcing a V-shaped mitre cutting blade 242 down through the placket shirt front cloth and through V-shaped opening 244 (FIG. 6) in sew clamp 74 and through shirt body 30 and into a corresponding nylon insert 246 in table 22 to result in the formation of the wedge shaped mitre cut in the sewn placket shirt front. Mitre cutter assembly 248 along with nylon insert 246 may be slideably mounted with respect to table 22 to allow the adjustment of the mitre to accomodate a variety of shirts. A slot 250 may be provided in member 252 which may be attached to sewing machine 98.
In addition to mitring the shirt, switch 238 may be employed to activate the stacker unit 126 (FIGS. 6, 7, 12, 13 and 14). Once the shirt has been advanced to the mitre cut portion the bottom portion of the placket shirt body 30 (FIGS. 7 and 14) is allowed to drop over the back end of table 22. Switch 238 may be utilized to clamp the bottom portion 254 of the shirt in a shirt clamp formed by a support 256 of a wedge shaped table 258 mounted on rollers 260 to ride in tracks 262 to allow the lateral movement with respect to a stationary bracket or bar 264. The activation of the clamp may be provided by a cylinder 266 (FIG. 14) or other available means to clamp support 256 against bracket 264. As will be discussed in greater detail a means is provided to maintain constant tension for the shirt clamp independent of the number of layers of shirts previously stacked on table 258.
Referring now to FIGS. 13 and 14 the operation of the stacker unit is illustrated wherein table top 258 a number of placket shirt fronts 287 are positioned on wedge shaped stacker table 258. In the rest position (FIG. 13), the wedge shaped stacking element is spaced from bracket 264 at a sufficient distance to allow a further shirt front bottom portion 254 to be received by the stacker unit 126. Switch 238 may also be employed before or after the mitre cut to activate cylinder 266 and thereby clamp bottom portion of shirt bodies 30.
Preferably the activation of cylinder 266 occurs after the mitre cut so that clamping of the shirt bottom portion 254 results in the activation of a switch 268 which results in the raising of sew clamp 74 to return the sew clamp to its starting position (FIG. 1). Switch 268 which is mounted to bracket 308 may also be conveniently employed to activate a cylinder 284 which is connected to raker bar 282 to pull sewn shirt and threads from sewing machine 98 in direction of arrow 285 (FIG. 14).
After a predetermined amount of travel the raker bar 282 actuates a switch 283 which activates cylinder 270 (FIG. 11) to drop a wedge shaped knife 272 to cut the threads pulled from the sewing machine needles 100 and 102. A mating element 274 is preferably disposed flush with table 22 and includes a slotted opening in which the sides 276 and 278 are razor sharp so when the threads from the machine needles is pressed into the slotted opening the threads are cut by wedge shaped knife 272. When raker bar 282 releases switch 283 it retracts cylinder 270 moving wedge shaped knife 272 to its start position so that when raker bar 282 reaches its full travel in the direction of arrow 285 (FIG. 14) it actuates switch 286. At this point shirt body 30 is thereby stacked on a wedge shaped table 258 over a number of layers of previous shirt fronts 287.
At the end of the travel of raker bar 282 the shirt is layered and switch 286 is contacted which returns the raker bar to its rest position. In returning to the rest position raker bar 282 contacts a futher switch 288 which results in the unclamping of the stacker unit 126 and returning the wedge shaped stacking table 258 back to its rest position.
The return of the wedge shaped table 258 to substantially the same position in the stacking operation to result in opening 290 is maintained at substantially the same distance which is achieved by an adjustable tensioning means 292 that also assists in maintaining the same amount of clamping pressure on the shirt fronts irrespective of the thickness of the layers of the shirt fronts. The adjustable tensioning means 292 may include a slotted arm 294 in which a threaded or other cylindrical peg 296 is tensionally engaged by the action of nuts 298 and 300 and the action of spring 302 which allows peg 296 to slide in slotted arm 294 when support 256 attached to platform 304 with or without layered parts 287 applies pressure on stationary bar 264. The forward travel of the slotted arm 294 terminates when cylinder 266 reaches its full extension. When slotted arm 294 reaches the end of its forward travel the lower portion of slotted arm 294 contacts switch 268 which activates sew clamp 74 to raise and also activates sew clamp 74 to return to its start position. When platform 304 contacts stops 306 platform 304 is reset to its start position.
Upon completion of the stacking of the shirt by the actuation of raker bar 282 and activation of switch 288 terminates the cycle of the stacking and clamping mechanism 126 and opens the clamp so that a futher shirt may be received. The actuation of a switch 288 may be utilized to allow the resetting of switch 54 or if already reset start the machine to again activate the transfer clamp to clamp and transfer the shirt to sew clamp and complete the cycle as heretofore described. It will be recognized by those skilled in the art that other switching arrangements are possible such as the return of the sew clamp activating the transfer clamp to restart the operation even prior to the stacking of the previous shirt.
Despite the particular arrangement of switching it will be recognized that the present apparatus and method requires the operator of the machine to only stack the shirt body, placket, and liner in there proper position and to initiate the operation of the placket sewing machine to produce a sewn, mitred, and stacked placket shirt front without futher manual operation. As a result, much of the human error, labor and skill heretofore required in the manual operation of the sewing of placket shirt fronts is eliminated by the fully automated system of the present invention.
It will be recognized that the advantages of the method of the invention which starts sewing at or near the center of the shirt and thereafter sews from the center up to the top of the shirt, allows the placket shirt fronts to be formed automatically and allows various types of sewing machines to be utilized, such as chain stitch, lock stitch and other varieties of sewing machines. Furthermore the method and apparatus of the present invention allows the formation of precisely sewn and mitred placket shirt fronts thereby improving the quality of placket shirt fronts and reducing the number of "second" quality shirts produced. Production of placket shirt fronts by the method and apparatus of the present invention is extremely rapid since the entire cycle of the machine takes about 16 hundredths of a minute to complete. Consequently about 6 shirts a minute can be produced provided the operator could keep up with the apparatus of the present invention.
The present invention is amenable to a wide range of applications even though it is particularly useful in providing for the production of an automated placket shirt front apparatus. For example the present method and apparatus may be utilized in the construction of types of garments utilizing a placket like shirt opening and for sewing various styles of garments. The invention is therefore susceptable to many mechanical modifications that could be made by those skilled in the art to utilize the present method to accomodate a variety of garments by modifications in the means for lining up and transferring the garment and modifications in the rack and pinion arrangement of the sewing machine. The application of the invention to the variety of operations to which it may be employed contemplates the modification to include a greater or lesser number of switches and the simultaneous performance or a number of functions either in direct relationship with one or more of the switches described or the elimination of certain switches.
In addition, the precise mechanical systems and their configuration described for the mitring, transferring and providing for the travel of the transfer clamp, sew clamp, mitre and stacking unit, may of course be modified to suit particular requirements.
It will also be recognized by those skilled in the art, that while the present system as has heretofore been described in the preferred embodiment employs a pneumatic or air system for driving the cylinders to perform the variously described functions. It will be understood the present invention may be implemented in a variety of ways such as the utilization of electric systems, computer-type systems of other types of switching and driving mechanisms and may utilize a timing mechanism for coordinating the relationship between the various functions in the operation of the machine.
It will be further recognized that variations the placket forming machine and stacker unit may be made to suit particular design and manufacturing requirements for various types of garments. It will further be recognized the advantages incumbent in the present invention, such as efficiency of use and the reduction of labor, increased production and quality of the finished garment may be implemented in a number of ways to suit a variety of manufacturing designs and requirements which are within the contemplation of the present invention. These and other modifications and other applications of the present invention may be made within the spirit and scope of the invention as defined in the appended claims.
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An automatic placket shirt front forming machine and method for sewing placket shirt fronts is provided which utilizes an apparatus and method to automatically position, sew, mitre cut and remove a sewn placket shirt front and stack the placket shirt front. The method and apparatus requires the operator to only master the task of properly layering the material which may be facilitated by utilizing a set of guides. Once the material is layered and aligned, the operator has only to activate a start or reset button to clamp, transfer and position the placket shirt front and automatically start the sequential operation of sewing and mitre cutting, thread cutting and stacking of the finished placket shirt front. The method of the present invention forms placket shirt fronts by initiating the sewing of the placket shirt from the bottom of the placket shirt opening and sewing outwardly to the top or neck portion of the shirt resulting in the application of the invention to chain stitch, lock stitch and a variety of other types of sewing machines. The present apparatus includes means for incrementally advancing the placket shirt front as the sewing machine slits and sews the garment and thereafter automatically positions the garment for the mitre cut and automatically removes and stacks the shirt.
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This application claims Priority from Provisional Application 60,365,809 filed on Mar. 21, 2002.
FIELD OF THE INVENTION
Present invention relates to a novel, aerobic biological process for the degradation of lignin using the defined consortium of ligninolytic bacteria isolated from the specific site.
DESCRIPTION OF THE PRIOR ART
Fungi
Lignin is the most abundant aromatic polymer in the biosphere. It is found in the cell wall of all vascular plants in association with cellulose and hemicellulose. Because inter-unit bonds in lignin are not hydrolysable, lignin is difficult to degrade either chemically or biologically. Lignin surrounds cellulose in the plant cell wall forming a matrix, which is itself resistant to degradation. Lignin biodegradation is responsible for much of the natural destruction of wood in use, and it may have an important role in plant pathogenesis. On the other hand, potential applications utilizing lignin-degrading organisms and their enzymes have become attractive, because they may provide environmentally friendly technologies for the pulp and paper industry. To date, only a few groups of organisms are capable of degrading complex lignin polymers, and they are best exemplified by the white rot fungi. Most of the research concerning biodegradation of lignin has been centered on some fungi only such as Phanerochaete chrysosporium, Streptomyces viridosporus, Pleurotus eryngii, Trametes trogii, Fusarium proliferatum (Regaldo et al., 1997) etc. (1)
Wood-rotting basidiomycetous fungi that cause white rot in wood are the most efficient lignin degraders in nature (Kirk and Farrell, 1987; Eriksson et al., 1990), and they are perhaps nature's major agents for recycling the carbon of lignified tissues. No other microorganisms as pure culture have been described to mineralize lignified tissues as efficiently (Kirk and Cullen, 1998). They are a group of taxonomically heterogeneous higher fungi, characterized by their unique ability to depolymerize and mineralize lignin using a set of extracellular lignnolytic enzymes. Lignin degradation by white-rot fungi has been intensively studied during the last thirty years in relation to biotechnical applications such as biopulping, biobleaching, treating of pulp mill effluents, and soil bioremediation (Akhtar et al., 1992, 1998; Lamar et al., 1992; Messner and Srebotnik, 1994).
The enzymology and molecular biology of lignin degradation has been mainly studied in Phanerochaete chrysosporium (Gold and Alic, 1993; Cullen, 1997; Kirk and Cullen, 1998). Many of the enzymes necessary for lignin degradation were not characterized before the beginning of the 1980s when virtually only laccase had been known. Since the discovery of two important peroxidases in the beginning of the 1980s, namely lignin peroxidases (LiPs) in 1983 and manganese peroxidases (MnPs) in 1984 (Kirk and Farrell, 1987), an array of enzymes have been isolated from fungi and characterized in detail.
LiP (lignin peroxidase) is believed to be one of the key enzymes in lignin biodegradation by white rot fungi. DNA probes specific for the genes encoding major lignin peroxidases (LiP) isozymes of P. chrysosporium were constructed. These probes were used to study the temporal expression of LiP enzymes in defined low nitrogen medium. (Boominathan et al. 1993).
Aspergilli , the versatile ascomycetes are also found to transform at a rapid rate a wide spectrum of lignin related aromatic compounds. They are shown to overproduce high levels of hemicellulolytic enzymes. (4)
Maria Teresa et al. have shown that Bjerkandera sp. Strain BOS55 is a white rot fungus that can bleach EDTA extracted eucalyptus oxygen delignified Kraft pulp (UKP) without any requirement for manganese. Furthermore, under manganese free conditions, addition of simple physiological organic acids (e.g. Glycolate, glyoxylate, oxalate and others) at 1–5 mM stimulated brightness gains and pulp delignification two to three fold compared to results not receiving acids. The stimulation was attributed to increase production of MnP and LiP as well as increased physiological concentrations of veratryl alcohol and oxalate. These factors contributed to greatly improved production of superoxide anion radicals, which may have been accounted for the more extensive biobleaching. (5)
Till now, all the basics and applied research work has centered on fungi only. In case of biobleaching of raw pulp, the application of fungi is not feasible due to its structural hindrance caused by fungal filaments. Therefore, identification of bacteria having lignin oxidizing enzymes would be of significant importance.
Bacteria
The role of bacteria in lignin biodegradation is still a matter of conjecture. Some workers have demonstrated that either mixed (Sundman et al., 1968) or pure culture of bacteria (Sorensen, 1962) can grow on lignin as a carbon source. Pseudomonas spp. was claimed by Kawakami (1976) and Odier and Monties (1977) to degrade plant lignins. Odier and Montis also indicated several other bacterial strains that can use within seven days time more than 50% of the lignin supplied in a mineral medium containing glucose.
Several Nocardia and Pseudomonas spp. as well as some unidentified bacteria, isolated from lake water containing high loads of waste lignin, were tested for their capacity to release 14 CO 2 from specifically 14 C-labelled dehydropolymer of coniferyl alcohol (DHP) or corn stack lignins. However only some of them could release significant amounts of 14 CO 2 from the labeled lignin. The tested Nocardia spp. was more active than the Pseudomonas spp. and the unidentified bacteria.(6)
Actinomycetes are filamentous bacteria which are found in soil and composts where lignocellulose is decomposed. Several reports provide evidence that several species belonging to the genus Streptomyces are able to degrade lignin. Other lignin degrading Actinomycetes include Thermomonospora mesophila, Actinomadura, Micromonospora with Streptomyces exibiting the highest lignin degrading ability. In most of the studies, the lignin degrading enzyme was produced at higher levels in cultures containing lignocellulose which suggests that an induction mechanism was active.
Ajit Verma et al.(1994) while working on symbiotic relationship between termites and their intestinal microbes concluded that both termite soil and termite gut bacteria play an important role in polymer depolymerization. Gut bacteria have the capacity to degrade cellulosic and hemicellulosic materials more efficiently. Several bacterial isolates which hydrolyze cellulose and hemicellulose have been obtained in pure culture from the termite gut. Some of these are Arthrobacter sp., Bacillus cereus, Clostridium sp., Micrococcus sp., Streptomyces sp., Serratia marcescens. Only a few xylan decomposing bacteria have been obtained from the termite gut ( Micrococcus luteuns, Pseudomonas aeruginosa ). The question of lignin degradation by termites is intriguing, since much of the termite gut is anaerobic and natural anaerobic mechanisms of lignin degradation are unknown.(7)
Berrocal et al. (1997) have shown that cell free filtrates from streptomyces sp. Grown in solid state fermentation were capable of solubilising up to 20% of the [ 14 C] lignin. The activity of two enzymes, extracellular peroxidase and phenol oxidase (laccase) was found to correlate with both solubilisation and mineralisation rates of lignin.(8)
The presence of bacteria in rotted wood often in association with fungi has been the subject of numerous reports. However, their exact role in degradation of wood components is still unclear. While the availability of nutrient nitrogen represses metabolism of synthetic 14 C lignin to CO 2 by Phanerochaete Chrysosporium, high levels of organic nitrogen were optimal for lignin degradation by the bacterium Streptomyces badius. (9)
Few bacterial isolates which exhibited a remarkable capability of bleaching the hardwood kraft pulp as reported in a previous pending patent application, have shown lignin degradation capability.
Enzymes are the catalytic cornerstones of metabolism, and as such are the focus of intense worldwide research, not only in biological community, but also with process designers/engineers, chemical engineers, and researchers working in other scientific fields. Since ancient times, enzymes have played a central role in many manufacturing process, such as in the production of wine, cheese, bread etc. The latter half of the twentieth century saw an unprecedent expansion in our knowledge of the use of microorganisms, their metabolic products, and enzymes in a broad area of basic research and their potential industrial applications. Only in the past two decades, however have microbial enzymes been used commercially in the Pulp and Paper industry. (10)
The most common application of enzymes in paper industry is to enhance bleaching. At least 15 patents or patent disclosures dealing with enzymatic treatments to enhance bleaching of Kraft pulps were submitted between 1988 and 1993.
Lignin, correctly known as “nature's plastic”, although resistant to microbial attack, certain filamentous fungi is capable of degrading it to the level of CO 2 . Until 1981, it was not even known whether enzymes are involved in lignin depolymerization. Ming Tien et al. from university of Michigan have discovered enzymes that degrade lignin.
The major enzymes involved in lignin biodegradation by fungi are two extracellular heme containing peroxidases: Lignin Peroxidase (LiP, EC 1.11.1.14) and Manganese Peroxidases (MnP, EC: 1.11.1.13) (Kirk et al., 1987), Gold et al. (1989); Hatakka (1994). The main difference between LiP and MnP is the nature of substrate that is oxidized. LiP is capable of oxidizing non phenolic or phenolic lignin structures directly to yield aryl cation radicals and phenoxy radicals, respectively. (Kirk, 1987). For MnP, the primary reducing substrate is divalent manganese ion Mn 2+ . The catalytic cycle of MnP in the presence of appropriate chelators generates highly reactive Mn 3+ chelate complexes that are able to oxidize various phenols and carbon centered radicals, respectively. (Wariishi et al., 1989; Hofrichter et al., 1998).
Usually MnP is not able to oxidize or depolymerize the more recalcitrant non-phenolic lignin structures that make up about 90% of the lignin in wood. Interestingly, it seems that primary attack on lignin requires low molecular weight agents, because LiP and other enzymes are too large to penetrate lignocellulose. (Call et al., 1997). Because of these discrepancies, it has been proposed that there are mechanisms that enable MnP to cleave non-phenolic lignin structures via the action of small mediators such as thiyl or lipid radicals. (Wariishi et al., (1989), Bao et al., (1994)).
The Mn (II) concentration of the growth medium strongly affects the secretion patterns of lignin peroxidase and laccase. Mn Peroxidase was not found in fast protein liquid chromatography profiles of extracellular proteins under either low (2.4 μM) or elevated (24 and 120 μM) Mn (II) concentrations.(16)
The role of one more enzyme, extracellular phenol oxidases (laccases) in lignin degradation has been suggested and it has recently been demonstrated that laccase can take part in lignin degradation. (Bourbonnais and Paice 1990; 1992: Srinivasan et al. 1995). Laccase is a type of copper containing polyphenol oxidase known to catalyze the oxidation of a range of inorganic and aromatic substances by the removal of electrons with the concomitant reduction of O 2 to water. But its application in Bioblecahing has to be proved yet.
CITED REFERENCES
(1) Etienne Odier and Isabelle Artaud ‘Degradation of Lignin’. Prof. Dr. Annele Hatakka, ‘Biodegradation of Lignin’.
(2) Frederick S. Archibald, ‘Lignin Peroxidase activity is not important in biological bleaching and delignification of unbleached kraft pulp by Trametes versicolor’ Appl. and Env. Microbiol., September 1992 p. 3101–3109.
(3) Brian P. Roy and Frederick Archibald, ‘Effects of Kraft pulp and lignin on Trametes versicolor carbon metabolism’, Appl. and Environmental Microbiol., June 1993, P. 1855–1863.
(4) Daurte J C, Costa-Ferreira M; ‘ Aspergilli and Lignocellulosics: Enzymology and biotechnological applications’, FEMS Microbiol. Rev., March 1994; 13 (2–3):377–86.
(5) Maria Teresa, Gumersindo Feijoo, tuned mester, Pablo Mayorga, Reyes sierra-Alvarez and Jim A. Field.; ‘Role of Organic acids in the Manganese independent biobleaching system of Bjerkandera sp. Strain BOS55 ’, Appl. and Env. Microbiol., July 1998, p. 2409–2417.
(6) K. Haider, J, Trojanowski, and V. Sundman, ‘Screening for lignin degrading Bacteria by means of [ 14 C] labeled lignin’ Arch. Microbiol. 119, 103–106 (1978).
(7) Varma A., Koll's B. K., Paul J., Saxena S., Koniig H; Lignocellulose degradation by microorganisms from termite hills and termite guts: A survey on the present state of art. FEMS Microbiology Reviews 15 (1994) 9–28.
(8) M. M. Berrocal. J. Rodriguez. A. S. Ball, M. I. Perez-Lebric. M. E. Alias. ‘Solubilization and mineralization of [ 14 C] lignocellulose from wheat straw by Streptomyces cyaneus CECT 3335 during growth in solid state fermentation’, Appl. Microbiol. Biotechnol (1997) 48:379–384.
(9) Ian D. Reid, ‘Effects of Nitrogen supplements on degradation of aspen wood lignin and carbohydrate components by P. chrysosporium’, Appl. And Env. Micro, March 1983, p. 830–837.
(10) Q. K. Beg. M. Kapoor. L. Mahajan. G. S. Hoondal, Microbial xylanases and their industrial applications, A Review’, Appl. Microbiol. Biotech. (2001) 56:326–328.
(11) J. H. Clarke, K. Davidson, J. E. Rixon, J. R. Halstead, M. P. Fransen. H. J. Gilbert, G. P. Hazlewood., ‘A comparison of enzyme aided bleaching of softwood paper pulp using combinations of xylanase, mannanase and 2-galactosidase.’ Appl. Microbiol. Biotechnol. (2000) 53: 661–667.
(12) Thomas W. Jeffries, ‘Enzymatic treatments of pulps: Opportunities for the Enzyme Industry in Pulp and Paper Manufacture’.
(13) N. Gupta, R. M. Vohra and G. S. Hoondal. ‘A thermophillic extracellular xylanase from alkalophilic Bacillus sp. NG-27 ’, Biotechnology Letters, vol. 14 No. 11 (November 1992) pp. 1045–1046.
(14) Michael J. Bailey, Peter Biely and Kaisa Poutanen, ‘Interlaboratory testing of methods for assay of xylanase activity’, Journal of Biotechnology, 23 (1992) 257–270.
(15) Toshiya susaki, Tsutomu Kajono, BoLi, Hidehiko Sugiyama, and Harua Takatashi; ‘New pulp biobleaching system involving manganese peroxidase immobilized in a silicon support with controlled pore sizes’, Appl. and Env. Microbiol. May 2001, p 2208–2212.
(16) Tamara Vares, Outi Niemenmaa and Annele Hatakka, ‘Secretion of Lignolytic enzymes and mineralization of 14 C-ring labeled synthetic lignin by three Phlebia tremellosa strains’, Appl. and Environmental Microbiol. February 1994 569–573.
(17) Ryuichiro Kondo, Koichi Harazono, and Kokki Sakai; ‘Bleaching of hardwood Kraft pulp with Manganese Peroxidase secreted from Phanerochaete sordida YK-624 ’. Appl. and Env. Microbiol. December 1994, p. 4359–4363.
(18) J. C. Rols, G. Goma, C. Fonade. ‘Biotechnology and the paper industry, Aerated lagoon for the wastewater treatment’.
(19) J. Sealey and A. J. Ragauskas, ‘Residual lignin studies of laccase-delignified Kraft pulps’, Enz. And Micro Tech. 23: 422–426, 1998.
Objects of the Invention
The main object of the present invention is to provide a novel consortium of ligninolytic bacteria for degradation of lignin.
Another object of the present invention is to provide a novel biological process for the degradation of lignin using the above-defined consortium of ligninolytic bacteria.
Yet another object of the invention is to provide a process for preparing a consortium of ligninolytic bacteria capable of degrading lignin.
SUMMARY OF THE INVENTION
The present invention provides a novel consortium of ligninolytic bacteria for degradation of lignin and also a biological process for the degradation of lignin using said consortium of ligninolytic bacteria. Ligninolytic bacteria were isolated from a specific Indian site where sawdust continually accumulated over the long period. The said bacteria were acclimatized to improve their capability to degrade lignin and finally formulated in a consortium to degrade the lignin.
DETAILED DESCRIPTION OF THE INVENTION
The present invention relates to a synergistic consortium of ligninolytic bacteria for degradation of lignin, said consortium comprising bacterial strains CBTCC/52-03, CBTCC/53-03 and CBTCC54-03 deposited on Mar. 5, 2003 at the International Depository at Microbial Type Culture Collection & Gene Bank (MTCC) Institute of Microbial Technology (IMTECH), Sector 39-A Chandigarh, 160 036 (Union Territory) India, and having accession numbers MTCC 5094, MTCC 5095 and MTCC 5098 respectively in any possible combination. MTCC 5094, MTCC 5095 and MTCC 5098 respectively correspond to Serratia marcescens. Pseuodomonas aeruginosa and Pseuodomonas aeruginosa.
In an embodiment of the present invention, the consortium comprises bacterial strains MTCC 5094, MTCC 5095 and MTCC 5098.
In another embodiment of the present invention, the consortium comprises bacterial strains MTCC 5094, MTCC 5095 and MTCC 5098 in the range of 20 to 40% by wt. each.
In yet another embodiment of the present invention, the consortium comprises bacterial strains MTCC 5094, MTCC 5095 and MTCC 5098 are in equal proportions.
In still another embodiment of the present invention, wherein the bacteria are isolated from a mixture of sawdust and soil.
In one more embodiment of the present invention, the bacteria are isolated from a mixture of sawdust and soil from Roorkhee, India.
In one another embodiment of the present invention, the consortium exhibits lignin degradation of up to 0.8%.
In a further embodiment of the present invention, the characteristics of MTCC 5094 are as follows: Gram—Negative, Shape—Small rods.
In an embodiment of the present invention, the characteristics of MTCC 5095 are as follows: Gram—Negative, Shape—Cocci.
In another embodiment of the present invention, the characteristics of MTCC 5098 are as follows: Gram—Negative, Shape—Long rods.
The bacterial isolates concerned with the present invention are being deposited at Institute of Genomics and Integrative Biology (IGIB) as CBTCC, and their identification is underway.
S. No.
Culture
Accession No.
1.
CBTCC/52-03
MTCC 5094
2.
CBTCC/53-03
MTCC 5095
3.
CBTCC/54-03
MTCC 5098
These bacterial isolates are exhibiting a remarkable capability to degrade the lignin under defined conditions.
The bacterial isolates in the present invention have been isolated from a wood workshop situated at Roorkee, India, where sawdust continually accumulated over the period of 10–12 years.
The invention further provides a process of isolation and acclimatization of bacterial isolates capable to degrade the lignin which comprises:
a) enriching the bacterial flora of the said site using soil extract and particular inducers under defined conditions; b) using different media (0.3 lignin+agar; soil extract+agar; 50% soil extract+agar; 0.3% lignin+50% soil extract) to entrap the maximum bacterial flora from the said site; c) culturing the said bacteria isolated from specific site under defined conditions such as media, temperature, pH, carbon source etc.; d) checking the lignin degrading capability of isolated bacterial isolates by inoculating them in 10 ml 0.4% lignin; e) lignin degradation was estimated by a known spectrophotometric method; f) selecting the bacterial isolates which can decolorize the lignin effectively; g) acclimatizing the short listed bacterial isolates for higher concentration of lignin to see the enhancement of their ligninolytic activity; h) Further short listing and formulation of different bacterial isolates in order to see their synergistic effect for lignin degradation; i) culturing the said bacteria under defined conditions for the detection of enzyme activity in crude as well as in concentrated sample. MSM having 1.0% glucose was used to grow the culture in 2 litre flask having 1000 ml culture. The culture flask was incubated at 30° C./120 rpm for 3 days in order to obtain heavy growth; j) centrifuging the resulting culture after attaining the heavy growth O.D. (1.00); k) collecting the supernatent and concentrating through ammonium sulphate precipitation followed by dialysis; l) assaying the lignin peroxidase in both the samples, crude as well as in concentrated by measuring the product (veratryldehyde)formation spectrophotometrically at 310 nm.
In an embodiment of the present invention, the bacteria are isolated from specific sawdust site located in Roorkee, India.
In another embodiment of the present invention, enrichment of the soil from said site is done by taking 5 g of fresh soil in the 500 ml autoclaved flask containing 100 ml soil extract, 0.3% lignin, 1 mM veratryl alcohol and 50 ul Candid B. Enrichment flask is kept at 120 rpm for 96 hours at 30° C.
In another embodiment of the present invention, four types of different media (0.3 lignin+agar; soil extract+agar; 50% soil extract+agar; 0.3% lignin+50% soil extract) are used to entrap the maximum bacterial flora of the said site.
In another embodiment of the present invention, isolated bacterial isolates are cultured under defined conditions such as media, temperature, pH, carbon source etc.
In another embodiment of the present invention, all the bacterial isolates are tested for their lignin degrading capability by inoculating them in 10 ml 0.4% lignin. Lignin degradation was estimated by a known spectrophotometric method.
In another embodiment of the present invention, some selected bacterial isolates are acclimatized for higher concentration of lignin to see the enhancement of their ligninolytic activity. Bacteria are inoculated in lignin ranging from 0.5% to 1.0% and kept at 30° C. for a period of three months. Lignin degradation was estimated by a known spectrophotometric method.
In another embodiment of the present invention, further short listed bacterial isolates are formulated in a number of consortia to see their synergistic effect for lignin degradation.
In another embodiment of the present invention, MSM having 1.0% glucose is used to grow the culture in 2 litre flask having 1000 ml culture for the enzyme study. The culture flasks are incubated at 30° C./120 rpm for 3 days in order to obtain heavy growth.
In another embodiment of the present invention, cultures are centrifuged and supernatent is collected followed by 80% ammonium sulphate precipitation and dialysis.
In another embodiment of the present invention, lignin peroxidase is assayed in both the samples, crude as well as in concentrated by measuring the product (veratryldehyde)formation spectrophotometrically at 310 nm.
The present invention further provides a process of lignin degradation, said process comprising inoculating the bacterial consortium comprising bacterial strains CBTCC/52-03, CBTCC/53-03 and CBTCC54-03 deposited at International Depository at IMTECH, Chandigarh, India, and having accession numbers MTCC 5094, MTCC 5095 and MTCC 5098 in an solution containing lignin for 1 to 5 days at temperature between 25 to 35° C.
In an embodiment of the present invention, the bacterial consortium comprises whole cell bacterial isolates of bacterial strains MTCC 5094, MTCC 5095 and MTCC 5098.
In another embodiment of the present invention, the consortium comprises bacterial strains MTCC 5094, MTCC 5095 and MTCC 5098.
In yet another embodiment of the present invention, the consortium comprises bacterial strains MTCC 5094, MTCC 5095 and MTCC 5098 in the range of 20 to 40% by wt. each.
In still another embodiment of the present invention, the consortium comprises bacterial strains MTCC 5094, MTCC 5095 and MTCC 5098 in equal proportions.
In one more embodiment of the present invention, the bacteria are isolated from a mixture of sawdust and soil.
In one another embodiment of the present invention, the bacteria are isolated from a mixture of sawdust and soil from Roorkhee, Uttar Pradesh, India.
In a further embodiment of the present invention, the consortium exhibits lignin degradation of up to 0.8%.
For the isolation of ligninolytic bacteria, proper enrichment was done. To improve the yield of desired bacteria, 5 g of fresh soil from the said site was inoculated in the 500 ml autoclaved flask containing 100 ml soil extract, 0.3% lignin and 50 ul Candid B (antifungal). Enrichment flask was kept at 120 rpm for 96 hours at 30° C.
For the preparation of soil extract, 1 Kg soil was taken and dried at 50° C. for 2 hours. 400 g of dried soil was dissolved in 960 ml single distilled water and autoclaved at 15 lbs for 1 hour. After autoclaving, the sample was centrifuged at 5000 rpm for 10 minutes. The supernatant (extract) was collected and stored in sterile bottle for the preparation of enrichment flask till further use.
The enriched soil samples were serially diluted in 0.85% saline. 100 ul from each respective dilution was spread onto petriplates containing soil extract, 50% nutrient agar and 0.2% lignin for the the isolation of ligninolytic bacteria. The plates thus obtained were incubated at 30±2° C. for 24–96 hrs in inverted position.
On the basis of colony morphology and colour, total 36 isolates were selected to check their ligninolytic activity. The single isolated colonies were picked and streaked on fresh plates containing the same medium. The above step was repeated till pure colonies were obtained.
To check the ligninolytic activity of the isolated bacteria, 10 ml of 0.4% lignin was taken in 30 ml test tubes and all the bacterial isolates were inoculated individually. After 3 days, different bcaterial isolates showed different degree of decolorization of lignin. Lignin degradation was estimated by a known spectrophotometric method.
On the basis of lignin decolorization, total 15 bacterial isolates out of 36 isolates were selected for further study. To enhance the ligninolytic activity of the selected bacterial isolates, acclimatization was done for higher concentration of lignin. All the 15 isolates were inoculated in 10 ml lignin for the range from 0.5% to 1.00%. All the tubes were kept at 30° C. for three months. After the long acclimatization, 8 bacterial isolates were chosen for the further study. The selected isolates were able to decolorize the lignin upto 0.7%. Lignin degradation was estimated by a known spectrophotometric method.
In order to see the synergistic effect of these bacterial isolates, a number of consortia were designed and tested for their capability of degrading the lignin. One consortium comprising of three bacteria designated as MTCC 5094, MTCC 5095 and MTCC 5098 was found able to degrade the lignin upto 0.8%.
To find out the mechanism of lignin degradation at enzyme level, enzyme assay for lignin peroxiadse, a key enzyme for lignin degradation, was carried out. All the three bacteria were inoculated in 1 litre minimal salt medium (MSM) having 1% glucose. For the induction of ligninolytic enzymes, 1 mM veratryl alcohol was added to the cultures. All the cultures were incubated at 30–35° C. for three days under shaking conditions (100–120 rpm). After observing the heavy bacterial growth, all the cultures were centrifuged at 10,000 rpm at 4° C. Supernatent was collected to check the enzyme activity.
For the concentration of extracellular enzymes, 80% ammonium sulphate precipitation was carried out using 100% saturated ammonium sulphate solution followed by subsequent dialysis.
Enzyme assay for lignin peroxidase was performed for both, crude cell free extract as well as concentrated sample. For the enzyme assay, 10 mM veratryl alcohol, 5 mM H 2 O 2 and 400 μl enzyme solution was added in tartaric acid (pH 3) buffer. The formation of product (veratryldehyde) was monitored at 310 nm. Lignin peroxidase catalyzes the oxidation of veratryl alcohol by H 2 O 2 to veratryldehyde. Veratry alcohol exhibits no absorbance at 310 nm wherease veratrlydehyde absorbs strongly (molar extinction coefficient=9300 M−1 cm−1). All the three bacterial isolates showed different degree of ligninolytic activity.
The present invention is further described with reference to the accompanying examples, which are given by way of illustration and hence, should not be construed to limit the scope of the present invention in any manner.
EXAMPLE 1
In the endeavor of exploring ligninolytic bacteria, strategic isolation was done to entrap the maximum ligninolytic bacterial flora from the specific site.
Isolation point was a workshop situated at Roorkee, India, where sawdust continually accumulated over the period of 10–12 years.
For the isolation of ligninolytic bacteria, proper enrichment was done. To improve the yield of desired bacteria, 5 g of fresh soil from the said site was inoculated in the 500 ml autoclaved flask containing 100 ml soil extract, 0.3% lignin and 50 ul Candid B. Enrichment flask was kept at 120 rpm for 96 hours at 300 C.
For the preparation of soil extract, 1 Kg soil was taken and dried at 500 C. for 2 hours. 400 g of dried soil was dissolved in 960 ml single distilled water and autoclaved at 15 lbs for 1 hour. After autoclaving, the sample was centrifuged at 5000 rpm for 10 minutes. The supernatant (extract) was collected and stored in sterile bottle for the preparation of enrichment flask and further use.
The enriched soil samples were serially diluted in 0.85% saline. 100 ul from each respective dilution was spread onto petriplates containing soil extract, 50% nutrient agar and 0.2% lignin for the isolation of ligninolytic bacteria. The plates thus obtained were incubated at 30±2° C. for 24–96 hrs in inverted position.
On the basis of colony morphology and color, total 36 isolates were selected to check their ligninolytic activity. The single isolated colonies were picked and streaked on fresh plates containing the same medium. The above step was repeated till pure colonies were obtained.
EXAMPLE 2
For the isolation of ligninolytic bacteria, proper enrichment was done. To improve the yield of desired bacteria, 5 g of fresh soil from the said site was inoculated in the 500 ml autoclaved flask containing 100 ml soil extract, 0.3% lignin and 50 ul Candid B. Enrichment flask was kept at 120 rpm for 96 hours at 300 C.
For the preparation of soil extract, 1 Kg soil was taken and dried at 500 C for 2 hours. 400 g of dried soil was dissolved in 960 ml single distilled water and autoclaved at 15 lbs for 1 hour. After autoclaving, the sample was centrifuged at 5000 rpm for 10 minutes. The supernatant (extract) was collected and stored in sterile bottle for the preparation of enrichment flask and further use.
The enriched soil samples were serially diluted in 0.85% saline. 100 ul from each respective dilution was spread onto petriplates containing soil extract, 50% nutrient agar and 0.2% lignin for the isolation of ligninolytic bacteria. The plates thus obtained were incubated at 30±2° C. for 24–96 hrs in inverted position.
On the basis of colony morphology and color, total 36 isolates were selected to check their ligninolytic activity. The single isolated colonies were picked and streaked on fresh plates containing the same medium. The above step was repeated till pure colonies were obtained.
To check the ligninolytic activity of the isolated bacteria, 10 ml of 0.4% lignin was taken in 30 ml test tubes and all the bacterial isolates were inoculated individually. After 3 days, different bacterial isolates showed different degree of decolorization of lignin. Lignin degradation was estimated by a known spectrophotometric method.
TABLE 1
Bacterial degradation of lignin
(0.4%) as a sole carbon source
Isolate No.
Lignin percentage
Decolourization
L1
0.4%
5%
L2
0.4%
10%
L3
0.4%
4%
L4
0.4%
29%
L5
0.4%
36%
L6
0.4%
9%
L7
0.4%
4%
L8
0.4%
31%
L9
0.4%
20%
L10
0.4%
35%
L11
0.4%
40%
L12
0.4%
5%
L13
0.4%
32%
L14
0.4%
14%
L15
0.4%
12%
L16
0.4%
5%
L17
0.4%
6%
L18
0.4%
23%
L19
0.4%
9%
L20
0.4%
38%
L21
0.4%
12%
L22
0.4%
30%
L23
0.4%
25%
L24
0.4%
6%
L25
0.4%
14%
L26
0.4%
4%
L27
0.4%
42%
L28
0.4%
29%
L29
0.4%
33%
L30
0.4%
11%
L31
0.4%
13%
L32
0.4%
15%
L33
0.4%
7%
L34
0.4%
11%
L35
0.4%
34%
L36
0.4%
36%
EXAMPLE 3
For the isolation of ligninolytic bacteria from specific site, proper enrichment was done. To improve the yield of desired bacteria, 5 g of fresh soil from the said site was inoculated in the 500 ml autoclaved flask containing 100 ml soil extract, 0.3% lignin and 50 ul Candid B. Enrichment flask was kept at 120 rpm for 96 hours at 300 C.
For the preparation of soil extract, 1 Kg soil was taken and dried at 500 C for 2 hours. 400 g of dried soil was dissolved in 960 ml single distilled water and autoclaved at 15 lbs for 1 hour. After autoclaving, the sample was centrifuged at 5000 rpm for 10 minutes. The supernatant (extract) was collected and stored in sterile bottle for the preparation of enrichment flask and further use.
The enriched soil samples were serially diluted in 0.85% saline. 100 ul from each respective dilution was spread onto petriplates containing soil extract, 50% nutrient agar and 0.2% lignin for the isolation of ligninolytic bacteria. The plates thus obtained were incubated at 30±2° C. for 24–96 hrs in inverted position.
On the basis of colony morphology and color, total 36 isolates were selected to check their ligninolytic activity. The single isolated colonies were picked and streaked on fresh plates containing the same medium. The above step was repeated till pure colonies were obtained.
To check the ligninolytic activity of the isolated bacteria, 10 ml of 0.4% lignin was taken in 30 ml test tubes and all the bacterial isolates were inoculated individually. After 3 days, different bacterial isolates showed different degree of decolorization of lignin.
On the basis of lignin decolorization, total 15 bacterial isolates, namely, L4, L5, L8, L10, L11, L13, L18, L20, L20, L22, L23, L27, L28, L29, L35 AND L36 from 36 were selected for further study. To enhance the ligninolytic activity of the selected bacterial isolates, acclimation was done for higher concentration of lignin. All the 15 isolates were inoculated in 10 ml lignin for the range from 0.5% to 1.00%. All the tubes were kept at 30° C. for three months. After the long acclimatization, 8 bacterial isolates, namely, L4, L5, L10, L13, L28, L29, L35 and L36 were chosen for the further study. Lignin degradation was estimated by a known spectrophotometric method the selected isolates had been able to decolorize the lignin upto 0.7%. (Table 2)
TABLE 2
Acclimatization of selected ligninolytic bacteria to
higher concentration of lignin
Percentage decolorization of lignin
Isolate No.
0.5%
0.6%
0.7%
0.8%
0.9%
1.0%
L4
30%
25%
11%
0.0%
0.0%
0.0%
L5
40%
30%
12%
1.0%
0.0%
0.0%
L8
34%
22%
10%
0.0%
0.0%
0.0%
L10
33%
27%
12%
0.0%
0.0%
0.0%
L11
37%
27%
10%
0.0%
0.0%
0.0%
L13
30%
23%
14%
1.0%
0.0%
0.0%
L18
20%
15%
8%
0.0%
0.0%
0.0%
L20
33%
20%
7%
0.0%
0.0%
0.0%
L22
25%
15%
3%
0.0%
0.0%
0.0%
L23
24%
14%
2%
0.0%
0.0%
0.0%
L27
40%
19%
11%
0.0%
0.0%
0.0%
L28
26%
20%
15%
2.0%
0.0%
0.0%
L29
35%
30%
12%
0.0%
0.0%
0.0%
L35
40%
30%
20%
3.0%
0.0%
0.0%
L36
39%
22%
14%
1%
0.0%
0.0%
EXAMPLE 4
In order to see the synergistic effect of the acclimatized bacteria, a number of consortia were designed and tested for their capability of degrading the lignin. Consortia were designed in taking three bacterial isolates together. All the consortia were made from 8 bacterial isolates, namely, L4, L5, L10, L13, L28, L29, L35 and L36, which have been able to degrade the lignin upto 0.7%. These consortia were tested for their ligninolytic activity in a synergistic manner.
To make the inoculum from consortium for biodegradation study, a loop from agar plate of three different bacteria were inoculated individually in 10 ml MSM with 1% glucose. The cultures were incubated at 30° C. for 16–24 hours in an incubator shaker at 100–120 rpm. After incubation, optical density was measured at 650 nm. Optical density of the culture was maintained to 1.00 either by diluting or concentrating the bacterial suspension. All the three cultures were mixed together in equal proportion in order to make the inoculum. Different concentrations of lignin (0.7%, 0.8%, 0.9%, 1.0%) were inoculated by the inoculum of different consortia. All the tubes were incubated for 3 days at 30° C. Lignin degradation was estimated by a known spectrophotometric method. Finally a consortium comprising the bacterial isolate, L35, L36 and L13, was selected as a potent lignin degrader which was able to degrade the lignin upto 0.8%
TABLE 3
Synergistic effect of ligninolytic
bacteria on lignin degradation.
Consortia
Percentage decolorization of lignin
No.
0.7%
0.8%
0.9%
1.0%
1
13%
6.0%
0.0%
0.0%
2
12%
5.0%
0.0%
0.0%
3
18%
12.0%
2.0%
0.0%
4
12%
11.0%
0.0%
0.0%
5
14%
10.0%
0.0%
0.0%
6
16%
12.0%
0.0%
0.0%
7
20%
15.0%
0.0%
0.0%
8
17%
15.0%
3.0%
0.0%
9
13%
15.0%
0.0%
0.0%
10
12%
13.0%
0.0%
0.0%
11
11%
6.0%
0.0%
0.0%
12
15%
2.0%
0.0%
0.0%
13
22%
8.0%
0.0%
0.0%
14
20%
10.0%
0.0%
0.0%
15
15%
11.0%
0.0%
0.0%
16
29%
40%
8.0%
1.0%
17
12%
14.0%
0.0%
0.0%
18
15%
12.0%
0.0%
0.0%
19
22%
18.0%
1.0%
0.0%
20
23%
10.0%
0.0%
0.0%
EXAMPLE 5
To find out the mechanism of lignin degradation at enzyme level, enzyme assay for lignin peroxidase, a key enzyme for lignin degradation, was carried out. All the three bacteria, L35, L36 and L13 of the consortium 16 (Table 3) which was able to degrade the lignin upto 0.8%, were inoculated individually in 1 liter minimal salt medium (MSM) having 1% glucose. For the induction of ligninolytic enzymes, 1 mM veratryl alcohol was added to the cultures. All the cultures were incubated at 30–35° C. for three days under shaking conditions (100–120 rpm). After seeing the heavy bacterial growth, all the cultures were centrifuged at 10,000 rpm at 4° C. Supernatant was collected to check the enzyme activity.
For the concentration of extracellular enzymes, 80% ammonium sulfate precipitation was carried out using 100% saturated ammonium sulfate solution followed by subsequent dialysis.
Enzyme assay for lignin peroxidase was performed for both, crude cell free extracts as well as concentrated sample. For the enzyme assay, 10 mM veratryl alcohol, 5 mM H 2 O 2 and 400 μl enzyme solution was added in tartaric acid (pH 3) buffer. The formation of product (veratryldehyde) was monitored at 310 nm. Lignin peroxidase catalyzes the oxidation of veratryl alcohol by H 2 O 2 to veratryldehyde. Veratry alcohol exhibits no absorbance at 310 nm whereas veratrlydehyde absorbs strongly (molar extinction coefficient=9300 M−1 cm−1). All the three bacterial isolates showed different degree of ligninolytic activity (table 4).
TABLE 4 Enzyme activity of L35, L36 and L13 in term of increase in O.D. after incubation of 15 minutes ABSORBANCE AT 310 nm ISOLATE 24 hrs. 72 hrs. S. NO. NO. INITIAL FINAL INITIAL FINAL 1 L35 0 0 1.352 1.491 2 L36 0 0 1.265 1.438 3 L13 0 0 1.426 1.537
Advantages
1. Degradation of lignin by bacteria has tremendous significance for the bioremediation of pulp and paper industrial wastewater. 2. Bacterial degradation of lignin confers a new understanding of conversion of industrial lignin waste into useful commodities.
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The invention provides a novel process of lignin degradation using a consortium of bacteria. To date, biodegradation of lignin has been centered to fungi only. Degradation of lignin by bacteria confer a new understanding that may be of tremendous industrial significance. This invention also discloses the isolation and acclimatization of ligninolytic bacteria from a specific site.
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CROSS REFERENCE TO RELATED APPLICATIONS
The present application is a 35 U.S.C. 371 National Application of PCT/EP2009/067827 filed Dec. 23, 2009, which claims priority to European Patent Application No. 08022476.9, filed Dec. 29, 2008, the entire contents of which are incorporated entirely herein by reference.
FIELD OF INVENTION
This invention relates to injection devices for delivering medicine to the human or animal body and in particular, but not exclusively, to devices having a replaceable medicament cartridge, including auto-injectors. Such devices are commonly used by those with diabetes for the administration of insulin.
BACKGROUND
Medicament delivery devices are routinely used by persons without formal medical training, i.e. patients where self-management of their condition is increasingly common. These circumstances set a number of requirements for medicament delivery devices of this kind. The injector should be robust in construction, yet easy to use in terms of its operation by a user and the manipulation of the parts. In the case of those with diabetes, many users will be of impaired vision and may also be physically infirm. Devices that are too large of cumbersome may therefore prove difficult to use, particularly someone with reduced dexterity.
Patent Specification U.S. Pat. No. 6,340,357 describes a drug delivery system in which the dose setting is read into an electronic circuit and the dose setting movement of the dose setting elements relative to each other is performed by an electromechanical device, e.g. a motor controlled by the electronic circuit in accordance with the read in dose setting. The electronic control enables the apparatus to intervene by resetting a dose if a miss-handling of the device by the user is detected during dose setting, such as opening of the cartridge holder.
Patent Specification WO 2007/094833 describes a metering system for automatically adjusting for differential thermal expansion/contraction for the efficient, accurate and reproducible metered delivery of fluids. The system allows the metering system drive to re-zero itself to produce an accurate volumetric delivery of fluid from the dispensing container.
It is also known to detect a stall of the motor that drives the dose delivery and to warn the user if a dose fails to be delivered. However, there remains a problem in the resetting of the device following detection of a motor stall event.
It is an aim of the present invention to provide a medication delivery device that alleviates this problem.
According to the present invention, there is provided an injection device for delivering a medicament to a patient, wherein the injector device comprises: a housing; a piston rod for driving a bung of a medicament container; a drive mechanism including a motor for providing an output drive to the piston rod for delivering the medicament; and control means for controlling operation of the device; characterised in that:
the control means comprises: a drive signal generator for generating an input drive signal for the motor; an encoder for generating an encoder output signal indicative of the output drive of the motor; and means for varying the operational control of the device in dependence on a comparison between the input drive signal and the encoder output.
The input drive signal may be stepper pulses for driving the motor. The encoder output signal may be a pulsed signal having a timing characteristic that corresponds to the output drive of the motor. A plurality of reference points may be included in the device, each reference point being indicative of a different operational aspect of the device, including any one or more of: backstop position; dose delivered; door position; drive position; and reset threshold. The reference points preferably relate to the input drive signal such that respective reference points correspond to respective counts of the stepper pulses with reference to a device datum. A comparison between counts of the pulsed encoder output with counts of the stepper pulses may be indicative of motor slip. In the event that motor slip or stall is detected the control means is operative for determining the quantum of slip relative to one of the reference points whereupon said varying means adjusts the operational control of the device according to a predetermined criteria. The variation in operation control may be such as to urge the device to a target operational state. For example, when the quantum exceeds a predetermined threshold value, the motor may be deliberately stalled against a predetermined reference point representative of the target state. For example, the motor drive may be varied so the state of the device is changed to a dose reset position or a ‘cartridge door open state’ for enabling replacement of the cartridge. Alternatively, the motor may be controlled such as to rewind the piston rod to a backstop which defines a device datum or device reset position.
Embodiments of the present invention are advantageous in that the injector automatically initiates a reset action when necessary and without needing user interaction. This leads to an improvement in battery life and an avoidance or reduction in motor stall noise.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will now be further described by way of example with reference to the accompanying drawings, in which like reference numerals designate like elements:
FIG. 1 is a front view of an auto-injector that may include an embodiment of the present invention;
FIG. 2 is a front view of the auto-injector of FIG. 1 with a medicament cartridge door shown in an open position for receiving a medicament cartridge;
FIG. 3 is a perspective view of a motor for use in embodiments of the present invention;
FIG. 4 is a side view of the motor of FIG. 3 with an encoder;
FIG. 5 a is a timing chart of motor drive and encoder output;
FIG. 5 b is a timing chart of motor drive and encoder output showing motor slip;
FIG. 6 is a flow chart illustrating a decision sequence that may be performed by the control means; and
FIG. 7 is a functional block diagram of the control means.
DETAILED DESCRIPTION
In FIG. 1 , an auto-injector 1 comprises a case 2 having a display 3 for displaying functional information relating to the operation of the auto-injector, including the set dose, number of doses remaining in the medicament cartridge. User interface buttons 4 , 5 and 6 are provided to allow the user to operate the injector including priming, setting a dose, opening a medicament cartridge holder and door 7 , and activating the dispensing of the set dose. A threaded needle attachment 8 is provided to which a needle can be attached for dose delivery and subsequently removed and discarded. A cover (not shown) may be provided to fit over the lower portion of the case 2 to assist in protect the device from the ingress of particles and fluid. FIG. 2 shows the auto-injector 1 with the cartridge holder and door 7 in an open position for receiving a replacement medicament cartridge 9 .
FIG. 3 shows a motor 13 within a drive mechanism (see FIG. 7 ). The motor is provided with a pair of flags 15 disposed at 180 degrees with reference to one another. An output gear 17 engages with a gear train of the drive mechanism for driving the piston rod of the auto-injector 1 . The motor 13 may be a stepping motor driven by a pulsed drive signal or stepper pulses illustrated schematically in FIGS. 5 a and 5 b below. The pulsed drive signal is generated by an electronic control circuit within the control means. The control means will be described in more detail with reference to FIGS. 5 a to 7 .
FIG. 4 is a side view of the motor 13 showing an optical encoder 19 in registration with the flags 15 . As the drive shaft of the motor 13 rotates the flags 15 , every edge of a flag causes a change in the output of the optical encoder 19 , so that the encoder outputs a series of output pulses representative of the angular velocity of the drive shaft. The control means (microcontroller/microprocessor) detects and counts these pulses. The encoder signal causes an interrupt in the microcontroller/microprocessor. An interrupt causes an interruption of the current software program flow, executes a special interrupt software routine and returns to the normal software flow after finishing the interrupt routine. This technique is used to react immediately to external signals to make sure that every signal is recognized by the microprocessor. In the embodiment shown in FIG. 4 , a pair of flags 15 is located at 180° and will therefore generate 4 pulses per motor turn. One encoder pulse is therefore equivalent to 5 motor pulses, assuming 20 motor pulses for a single turn of the motor shaft.
FIG. 5 a illustrates the relative timing between the motor drive or stepper pulses and the encoder output pulses during normal drive mechanism movement of the device. In this example, there are 5 motor stepper pulses to one encoder output pulse, the control means being programmed to expect 5 motor stepper pulses to one encoder output pulse. Consequently, when 20 motor stepper pulses are counted at the same time that the control means counts 4 encoder output pulses, the control comparison determines that the device is driving normally. That is, there is no motor slippage or no motor stall.
FIG. 5 a illustrates a situation where a count comparison between the encoder pulse output is such as to indicate 15 motor stepper pulses whereas the actual count by the control means corresponds to 19 or 20 pulses. In this case the control means determines from the comparison that the motor movement has encountered slippage. At this point, a subroutine is run by software programmed into the control means to make a determination as to the state of the auto-injector in relation to predetermined reference points and a device datum position. The position of the piston rod when in a fully retracted position may represent a backstop position or datum position (i.e. “zero”) from which other device reference points may be referenced. The datum position also corresponds to an absolute motor position so that incremental movements relative to that correspond to other operational states of the device. These other device reference points are between zero and a maximum motor travel position through 26858 motor stepper pulses. For example, from the datum position, a medicament cartridge 9 door latch open position may be represented by, for example, a motor position that corresponds to “datum position+4 pulses”. A priming dose may be determined to have been effected by movement of the motor 13 through 84 pulses from the backstop datum position.
FIG. 6 shows an example of an administration routine that may be run with the control means software during the administration of medicament. At 60 , the user inputs via input buttons 4 - 6 a desire to start the administration of a dose of medicament. The motor stepper and encoder pulse counts are examined at step 62 to determine if they differ from one another by more than a predetermined amount. If YES, the control means rewinds the drive mechanism until the motor stalls at the backstop, at which point the device may be datumed or reset. The control means software may then calculate the deficit in the medicament administered and perform means to administer this dose. If NO, the administration continues until the dose is completely expelled.
FIG. 7 is a functional block diagram of the control means 70 , to which is connected a user input 72 corresponding to the user interface buttons 4 - 6 of FIG. 1 , and the drive mechanism 74 . The control means 70 includes dial buttons 76 through which the user can dial the required dose and an LC display 78 for displaying the set dose. The control means software sets a dose value corresponding to that set by the user at 80 and converts this into an appropriate pulse value for the stepper motor 13 at 82 . At 84 , the software determines the current position of the motor 13 by looking at the current pulse count of the stepper pulses generated by the motor and determines a motor target position 86 in terms of stepper pulses that corresponds to the reference point representative of the piston rod position that will deliver the dose set at 76 / 80 . The control means software, motor control 88 , generates the required stepper pulses to drive the motor 13 of the drive mechanism 74 and compares encoder and motor pulses.
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An injection device for delivering a medicament to the human or animal body. The injection device comprising a housing, a piston rod for driving a bung of a medicament container, a drive mechanism including a motor for providing an output drive to the piston rod for delivering the medicament; and controller for controlling operation of the device.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] The present application is a continuation-in part application and claims the priority benefit of U.S. patent application Ser. No. 13/240,419, filed 22 Sep. 2011, which is a continuation of U.S. patent application Ser. No. 12/264,726, filed 4 Nov. 2008, which in turn claims priority from Finnish patent application 20080032, filed 16 Jan. 2008. Each of the applications and herein incorporated by reference in their entirety.
BACKGROUND
[0002] 1. Field of the invention
[0003] The invention relates to methods, apparatuses and software products for providing a wireless broadband internet connection via a mobile communication network. In the context of the present invention, a broadband connection means a connection capable of transmitting traffic, in good network conditions, faster than a V.90 modem can, or faster than 64 kilobits per second.
[0004] 2. Background of the Invention
[0005] Wireless broadband modems can be used to couple personal computers or client terminals to the internet in places where wired internet connections or local-area networks are not available. Prior art wireless broadband modems exhibit certain problems. For instance, sharing a single wireless broadband connection among several users (client terminals) is awkward at best. Normally this requires setting up one of several client terminals as a master terminal that provides the internet connection to the remaining client terminals. This process consumes resources of the master terminal and the client terminals cannot operate without the master. The difficulty of sharing a single wireless broadband connection among several users is understandable in view of the fact that most wireless broadband modems are given or sold at a nominal cost by mobile network operators in connection with a network subscription. The network operators' obvious desire is to sell a subscription to each user instead of sharing a single connection among several users.
[0006] Another problem of prior art wireless broadband modems is the fact that most of them are “wireless” only towards the mobile network and the connection to the client terminal takes place via a USB cable. The wired connection is actually a benefit in connection with fixed client terminals, such as home computers, because the wired connection can also supply power to the wireless broadband modem, but in connection with mobile client terminals, the wired nature of the USB connection is a definite handicap. A still further problem is that it is difficult to share content among the several users or client terminals.
SUMMARY
[0007] An object of the present invention is to develop a method, an apparatus and software products so as to alleviate one or more of the problems identified above. The object is achieved by methods, apparatuses and software products as defined in the attached independent claims. The dependent claims and the drawings with their associated descriptions relate to specific embodiments.
[0008] An aspect of the invention is a method for operating mobile station as wireless local-area network (“WLAN”) gateway. The mobile station comprises a memory for storing applications and data; a processor for executing the stored applications; a user interface comprising an input section and an output section; reception/transmission circuitry for providing a communication interface to one or more access networks; authentication means operable to authenticate a user of the mobile station; a radio transceiver operable to establish and maintain a broadband connection with a mobile communication network in response to a successful authentication of the user of the mobile station; and wireless WLAN means responsive to an activation or deactivation command according to a setting received via the input section of the user interface. The inventive method comprises instructing the processor by a gateway application to control the following operations:
[0009] activating the WLAN means as a WLAN base station capable of communicating with at least one WLAN terminal over a WLAN network;
[0010] creating a network identifier for the WLAN base station;
[0011] assigning an internet protocol address for the at least one WLAN terminal;
[0012] resolving domain name service (“DNS”) queries in cooperation with an external DNS service system;
[0013] assigning at least one port number for each protocol supported by the gateway application; and
[0014] tunneling internet traffic between the at least one WLAN terminal and an internet host over the broadband connection.
[0015] Another aspect of the invention is gateway application implemented as a software product which comprises a code portion for instructing the mobile station's processor to control the mobile station to perform each of the six above-defined operations. Yet another aspect of the invention is a mobile station which comprises the inventive gateway application, either as a factory-installed application or as a downloadable application.
[0016] In one specific embodiment the mobile station further comprises means for receiving, installing and executing downloadable programs and the inventive gateway application is a downloadable application. Implementing the inventive gateway application as a downloadable application provides the added benefit that the inventive technique is applicable to mobile stations which are physically capable of performing the inventive method but do not contain the necessary software.
[0017] In another specific embodiment the gateway application further comprises a code portion to redirect a first HTTP page request from each mobile station during an internet session to a predetermined internet address. Redirecting the mobile station's first HTTP page request during an internet session provides the owner of the predetermined internet address with the benefit that the mobile station user must begin an internet session via the predetermined internet address. That address may contain useful information or advertisements, for example.
[0018] Yet another specific embodiment is a gateway application for a mobile station, wherein the mobile station comprises a GPS receiver or other means for determining the mobile station's location, and the gateway application comprises a code portion for associating the determined location to the tunneled internet traffic. The gateway application and/or some internet-based supplementary server(s) may use the determined location to produce one or more additional or supplementary services to the WLAN terminal.
[0019] The gateway application may further comprise a code portion for collecting traffic statistics in respect of the tunneled traffic and for transmitting at least some of the collected traffic statistics to an advertising server and/or billing server, so as to use the traffic statistics for advertising and/or billing.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] In the following the invention will be described in greater detail by means of specific embodiments with reference to the attached drawings, in which:
[0021] FIG. 1 is a schematic block diagram of a representative mobile station.
[0022] FIG. 2 shows some preparatory acts, some of which may be optional.
[0023] FIG. 3 shows an illustrative scenario involving a client terminal and a mobile station which supports a gateway application according to the present invention.
[0024] FIG. 4 shows an embodiment in which the gateway application in the mobile station is activated automatically in response to detection of a nearby WLAN client terminal.
[0025] FIG. 5 shows an embodiment in which the mobile station's location-determination functionality is used to enhance image uploading to an image hosting server.
[0026] FIG. 6 shows applications for a forced homepage feature.
[0027] FIG. 7 is a block diagram of an exemplary system for implementing a computing device.
DETAILED DESCRIPTION
[0028] FIG. 1 is a schematic block diagram of a representative mobile station MS. The mobile station MS includes a central processing unit CP 105 and memory 110 . In addition, the mobile station MS includes or utilizes external input-output circuitry 115 which constitutes the multimode terminal's user interface and includes an input circuitry 120 and an output circuitry 125 . The input circuitry 120 includes the mobile station's microphone and user-input device, such as a keypad and/or touch screen. The output circuitry 125 includes the mobile station's display and earphone or loudspeaker. The mobile station MS further includes reception/transmission circuitry 130 which includes a transmission circuitry 135 , reception circuitry 140 and antenna 145 . A subscriber identity module, SIM, 150 is used by an authentication function 160 to authenticate the mobile station user and to identify the user's subscription to the access network. The mobile station also includes WLAN (Wireless Local Area Network) circuitry 155 whose normal mode of usage is acting as a WLAN client to a WLAN base station (not shown).
[0029] In order to support installable program modules, the mobile station's memory MEM 110 may include routines for downloading installable program modules and for storing the installable program modules in the memory MEM for execution by the central processing unit CP. FIG. 1 shows an arrangement in which the mobile station is configured to download installable program modules from a repository RP via a data network DN, an access network AN, the antenna 145 and reception circuitry 140 , although other arrangements are equally possible, such as downloading the installable program modules via the data network DN to a personal computer PC, from which the installable program modules are transferred to the mobile station the WLAN circuitry 155 or via some other short-range connection, such as Bluetooth or Universal Serial Bus (USB, not shown separately). The reference sign PC/CT means that the personal computer PC serves as an example of a client terminal CT. The access network AN is typically a broadband-capable mobile communication network, while the data network DN is typically the internet or some closed subnetwork implementing internet protocol (IP), commonly called intranets or extranets. At this level of generalization, all previously-discussed elements of FIG. 1 can be conventional as used in the relevant art. One or more external hosts 190 are accessible via the access network AN and data network DN, as will be described in more detail below. Finally, reference numeral 180 denotes an area of the memory 110 used to store parameters and variables.
[0030] The foregoing description of FIG. 1 describes an applicable mobile station in technical terms. Such mobile stations are commercially available: For instance, at the priority date of the present invention, mobile stations based on Symbian S60 or S80 platforms can be used, provided that they support WLAN and broadband communications. A departure from prior art mobile stations can be seen in the fact that the mobile station includes the inventive gateway application 170 , either as a factory-installed software application or as a downloadable application. The reference sign PC, which denotes the personal computer being used as the client terminal, is derived from “personal computer”, but those skilled in the art will realize that the mobile station MS provided with the inventive gateway application 170 supports virtually any client terminal capable of acting as a WLAN client, such as laptop computers, smart telephones, personal digital assistants, home entertainment devices, digital cameras, etc., to name just a representative sample of applicable device types.
[0031] FIG. 2 shows some preparatory acts, some of which may not be necessary in all embodiments of the present invention. In step 2 - 2 the mobile station MS is authenticated. This step, which is well known to those skilled in the art, involves reception of a PIN code via the mobile station's user interface, and using the mobile stations SIM card in a registration process to the access network AN. In step 2 - 4 the mobile station's WLAN circuitry is activated according to a setting from the mobile station's user interface. In steps 2 - 6 through 2 - 8 the inventive gateway application is downloaded via a personal computer PC from the repository RP. In cases wherein the gateway application is downloaded without the personal computer, the download request and application download would take place directly between the mobile station MS and the repository RP. In step 2 - 10 the downloaded gateway application is stored in the mobile station's memory for later execution, as will be further described in connection with FIG. 3 .
[0032] The WLAN activation step may not be necessary if the mobile station's WLAN circuitry is permanently enabled. The downloading and storing acts may be omitted in embodiments having the gateway application permanently stored or pre-installed in the mobile station's memory.
[0033] FIG. 3 depicts an illustrative scenario involving a client terminal (represented in FIG. 3 by a personal computer PC) and a mobile station which supports a gateway application according to the present invention. In step 3 - 0 the inventive gateway application is executed in the mobile station. The execution of the gateway application is typically started in response to a user instruction via the mobile station's user interface. In a typical implementation, the mobile station receives user interface navigation instructions to “Applications” from which the inventive gateway application is selected for execution. One of the acts performed by the mobile station's processor, under control of the inventive gateway application, is to ensure that the WLAN circuitry of the mobile station is operational. The significance of step 3 - 0 , and of the corresponding deactivation step 3 - 40 , is that the mobile station is only reserved for wireless broadband gateway applications for a user-specified time, and at other times the mobile station can perform whatever tasks required by its user.
[0034] In step 3 - 2 the gateway application instructs the mobile station's processor to prepare an ad-hoc WLAN network around the mobile station, by acting as a WLAN base station (as opposed to the mobile station's more conventional usage as a WLAN client). In step 3 - 4 the gateway application instructs the mobile station to initiate broadcasting of a beacon ID message, which typically is an IBSSID message as defined in standard IEEE 802.11x. Step 3 - 4 is depicted as an arrow, but in practice the broadcasting of the beacon ID message should be repeated until step 3 - 40 in which the execution of the gateway application is terminated.
[0035] In step 3 - 6 the client terminal PC searches for available WLAN networks and detects the broadcasted beacon ID and selects the WLAN network created by the mobile station MS. In step 3 - 8 the client terminal PC, as part of a conventional WLAN attach procedure, requests an IP address from the mobile station's WLAN base station, which returns the requested IP address in step 3 - 10 . Dynamic Host Configuration Protocol (DHCP) is typically used for steps 3 - 8 and 3 - 10 .
[0036] Let us assume that the client terminal PC tries to retrieve a web page from the internet host (item 190 in FIG. 1 ). In step 3 - 12 the client terminal PC sends a domain name service (DNS) query for the IP address of the host's web page to the DNS server of the mobile station's gateway application. In step 3 - 14 the mobile station's gateway application forwards the DNS query to internet's domain name service and obtains the host's IP address in step 3 - 16 . In step 3 - 18 the mobile station's gateway application returns the host's IP address to the client terminal PC.
[0037] In step 3 - 20 the client terminal PC requests a web page from the host's IP address. Hypertext Transfer Protocol (HTTP) is typically used for this purpose. This request, like any communication between the client terminal PC and any internet hosts, takes place via the inventive gateway application being executed in the mobile station. Step 3 - 22 is an optional step which may be omitted in some embodiments. When performed, step 3 - 22 includes redirecting the first HTTP page request from client terminal PC to another internet host, called Host′. This means that in step 3 - 24 the gateway application forces the client terminal's first HTTP page request to a forced home page at the IP address of Host′. For example, the operator of the site Host′ may display advertisements in exchange of sponsoring communication costs over the access network AN. In step 3 - 26 the web site Host′ returns the requested web page, which the gateway application relays to the client terminal PC in step 3 - 28 .Another application for the forced home page feature will be described in connection with FIG. 6 .
[0038] In step 3 - 30 the client terminal PC again requests the web page from the host's IP address. Since this the second (or further) page request from the client terminal, the gateway application no longer redirects the HTTP request but relays it to the Host in step 3 - 32 . In steps 3 - 34 and 3 - 36 the requested web page from the Host is transmitted to the client terminal. As shown by arrow 30 , the process can return from step 3 - 36 to step 3 - 20 when future web pages are requested. The loops 3 - 30 through 3 - 36 can be repeated until the gateway application is terminated in step 3 - 40 . If the forced home page feature (step 3 - 22 ) is not implemented, the first HTTP request (step 3 - 20 ) is processed similarly to the subsequent HTTP requests (step 3 - 30 ). In subsequent executions of step 3 - 30 , if the HTTP page request relates to a web page for which the gateway application does not have an IP address, a DSN query will be performed (cf. steps 3 - 14 and 3 - 16 ).
[0039] FIG. 3 also shows an additional client terminal, denoted PC′. Steps 3 - 6 through 3 - 36 will be repeated for each additional client terminal. This means that by virtue of the inventive gateway application, which instructs the mobile station MS to act as a WLAN base station (as opposed to a WLAN client), the mobile station MS can support an arbitrary number of client terminals which act as WLAN client terminals and which, by virtue of the authentication performed by the mobile station, can share a single subscription to the access network.
[0040] FIG. 3 and the foregoing description of it illustrate use of HTTP protocol. The inventive gateway application supports other protocols in an analogous manner and assigns a specific port number to each supported protocol. For instance, the gateway application can instruct the mobile station to convey encrypted HTTPS traffic by utilizing the Proxy Configuration field of HTTPS protocol.
[0041] In addition to merely conveying internet traffic between the client terminal PC and the internet host, the inventive gateway application can, in some specific embodiments, provide additional or supplementary services which utilize some of the functionality of modern mobile stations. In some implementations, such supplementary services are provided by an arrangement in which a supplementary server enhances the service(s) provided by a primary server. Such a supplementary server can be part of the functionality of the inventive WLAN gateway application, or it can be implemented as a network element distinct from the primary server.
[0042] One exemplary implementation of such additional services involves utilization of GPS (Global Positioning System) devices incorporated into some mobile stations. The inventive gateway application may be enhanced to associate GPS-provided geographical coordinates to the PC-to-host traffic, or some of that traffic. For instance, the gateway application can tag still or video image data with geographical coordinates and/or use some additional service (not shown separately) that maps the geographical coordinates to a plaintext name of the relevant location. In another implementation the gateway application associates GPS-provided coordinates to the traffic, or some of it, while the actual tagging of the images with the coordinates is provided by some additional server, such as an image sharing server (not shown separately). Actually, what matters is the location of the client terminal and not the location of the mobile station acting as a WLAN gateway. But considering the short range of the mobile station's WLAN transmission, the mobile station's location can be used as the client terminal's location for virtually all practical purposes.
[0043] In a more ambitious implementation, the gateway application can provide additional services on the basis of the geographical coordinates. For instance, the gateway application can recognize various queries initiated by the client terminal and/or responses to those queries by internet servers and enhance the query responses by relevant map or photography information. For instance, the gateway application can detect a query to “post” and provide the query response with a map and/or photograph of the post office closest to the mobile station's GPS-provided geographical coordinates. In order to obtain the map and/or photograph, the gateway application may query a supplementary server which provides the requested functionality.
[0044] Another example of such additional services relates to traffic statistics which the gateway application collects and transmits to some internet-based supplementary server (not shown separately). For example, such a supplementary server may use the traffic statistics to monitor Quality of Service (QoS) parameters, which can be used to maintain the QoS at a specified level and/or to optimize resource usage in the access network. In some embodiments the supplementary server is an advertising server. The advertising server may utilize the traffic statistics for targeted or tailored advertising to the client terminal PC. Such traffic statistics may include, for example, user identification, usage (amount of traffic, usage times, internet addresses visited, query parameters, or the like). Alternatively or additionally, the gateway application may transmit traffic statistics to a billing server which participates in charging the client terminal's subscriber. Yet further, the advertising server and the billing server may cooperate in such a mariner that the advertising server's operator sells advertisement space or time and the advertising server credits the client terminal's subscriber for any advertisements received. The credits are then relayed to and used by the billing server in order to reduce the client terminal's subscriber's invoice, generate additional services, extend pre-paid subscription time, to name just a few examples.
[0045] Finally, the gateway application may be configured to convey the mobile station's location, or some derivative it, to the advertising server for targeted or tailored advertising on the basis of the mobile station's location. For instance, targeted advertising for some goods or service may include sending an advertisement to a client terminal only if the mobile station's location indicates that the client terminal is reasonably close to the outlet of the goods or service. On the other hand, tailored advertising may be implemented such that the advertisement indicates the address or location of the closest outlet.
[0046] FIGS. 4 and 5 illustrate some exemplary embodiments in which the present invention benefits from the functionality of modem mobile stations, such that the resulting WLAN gateway is functionally superior to dedicated WLAN base stations. FIG. 4 shows an embodiment in which the WLAN circuitry, and optionally the WLAN gateway application, in the mobile station MS is activated periodically to detect possible WLAN client terminals CT nearby. In one representative scenario, a WLAN-capable digital camera acts as a WLAN client terminal. In the embodiment shown in FIG. 4 , the mobile station MS employs two timers which may be realized by means of software-implemented tick counters, as is well known to those skilled in the art. One of the timers is called a sleep timer while the other is called a watchdog timer. The sleep timer's function is to periodically wake up the mobile station's WLAN circuitry, and optionally the WLAN gateway application. The watchdog timer is used to detect non-activity periods of predetermined length in the WLAN network so that the WLAN circuitry can be powered off in order to optimize battery resources.
[0047] In step 41 the WLAN circuitry of the mobile station MS is powered off and the execution of the WLAN gateway application may be suspended or terminated. Step 41 terminates when the sleep timer expires. For instance, the sleep timer may generate a processor interrupt which directs the mobile station's processor to perform program routines for activating the WLAN circuitry and starting or resuming execution of the WLAN gateway application. After step 42 the mobile station has established a WLAN network. In step 43 the mobile station checks if any client terminal(s), such as the exemplary digital camera, attempt(s) to attach to the WLAN network. If not, the process proceeds to step 48 , in which the WLAN network and circuitry are deactivated and the process begins anew at step 41 . On the other hand, if any client terminal attaches to the WLAN network, the mobile station starts a watchdog timer in step 44 and maintains the WLAN network as indicated in step 45 . Step 46 includes a test to detect client terminal activity. If client terminal activity is detected, the process returns to step 44 in which the watchdog timer is restarted. Naturally, any client-related requests are served as well, as part of the basic functionality of the WLAN gateway application. On the other hand, if no client terminal activity is detected, the process proceeds to step 47 which is a test as to whether the watchdog timer has expired. If not, the process returns to step 45 in which the WLAN network is maintained without restarting the watchdog timer. Eventually, a moment occurs when no client activity has been detected and the watchdog timer expires, and this is detected in step 47 . Then, in step 48 , the WLAN network and circuitry are deactivated and the process begins anew at step 41 .
[0048] By virtue of the embodiment described in connection with FIG. 4 , the WLAN gateway application may terminate its own execution and power off the mobile station's WLAN circuitry. The automatic execution of the gateway application and the accompanying automatic activation of the mobile station's WLAN circuitry provides certain benefits. For instance, both digital cameras and mobile stations are handicapped by small user interfaces and relatively short battery life, particularly when their liquid-crystal displays (LCD) are illuminated. The automation described in connection with the present embodiment alleviates such handicaps.
[0049] FIG. 5 shows an embodiment in which the mobile station's location-determination functionality is used to enhance image uploading to an image hosting server. In step 5 - 0 a WLAN connection is established between the gateway application being executed in the mobile station MS and the WLAN-equipped digital camera CAM acting as a client terminal CT. For details of the WLAN connection establishment a reference is made to FIGS. 3 and 4 . In step 5 - 2 the camera CAM/CT initiates a DNS inquiry to obtain the internet address of the image hosting server. In step 5 - 4 an embodiment of the gateway application being executed in the mobile station MS detects that the camera/client terminal CAM/CT executes a location-aware application. Accordingly, the gateway application uses the mobile station's location-determination functionality to determine the mobile station's location. For instance, the mobile station's location may be determined on the basis of the mobile station's built-in satellite-positioning device (GPS) or on the basis of cell ID determination in the access networks. In an optional step 5 - 8 , the gateway application sends the mobile station's location to an embodiment of the supplementary server SS, which in this scenario receives the mobile station's location and returns a plaintext-formatted location description. For instance, the geographical coordinates or cell ID of Piccadilly Circus might be converted to a plaintext description of “Piccadilly Circus, London”. In step 5 - 10 , the camera/client terminal CAM/CT begins uploading of image data to the image hosting server. In step 5 - 12 the gateway application complements the image data with the mobile station's location. In one particular implementation, the location data is placed in a metadata field of the image(s).
[0050] FIG. 6 shows applications for a forced homepage feature. Steps 3 - 22 through 3 - 28 described in connection with FIG. 3 related to a forced homepage feature, wherein, when a client terminal PC/CT requests a page from a server called Host, the gateway application forces the client terminal's first HTTP page request to a forced home page at the IP address of Host′. FIG. 6 shows a variation of this feature wherein the mobile station acting as the WLAN gateway also contains a media server for sharing media or content among the client terminals served by the mobile station's gateway application. An illustrative but non-exhaustive list of content types which may typically be used in connection with the media server includes image files, such as photographs, illustrations, or the like; moving images, such as video clips or computer-created animations, text documents, presentations, or any other types of content that people may share among friends, relatives or colleagues, or in business-to-business discussions. In connection with smart mobile phones, the list of useful content types further includes contacts (for name and contact information) and settings (for smart phones). The mobile station acting as the WLAN gateway stores the content for the media server locally.
[0051] In FIG. 6 , steps 3 - 0 through 3 - 20 are similar or can be similar to the corresponding steps discussed in connection with FIG. 3 , which is why these steps will not be described again. Step 6 - 22 is analogous with step 3 - 22 , in which the gateway application initiated redirection of the client terminal's first HTTP page request to the forced home page. In the embodiment shown in FIG. 6 , the forced home page points to the media server of the mobile station acting as the WLAN gateway. Step 6 - 24 is similar to step 3 - 24 , in which the client terminal makes its first HTTP page request. In the present embodiment the page request is redirected to the media server's opening screen. In a typical but non-restrictive implementation, the media server's opening screen may present links to the various content types offered by the media server, such as “Photos”, “Videos”, “Documents”, “Illustrations”, “Contacts”, “Settings”, etc. In step 6 - 26 the media server's opening screen is returned to the client terminal PC/CT. Assuming that the media server's opening screen contains links to the various content types offered by the media server, the user of the client terminal may now activate any one of these links at a time for navigating to the section, such as a folder, of the media server that stores the relevant content types. The user of the client terminal may then opt to transfer content from the client terminal to the media server or vice versa. Uploading of content from the client terminal to the media server and downloading of content from the media server to the client terminal takes place over the WLAN network established by the WLAN gateway. This feature thus eliminates the need to transfer locally shared content over a mobile network and the global internet. The client terminals may use an internet browser to access the content stored on the media server. Alternatively or additionally, the capability to access the content stored on the media server may be implemented in the client terminals.
[0052] FIG. 7 illustrates an exemplary computing system 700 that may be used to implement a computing device for use with the present technology. System 700 of FIG. 7 may be implemented in the contexts of the likes of a mobile station MS, a PC/CT, or host 190 . The computing system 700 of FIG. 7 includes one or more processors 710 and memory 720 . Main memory 720 stores, in part, instructions and data for execution by processor 710 . Main memory 720 can store the executable code when in operation. The system 700 of FIG. 7 further includes a mass storage device 730 , portable storage medium drive(s) 740 , output devices 750 , user input devices 760 , a graphics display 770 , and peripheral devices 780 .
[0053] The components shown in FIG. 7 are depicted as being connected via a single bus 790 . However, the components may be connected through one or more data transport means. For example, processor unit 710 and main memory 720 may be connected via a local microprocessor bus, and the mass storage device 730 , peripheral device(s) 780 , portable storage device 740 , and display system 770 may be connected via one or more input/output (I/O) buses.
[0054] Mass storage device 730 , which may be implemented with a magnetic disk drive or an optical disk drive, is a non-volatile storage device for storing data and instructions for use by processor unit 710 . Mass storage device 730 can store the system software for implementing embodiments of the present invention for purposes of loading that software into main memory 720 .
[0055] Portable storage device 740 operates in conjunction with a portable non-volatile storage medium, such as a floppy disk, compact disk or Digital video disc, to input and output data and code to and from the computer system 700 of FIG. 7 . The system software for implementing embodiments of the present invention may be stored on such a portable medium and input to the computer system 700 via the portable storage device 740 .
[0056] Input devices 760 provide a portion of a user interface. Input devices 760 may include an alpha-numeric keypad, such as a keyboard, for inputting alpha-numeric and other information, or a pointing device, such as a mouse, a trackball, stylus, or cursor direction keys. Additionally, the system 700 as shown in FIG. 7 includes output devices 750 . Examples of suitable output devices include speakers, printers, network interfaces, and monitors.
[0057] Display system 770 may include a liquid crystal display (LCD) or other suitable display device. Display system 770 receives textual and graphical information, and processes the information for output to the display device.
[0058] Peripherals 780 may include any type of computer support device to add additional functionality to the computer system. For example, peripheral device(s) 780 may include a modem or a router.
[0059] The components contained in the computer system 700 of FIG. 7 are those typically found in computer systems that may be suitable for use with embodiments of the present invention and are intended to represent a broad category of such computer components that are well known in the art. Thus, the computer system 700 of FIG. 7 can be a personal computer, hand held computing device, telephone, mobile computing device, workstation, server, minicomputer, mainframe computer, or any other computing device. The computer can also include different bus configurations, networked platforms, multiprocessor platforms, etc. Various operating systems can be used including Unix, Linux, Windows, Macintosh OS, Palm OS, and other suitable operating systems.
[0060] According to another optional feature, the media server contains an access control facility by which the user of the mobile station may determine which folders are visible to the client terminals of the local WLAN network.
[0061] As regards implementation, the media server can be a light server configured to support a few client terminals simultaneously. Highly complex server functions can be considered superfluous in a typical implementation, with file server functionality and, optionally, access control being the most important function(s).
[0062] It is readily apparent to a person skilled in the art that, as the technology advances, the inventive concept can be implemented in various ways. The invention and its embodiments are not limited to the examples described above but may vary within the scope of the claims.
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A technique for operating a mobile station as wireless local-area network [“WLAN”] gate-way. A gateway application sets up ( 3 - 0 ) a WLAN base station capable of communicating with WLAN terminals over a WLAN network; creates a network identifier ( 3 - 2, 3 - 4 ) for the WLAN base station; assigns ( 3 - 8, 3 - 10 ) an IP address for the WLAN terminals; resolves domain name service [“DNS”] queries ( 3 - 12 . . . 3 - 18 ) in cooperation with an external DNS service system; assigns a port number protocols supported by the gateway application; and tunnels internet traffic ( 3 - 30 . . . 3 - 36 ) between the WLAN terminals and an internet host over the broadband connection. The memory further comprises a media server application for sharing content among the one or more WLAN terminals. The gateway application may redirect ( 6 - 22 ) a first HTTP page request ( 6 - 24 ) from the WLAN terminals to a start page of the media server application.
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This is a division of application Ser. No. 901,500 filed Aug. 28, 1986.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a method of removing particles such as foreign matter and dust from a flexible support (hereinafter referred to merely as "a support"), and an apparatus for practicing the method (hereinafter referred to as "a dust removing apparatus").
2. Terminology
The term "support" as used herein is intended to mean a flexible belt-shaped article having a width of several centimeters to several meters, a length of more than several tens of meters, and a thickness of several micrometers to several hundreds of micrometers. The belt-shaped article is made of a plastic film of polyethylene terephthalate, polyethylene-2, 6-napthalate, cellulose diacetate, cellulose triacetate, cellulose acetate propionate, polyvinyl chloride, polyvinylidene chloride, polycarbonate, polyimide or polyamide. Alternatively, the belt-shaped article is paper coated or laminated with α-polyolefin such as polyethylene, polypropylene or ethylene butane copolymer or is a metal foil of aluminum, copper or tin. The flexible belt-shaped product includes one on which a preliminary manufactured layer is formed.
The support is coated with a coating solution such as a photo-sensitive coating solution, a magnetic coating solution, a surface-protecting coating solution, a charging-preventing coating solution, or a smoothing coating solution, depending on its purpose of use. After the coating solution thus applied has been dried, the support is cut into pieces having a predetermined length and width. Typical examples of the product are photographic films, photographic papers, and magnetic tapes.
However, this terminology is by way of example only and is not intended to limit the invention.
BACKGROUND ART
In a conventional method of removing particles, such as foreign matter or dust from a support (hereinafter referred to as "a dust removing method"), a piece of unwoven cloth or blade suitably held is pushed against the support so that the particles are caught by the piece of unwoven cloth or blade. In another conventional dust removing method, a stream of clean air is applied to the support at high speed so that the particles are separated from the support and led to a suction port. These methods are of dry type. On the other hand, a wet type dust removing method has been known in the art in which the support is immersed in a washing solution tank, in which the particles are separated from the support by ultrasonic vibration. In another conventional wet type dust removing method, a washing solution is applied to the support, and an air stream is applied to the support at high speed and sucked therefrom (cf. Japanese Patent Application Publication No. 13020/1974).
The above-described conventional dust removing methods still suffer from several disadvantages.
For instance, in the method in which the particles are caught by the unwoven cloth or blade, the support may be scratched or electrostatically charged by the friction, or the fibers of the unwoven cloth may stick to the support.
The dust removing method using the high speed air stream is effective in removing relatively large particles of several tens of micrometers or more from the support. However, it is scarcely effective in catching relatively small particles or particles strongly adhering to the support.
In the wet type dust removing methods, the equipment is large in scale. Furthermore, in removing particles from the support running at high speed, a large quantity of mist is produced which sticks to the peripheral devices and to the support from which the particles have been removed.
In order to eliminate the above-described difficulties the present applicant has proposed a dust removing method (Japanese Patent Application (OPI) No. 150571/1984, the term "OPI" as used herein meaning an "unexamined published application"). In this method, as shown in FIGS. 1 and 2, a solvent is applied to the surface of a support 1. While the solvent remains on the support 1, two stationary plates are pushed against the surface of the support 1 to remove the particles 18 together with a part of the solvent from the support.
Thereafter, the inventor has conducted intensive research on a more effective dust removing method and an apparatus for practicing the method, and accomplished the present invention.
SUMMARY OF THE INVENTION
In view of the above-described difficulties accompanying a conventional method of removing particles such as foreign matter or dust from a flexible support, an object of this invention is to provide an apparatus for removing particles such as foreign matter and dust from a flexible support.
The foregoing object and other objects of this invention have been achieved by the provision of a method of removing particles from a flexible support in which, according to the invention, the solvent-wetted surface of a rod member rotating in a direction opposite to direction of running of the flexible support is set close to one side of the flexible support so that the particles on the one side of the support are transferred onto the outer cylindrical surface of the rod member, and separated from the outer cylindrical surface of the rod member.
The invention further provides an apparatus for removing particles from the flexible support in which the solvent-wetted surface of the rod member rotating in a direction opposite to the direction of running of the flexible support is set close to one side of the support so that the particles on the one side of the support are transferred onto the outer cylindrical surface of the rod member and separated from the outer cylindrical surface of the rod member. According to the invention, the apparatus comprises a rod member connected to a rotating drive source so as to be rotated in a direction opposite to the direction of running of the flexible support and a block member having both a slit in which a negative pressure can be maintained and a slit into which a solvent can be supplied. The block member is able to rotatably hold the rod member. Alternatively, instead of the negative pressure, solvent can be applied to the support before it reaches the rod member.
It is preferable that the outside diameter of the rod member is in a range of from 1 mm to 50 mm.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view showing a part of a dust removing apparatus.
FIG. 2 is a sectional view showing a part of the apparatus in FIG. 1.
FIG. 3 is a sectional view, partly as a block diagram, showing a first example of a dust removing apparatus according to this invention.
FIG. 4 is a perspective view showing a part of the apparatus of FIG. 3.
FIG. 5 is an explanatory diagram outlining a coating apparatus used for determining the effect of the invention.
FIG. 6 is a sectional diagram, partly as a block diagram, showing a second example of the dust removing apparatus according to the invention.
FIG. 7 is a sectional diagram, partly as a block diagram, showing a third example of the dust removing apparatus according to the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Preferred embodiments of this invention will be described with reference to the accompanying drawings.
FIG. 3 is a sectional view showing a first example of an apparatus for removing dust from a flexible support according to the invention, and FIG. 4 is a perspective view showing an operating state of the apparatus.
A flexible support 1 laid over a plurality of guide rollers 2 is conveyed in a predetermined direction in the direction of the arrow A.
A rod 3 is disposed between the aforementioned guide rollers 2 and 2 in such a manner that it contacts the surface of the support 1 at a small lap angle and is rotated at a considerably low speed in the direction B opposite to the running direction A of the support 1. The peripheral speed of the rod 3 is at least 0.1 cm/sec.
In order to rotate the rod 3, any drive source 4 may be employed if it can provide a low speed rotation output. However, it is preferable to employ an oil pressure motor or an air pressure motor for environment security against solvent gas.
In general, the rod 3 is 1 to 50 mm in diameter, and at least its surface is composed of cemented carbide (such as WC-TAC) or fine ceramics such as alumina A-150 or zirconia) and has a surface roughness of 1 micrometers to 0.05 micrometer in R max . The length of the rod 3 is longer than the width of the support 1.
The rod 3 is rotatably supported by a block 5 whose width is substantially equal to the length of the rod 3.
The block 5 includes partitions 8, 9 and 10 which form slits 6 and 7 as shown in FIG. 3.
The upper ends of the partitions 9 and 10 are curved surfaces whose radius of curvature is substantially equal to the radius of the rod 3 in order to hold the rod 3. In the partition 10, a plurality of liquid outlet holes 11 are formed at suitable intervals in such a manner that they are arranged horizontally near the top.
A liquid pool 13 is provided outside of the partition 10. In other words, the block 5 includes an outside wall 12 to form the liquid pool 13 against the partition 10.
The slit 6 communicates through its bottom to an exhaust blower 14 so that the air pressure in the slit 6 is maintained -20 to -100 mm-aq., that is, a negative pressure relative to atmospheric pressure as measured in millimeters of water.
On the other hand, the slit 7 communicates with a solvent supplying system consisting of a solvent supplying tank 15, a pressurizing pump 16 and a filter 17, so that the slit 7 is filled with a solvent, such as xylole or butyl acetate. A larger part of the solvent flows through the liquid outlet holes 11 into the liquid pool 13, and is returned into the solvent supplying tank 15 when necessary. Additional solvent is supplied to the supplying tank 15 to compensate for solvent loss.
The apparatus thus constructed operates as follows.
The support 1 is run in the direction of the arrow A. When particles 18 such as dust stuck to the surface of the support 1 approach the surface of the rod 3 rotating in the direction B opposite to the direction of running of the support 1, they are separated from the surface of the support 1 by the rotation of the rod 3 and the air flow accompanying the support. As a result, the particles are transferred onto the surface of the rod 3, and are then delivered to the upper end of the slit 6 by the rotation of the rod 3.
When the particles are delivered to the upper end of the slit 6, as was described above, most of the particles are separated from the surface of the rod 3 and sucked into the slit 6 by the negative pressure in the slit 6. The particles 18 thus sucked are discharged through the exhaust blower 14.
On the other hand, some of the particles 18 remaining on the surface of the rod 3 are separated form the rod 3 by the washing action of the solvent supplied into the right-hand slit 7 while passing over the upper end of the slit 7. The particles thus separated are discharged through the liquid outlet holes 11.
The rod 3 covered with the solvent is continuously rotated, which increases the effect that the particles 18 are transferred onto the surface of the rod 3.
In the lap region of the support 1 and the rod 3, a small gap is formed therebetween by the air accompanying the support 1. The small gap thus formed permits the passage of fine particles. That is, it is difficult to completely remove the fine particles from the support because of the small gap thus formed. Therefore, it is desirable that a backing roll 19 confronts the rod 3 with the support 1 therebetween, as indicated by the broken line 19, as the case may be.
In the case where a number of particles 18 have adhered to the support 1, they are liable to transfer onto one and the same part of the surface of the rod 3. If this is repeated, then the gap between the support and the rod is locally increased to permit the passage of particles. That is, it becomes impossible to completely remove the particles from the support 1. In order to eliminate this difficulty, it is desirable to provide means for reciprocally sliding at least the rod in the
widthwise direction of the support.
SPECIFIC EXAMPLE
The dust removing apparatus as shown in FIG. 3 using a xylole solvent was used to remove dust from one side of a support of polyethylene terephthalate of 38 micrometer in thickness and 500 mm in width which was run at a speed of 200 m/min. After the dust was removed from the support, a coating apparatus 20, as shown in FIG. 5 and disclosed in Japanese patent application No. 94657/1984, was used to coat the one side of the support 1 with the magnetic coating solution whose composition is indicated in the following Table 1. The support 1 was coated by the magnetic coating solution to thicknesses of 3 micrometers, 5 micrometers and 10 micrometers. The coated surface was then checked for pin holes and stripes.
The rod 3 of the dust removing apparatus was made of carbide (WC-TAC), and had a diameter of 6 mm and a surface roughness of 0.5 micrometer in R max . The rod was rotated at a peripheral speed of 0.5 cm/sec.
The pressure in the slit 6 was -60 mm-aq. and the flow rate of xylole supplied to the slit 7 was 500 cc/min.
The magnetic coating solution was prepared as follows. The materials shown in Table 1 were sufficiently mixed and dispersed in a ball mill, and mixed with epoxy resin (epoxy equivalent 500) of 30 parts by weight. The resultant mixture was further subjected to mixing and dispersing, to prepare the magnetic coating solution.
TABLE 1______________________________________Υ-Fe.sub.2 O.sub.3 powder (needle-shaped 300 parts by weightparticles having an average powderdiameter of 0.5 micrometer in themajor diameter direction; a coerciveforce of 320 Oe)Vinyl chloride vinyl acetate 30 parts by weightcopolymer (copolymerizationratio 87:13, polymerizationdegree 400)Electrically conductive carbon 20 parts by weightPolyamide resin (amine value 300) 15 parts by weightRecithin 6 parts by weightSilicon oil (dimethyl polysiloxane) 3 parts by weightXylole 300 parts by weightMethyl isobutyl ketone 300 parts by weightn-butanole 100 parts by weight______________________________________
The results are as indicated in Table 2 below.
COMPARISON EXAMPLE
For a comparison, the magnetic coating solution was applied to the support under the same conditions as those of the above-described specific examples except that the dust removing apparatus was not used. The coated surface of the comparison example was then checked for pin holes and stripes. The results are as indicated in Table 2 below:
TABLE 2______________________________________ Coated magnetic Dust removing layer thickness apparatus Defect 3 μm 5 μm 10 μm______________________________________Specific Stripes 0.2 0 0example Used Pin holes 0.6 0.2 0Comparison Stripes 10.2 6.5 4.8example Not used Pin holes 85.1 41.3 35.3______________________________________ Note In both the specific example and the comparison example, ten supports eac of a length of 4000 m were used. The data in Table 2 indicate the numbers of defects per support.
Now, a second embodiment of the invention will be described. The embodiment provides a method of removing particles from a flexible support, in which one side of the flexible support is coated with a solvent. A solvent-wetted surface of a rod member rotating in a direction opposite to the direction of running of the support is set close to the one side of the support while the solvent also remains on the support. As a result, the particles on the one side of the support are transferred onto the outer cylindrical surface of the rod member and are then separated from the outer cylindrical surface of the rotating rod member. The embodiment further provides an apparatus for practicing the method.
A second example of the dust removing apparatus according to the invention will be described with reference to FIG. 6. In FIG. 6, those components which have been previously described with reference to FIG. 3 (the first example) are designated by the same reference numerals or characters.
As shown in FIG. 6, the apparatus has a block 5 having partitions 8, 9 and 10 which form slits 6 and 7.
Liquid pools 13-1 and 13-2 are provided outside of the partitions 8 and 10 on either side of the block 5. In other words, the block 5 includes outside walls 12-1 and 12-2 to form the liquid pools 13-1 and 13-2 against the outer partitions 8 and 10.
On the other hand, the slits 6 and 7 communicate with a solvent supplying system consisting of a solvent supplying tank 15, a pressurizing pump 16 and a filter 17, and are filled with a solvent, such as xylole or butyl acetate. A larger part of the solvent is discharged through the liquid outlet holes 11 into the liquid pools 13-1 and 13-2. The solvent in the liquid pools 13-1 and 13-2 is returned into the solvent supplying tank 15 when necessary.
In the apparatus thus constructed, the support 1 is run in the direction of the arrow A. When the particles 18 stuck to the surface of the support 1 approach the surface of the rod 3 rotating in the direction B opposite to the direction of the arrow A, the particles are separated from the surface of the support 1 by the rotation of the rod 3 and the action of the solvent applied to the support 1 from the slit 6 and the particles are transferred onto the surface of the rod 3. The particles thus transferred are brought to the upper end of the slit 6 as the rod 3 rotates.
On the other hand, the particles 18 transferred onto the surface of the rod 3 as described above are separated from the surface of the rod 3 by the washing action of the solvent supplied into the slits 6 and 7 while the solvent passes over the upper ends of the slits 6 and 7. The particles thus separated are discharged through the upper region of the slit 6 and through the liquid outlet holes 11.
The rod 3 covered with the solvent is continuously rotated, which action further increases the effect that the particles 18 are transferred onto the surface of the rod 3.
FIG. 7 shows a third example of the dust removing apparatus according to the invention. In the apparatus, a solvent applying section (equivalent to the slit 6 of FIG. 6) is provided separately. That is, the solvent is applied to the support by a roll coater 22. In FIG. 7, parts corresponding functionally to those already described with reference to FIG. 7 are therefore designated by the same reference numerals or characters.
SPECIFIC EXAMPLE
A convention roll coater was used to apply a xylole solvent to one side of a polyethylene terephthalate support at a flow rate of 100 cc/m 2 . The support was 38 micrometers in thickness and 500 mm in width. While the solvent remains on the support, the particles were removed therefrom with the dust removing apparatus of FIG. 7 using a xylole solvent. Thereafter, the coating apparatus 20 as shown in FIG. 5 was used to apply the magnetic coating solution to one side of the cleaned support 1 to thickness of 3 micrometers, 5 micrometers and 10 micrometers. The coated surface was then checked for defects such as pin holes and stripes.
In the dust removing apparatus, the rod 3 was made of carbide (WC-TAC) and had a diameter of 6 mm and a surface roughness of 0.5 micrometer, and it was rotated at a peripheral speed of 0.5 cm/sec. The xylole solvent was supplied to the slit 7 at a flow rate of 500 cc/min.
In the concrete example described above, the magnetic coating solution indicated in Table 1 was used. The results are as indicated in Table 3 below:
COMPARISON EXAMPLE
For a second comparison, the magnetic coating solution was applied to the support under the same conditions as those of the second specific example except that the solvent precoating operation and the dust removing apparatus were not employed. The coated but uncleaned surface was checked for defects such as pin holes and stripes. The results are as shown in Table 3 below:
TABLE 3______________________________________ Coated magnetic Dust removing layer thickness apparatus Defect 3 μm 5 μm 10 μm______________________________________Specific Stripes 0 0 0example Used Pin holes 0.1 0.2 0Comparison Stripes 10.2 6.5 4.8example Not used Pin holes 85.1 41.3 35.3______________________________________ Note Both in the specific example and in the comparison example, ten supports each 4000 m long were used. In Table 3, the numerical data are the number of defects per support.
The invention provides many beneficial effects.
As was described above, the cylindrical surface of the rod 3 rotating in the direction B opposite to the direction A of running of the support 1 is brought into sliding contact with the surface of the support 1 from which dust should be removed. As a result large air speeds are generated in the atmosphere near the surface of the support. Therefore, the dust (particles) 18 floats from the surface of the support, thus being effectively transferred onto the surface of the rod 3.
A negative pressure is held in the slit 6 in the embodiment of FIG. 3. Therefore, the particles 18 transferred onto the surface of the rod 3 are separated therefrom and discharged through the slit.
The solvent is supplied into the slit 7. Therefore, some of the particles remaining on the surface of the rod are washed by the solvent and discharged to the outside. At the same time, the surface of the rod 3 is wetted with the solvent, and therefore the particles are more effectively transferred onto the surface of the rod 3. Thus, the dust can be removed from the support with high efficiency.
In the second example of the dust removing apparatus shown in FIG. 6, the solvent is supplied into both of the slits 6 and 7. Therefore, not only are the particles 18 washed away from the surface of the rod 3 by the solvent, but also the surface of the rod 3 is covered with the solvent. Accordingly, the particles can be more effectively transferred onto the surface of the rod 3. That is, the particles can be removed from the support with high reliability.
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A method and apparatus for removing particles from a flexible sheet. The sheet is run over a rotating rod, rotating oppositely to the moment of the sheet. The rod is immersed on its lower side in a bath of solvent and excess solvent is removed from the bath and is filtered. Additionally, solvent may be applied to the sheet before it reaches the rotating rod or a negative pressure applied just upstream of the rod sucks away the particles.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to hermetic compressors having positive displacement liquid lubricant pumps to supply liquid lubricant to bearing surfaces. More specifically, the present invention relates to compressors including liquid lubricant pumps having cavities disposed within the pump and drive shaft to trap debris by magnetic and centrifugal force.
[0003] 2. Description of the Related Art
[0004] Compressor lubrication systems often include a positive displacement lubrication pump to supply liquid lubricant to bearings surfaces within the compressor. Liquid lubricant, or oil, often contains debris in the form of metallic particles circulating throughout the lubrication system. The particles detrimentally affect bearing surfaces by causing premature wear, and consequently, compressor performance is compromised. It is known to provide cartridge type or screen filters to capture debris, however an inherent disadvantage of cartridge and screen filters are that they clog and consequently block circulation of oil to bearing surfaces which significantly shortens the life of the compressor. Responsive to this clogged filter effect, compressor assemblies have been adapted with bypass valving, for example, which routes the oil around the filter when the filter becomes clogged to effectively maintain an adequate oil supply to the bearing surfaces. However, the circulating oil remains debris laden which may cause an abrasive attack on the bearing surfaces resulting in bearing seizure and imminent failure of the compression mechanism.
[0005] Hermetic compressor assemblies are susceptible to oil-entrained debris, the most destructive being the fine powdered debris, which may not be captured by standard cartridge and filtering methods. The fine powders entrained in the oil are often composed of ferrous material which is attracted to a magnet. While previous compressor assemblies have utilized magnets to attract entrained metallic particles, these compressors have proven to do so inefficiently. Typically, magnets are randomly placed within the interior of the compressor housing, producing marginal particle accumulation performance. Therefore, the marginal benefits provided by these types of compressors, in view of the substantial costs associated with installing magnets to attract ferrous particles, have limited their practicality.
[0006] Further, with evolving and more demanding environmental standards, the hydrocarbon based oils and refrigerants traditionally used are yielding to environmental friendly substitutes. However, it is not fully understood whether these substitute lubricants are equally effective in providing comparable levels of lubrication and durability to the compressor mechanism. Thus, improving the ability to remove foreign particles from liquid lubricant, without a substantial compressor assembly cost increase, would be highly desirable.
[0007] Yet another problem associated with the use of impeller type pumps in compressor assemblies is one of drive shaft misalignment, relative to the pump housing, during the assembly process. Traditionally, misalignment of the drive shaft and pump housing was avoided by providing the pump housing, compressor mechanism assembly and impeller pump assembly with precise tolerances. A significant labor and handling cost is associated with parts having precise tolerances. What is desired is an impeller type pump assembly structure which requires significantly less labor to manufacture and assemble compared to previously employed structures.
[0008] An inexpensive oil pump assembly which includes the ability to trap debris suspended in the oil while continuously providing an ample supply of oil to bearing surfaces is highly desired. Further, an oil pump assembly which provides further cost reduction attributable to avoiding precise part tolerances in preventing drive shaft and pump housing misalignment is desired.
SUMMARY OF THE INVENTION
[0009] The present invention overcomes the disadvantages of prior compressor assemblies by providing a hermetic compressor assembly which includes a compressor housing including a quantity of liquid lubricant therein, a compressor mechanism provided within the compressor housing, a drive shaft selectively rotatable and operably connected to the compressor mechanism, a liquid lubricant displacement element engaged to the drive shaft and a support member attached to the compressor housing, a pivotable magnetic member provided between the liquid lubricant displacement element and the support member provided with a suction port therein. The liquid lubricant displacement element is in fluid communication with the quantity of liquid lubricant through the suction port in the magnetic member. At least a portion of any ferrous particles contained in the liquid lubricant are attracted to and retained by the magnetic member as the liquid lubricant is passed through the suction port of the magnetic member.
[0010] The present invention further provides a hermetic compressor assembly including a compressor mechanism and a quantity of liquid lubricant provided in a compressor housing, a selectively operable drive shaft driveably connected to the compressor mechanism, a liquid lubricant displacement element supported by a support member and engaged to the drive shaft. The compression mechanism and the liquid lubricant displacement element are in fluid communication through a passage provided in the drive shaft. A centrifugal particle trap cavity is defined by a wall of the passage within the drive shaft and a portion of the liquid lubricant displacement element. A magnetic member is pivotably supported by the support member and a thrust member is superposed with the magnetic member. A magnetic particle trap cavity is provided within a lateral face of the thrust member and is partially enclosed by a lateral surface of the magnetic member. The liquid lubricant is urged from the sump to the compression mechanism through the passage in the drive shaft and any debris in the liquid lubricant is successively retained by the magnetic particle trap cavity and the centrifugal particle trap cavity prior to the lubricants introduction to the compression mechanism.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] The above-mentioned and other features and advantages of this invention, and the manner of attaining them, will become more apparent and the invention itself will be better understood by reference to the following description of embodiments of the invention taken in conjunction with the accompanying drawings, wherein:
[0012] [0012]FIG. 1 is a sectional view of a hermetic compressor assembly provided with an oil pump assembly in accordance with the present invention;
[0013] [0013]FIG. 2A is an exploded view of a first embodiment of an oil pump assembly in accordance with the present invention, viewing the pump from the bottom;
[0014] [0014]FIG. 2B is an exploded view of the thrust plate and magnetic disk assembly of a second embodiment of an oil pump assembly in accordance with the present invention, viewing the assembly from the bottom;
[0015] [0015]FIG. 3A is an exploded view of the oil pump assembly of FIG. 2A, viewing the pump from the top;
[0016] [0016]FIG. 3B is an exploded view of the thrust plate and magnetic disk assembly of FIG. 2B, viewing the assembly from the top;
[0017] [0017]FIG. 4 is a sectional view of the oil pump assembly taken along line 4 - 4 of FIG. 11, however shown in an operational mode, illustrating a flow of oil therethrough and particles being trapped in respective magnetic and centrifugal traps;
[0018] [0018]FIG. 5 is a sectional view of the oil pump assembly taken along lines 5 - 5 of FIG. 11, however shown in a non-operational mode;
[0019] [0019]FIG. 6 is a plan view of the bottom of the impeller of the oil pump of FIG. 2A, showing the plurality of impeller blades;
[0020] [0020]FIG. 7 is a plan view of the bottom of the thrust plate of the oil pump of FIG. 2A, showing the pair of arcuate slots and the magnetic particle trap cavity;
[0021] [0021]FIG. 8 is a plan view of the bottom of the magnetic disk of the oil pump of FIG. 2A;
[0022] [0022]FIG. 9 is a plan view of the top of the pump housing of the oil pump of FIG. 3A;
[0023] [0023]FIG. 10A is a fragmentary sectional view of the oil pump assembly according to the present invention enclosed within the circular portion shown as line 10 A- 10 A of FIG. 11, showing the engagement between the frustoconical surfaces of the pump housing and magnetic disk;
[0024] [0024]FIG. 10B is a fragmentary sectional view of a third embodiment of the oil pump assembly according to the present invention showing the engagement between the spherical surfaces of the pump housing and magnetic disk; and
[0025] [0025]FIG. 11 is a bottom view of the oil pump assembly of FIG. 2A.
[0026] Corresponding reference characters indicate corresponding parts throughout the several views. Although the drawings represent embodiments of the present invention, the drawings are not necessarily to scale and certain features may be exaggerated in order to better illustrate and explain the present invention. The exemplifications set out herein illustrate embodiments of the invention, and such exemplifications are not to be construed as limiting the scope of the invention in any manner.
DETAILED DESCRIPTION OF THE INVENTION
[0027] Referring to FIG. 1, compressor assembly 10 includes hermetically sealed housing 12 , having base 17 provided at a lower end thereof. Motor assembly 14 , enclosed within housing 12 , includes rotor 11 and stator 13 and is directly connected to, and operatively drives, compression mechanism 15 . Compression mechanism 15 may constitute a reciprocating piston-type compression mechanism, as shown, which includes cylinder block 16 having reciprocating piston 18 therein. Alternatively, compression mechanism 15 may be a rotary or scroll type mechanism. Drive shaft or crankshaft 20 is driveably coupled to motor assembly 14 and extends vertically from a lowermost portion of compressor assembly 10 upwardly towards compression mechanism 15 . Upper end of crankshaft 20 is rotatably supported by main bearing 22 and is generally hollow, including inner passage 23 extending axially, and continuously, along the length of crankshaft 20 . Arrows 25 illustrate flow of liquid lubricant (e.g., oil), which is directed through passage 23 of crankshaft 20 , to supply oil to bearing surfaces, such as rod bearing 24 , and to wrist pin 27 , as shown. Oil pump assembly 42 is positioned at lower end 36 of crankshaft 20 to urge oil from oil sump 30 to upper end 38 of crankshaft 20 . Support member 43 , provided within lower portion 28 of housing 12 to support pump 42 , includes a plurality of arms 33 equidistantly spaced and radially extended between pump 42 and inner surface 35 of housing 12 . Oil sump 30 , formed by lower portion 28 of housing 12 , contains surplus oil to supply pump assembly 42 with oil. Oil level 32 within sump 30 is preferably maintained above oil pump assembly 42 , as shown, such that a continuous supply of oil is pumped to bearing surfaces by pump assembly 42 .
[0028] Referring to FIGS. 2A and 3A, shown is oil pump assembly 42 , engaged with lower end 36 of crankshaft 20 . Lower end 36 of crankshaft 20 includes end face 50 and outer surface 46 . Lower end 36 of crankshaft is attached to oil displacement element or impeller 52 . Alternatively, oil displacement element 52 may include a gerotor or gear type element to transfer oil from sump 30 to compression mechanism 15 (FIG. 1). It may be seen that counterbore 40 (FIG. 2A) is formed in lower end 36 of crankshaft 20 to receive stem 56 of impeller 52 . End face 50 of crankshaft 20 includes angled counterbore or chamfer 44 provided in counterbore 40 of crankshaft 20 (FIG. 2A). A pair of diametrically opposed slots 48 (FIG. 2A) radially extend from counterbore 40 of crankshaft 20 toward outer surface 46 of crankshaft 20 to engageably receive tangs 60 of impeller 52 . Tangs 60 axially extend from disk shaped drive portion 54 and are attached to a periphery of impeller stem 56 (FIG. 3A).
[0029] Impeller stem 56 axially extends from drive portion 54 and includes circumferentially disposed groove 58 (FIGS. 4 and 5), having a U-shaped cross section and O-ring 62 is received therein. O-ring 62 provides a liquid seal between the outer periphery of impeller stem 56 and counterbore 40 of drive shaft 20 (FIGS. 4 and 5). Drive portion 54 of impeller 52 includes a plurality of radially arranged impeller blades 66 . Each impeller blade 66 is separated from an adjacent impeller blade 66 by circumferential spaced groove 65 (FIG. 6). As best seen in FIGS. 2A and 6, impeller 52 includes annular groove 68 located substantially centered on lower surface of drive portion 54 of impeller 52 . Impeller 52 includes center portion 69 provided with generally planar surface 71 which is coextensive with surface 73 of each respective impeller blade 66 (FIG. 6). Hole 64 extends axially through impeller 52 . Surfaces 71 and 73 form thrust face 70 (FIGS. 4 - 5 ) of impeller 52 .
[0030] Referring again to FIGS. 2A and 3A, shown is thrust member or thrust plate 72 having thrust face 74 which rotatably supports thrust face 70 of impeller 52 (FIGS. 4 - 5 ). It may be seen that a clearance “c” exists between main bearing 22 and shoulder portion 75 of crankshaft 20 such that the weight of crankshaft 20 and displacement element 52 urges displacement element 52 into engagement with face 74 of thrust plate 72 (FIG. 1). Those having ordinary skill will understand that the combined weight of crankshaft 20 , and displacement element 52 , bearing down on face 74 of thrust plate 72 prevents a significant and detrimental loss of lubricant through an interface provided by displacement element 52 and face 74 of thrust plate 72 .
[0031] Thrust plate 72 includes outer radial surface 76 and lateral surface 77 (FIG. 7). Lateral surface 77 is provided with lower faces 78 a , 78 b and 78 c which collectively form a planar support surface which abuts upper face 86 of magnetic member or disk 84 (FIGS. 2A and 7). Thrust plate 72 is provided with central hole 80 which is aligned with central hole 64 of impeller 52 (FIGS. 4 and 5). As best seen in FIGS. 2A and 4, thrust plate 72 includes extended annular nose portion 81 , split into two arcuate halves, each of which axially extend from lower face 78 b . The two halves of nose portion 81 are engaged with recess 94 in magnetic disk 84 to center thrust plate 72 relative to magnetic disk 84 (FIG. 3A).
[0032] Magnetic disk 84 includes upper face 86 , lower face 88 and peripheral surface 90 , and as best seen in FIGS. 3A and 8, is provided with semi-circular notch 92 which receives semi-circular protrusion 82 (FIG. 7) axially extended from thrust plate 72 . Protrusion 82 , extended into notch 92 , prevents rotation between magnetic disk 84 relative to thrust plate 72 . Lower face 88 of magnetic disk 84 includes three projections 96 intersected at centerline axis 85 and radially extended towards peripheral surface 90 of magnetic disk 84 (FIGS. 2A and 11). Referring to FIG. 11, radial projections 96 are engaged with three circumferentially spaced slots 116 (FIG. 9) located in pump housing 104 to prevent rotation between magnetic disk 84 and pump housing 104 . Housing 104 is fixed to support member 43 by, for example, a press fit engagement between outer surface 106 of housing 104 and counterbore 105 located in support member 43 (FIG. 1). Alternatively housing 104 may be eliminated and in its place support member 43 may be provided with identically internal characteristics as that of housing 104 .
[0033] Magnetic disk 84 may be manufactured from a magnetized metallic material through, for example, a sinterized powder metal process. The magnetic properties of magnetic disk 84 attract ferrous particles 87 (FIG. 4) entrained or suspended in the oil as described below. Impeller 52 and thrust plate 72 may be made of an abrasion resistant moldable plastic, such as a phenolic material for example, through an injection molding process. Crankshaft 20 may be preferably made from a carbon steel and formed through a forging process to produce high durability and abrasion resistant properties.
[0034] An alternate thrust plate and magnetic disk engagement is shown in FIGS. 2B and 3B. As best seen in FIG. 2B, magnetic disk 84 ′ includes a pair of through holes 98 aligned with a pair of holes 99 in thrust plate 72 ′. Holes 99 are engaged by a pair of fasteners 100 , which may include, for example, brads, to secure magnetic disk 84 ′ to thrust plate 72 ′.
[0035] Referring to FIGS. 2 - 5 , pump housing 104 is provided with cylindrical outer surface 106 and cylindrical inner surface 108 (FIGS. 3 - 5 ). Housing 104 and support member 43 may be made from an aluminum alloy through a die cast molding process or a powder metal process, for example. As best seen in FIG. 10A, lower end 109 of housing 104 includes annular platform 110 which provides support for magnetic disk 84 . Platform 110 includes inwardly angled frustoconical surface 112 providing support for outwardly angled frustoconical surface 102 (FIG. 8) provided on lower face 88 of magnetic disk 84 (FIGS. 4, 5 and 10 ). Lower end 109 of housing 104 includes through hole 114 extended axially through housing 104 to provide an inlet for oil to be drawn into pump 42 by the oil displacement element, e.g. impeller. Frustoconical surface 112 , provided on annular platform 110 , forms a frustoconical engagement with frustoconical surface 102 of magnetic disk 84 . The frustoconical engagement provides a degree of self alignment of the abutting faces of impeller 52 and thrust plate 72 , despite angular variations in the housing centerline relative to the shaft centerline. As a result, reliance on close manufacturing and assembling tolerances of impeller 52 , crankshaft 20 and thrust plate 72 , traditionally employed, are not required with oil pump 42 .
[0036] Referring to FIG. 10B, a third embodiment of a lubricant pump is shown and includes mating hemispherically shaped surfaces 102 ′, 112 ′ of magnetic member and housing 104 ′, 84 ′ respectively. As an alternative to frustoconical surfaces 102 , 112 shown, in FIG. 10A, hemispherical surfaces 102 ′, 112 ′ shown in FIG. 10B provide increased pivoting mobility between magnetic member 84 ′ relative to housing 104 ′ to remedy the angular variations in the housing centerline relative to the shaft centerline.
[0037] The flow of oil through oil pump assembly 42 will now be described. Referring to FIG. 4, oil is drawn through suction port or hole 114 of housing 104 from sump 30 and into a pair of arcuate suction ports 120 formed in magnetic disk 84 (FIGS. 4, 8 and 11 ). Arcuate suction ports 120 extend completely through the magnetic disk from lower face 88 to upper face 86 (FIG. 8). Similarly, arcuate suction port 122 extends completely through thrust plate 72 between thrust face 74 and lower face 78 a thereof (FIG. 7). Arcuate suction port 122 , provided in thrust plate 72 , is radially aligned with the pair of arcuate suction ports 120 in magnetic disk 84 . It may be seen that thrust plate 72 includes a pair of U-shaped discharge slots 126 provided in outer periphery 76 of thrust plate 72 (FIG. 3A). Slots 126 are oppositely located relative to one another and axially extend into a pair of arcuate channels 130 formed in thrust plate 72 (FIGS. 2A, 7). Channels 130 are provided in lateral surface 77 of thrust plate 72 as described below.
[0038] As best seen in FIGS. 7 , each channel 130 includes transverse wall 132 , first sidewall 136 , and second sidewall 138 . Transverse wall 132 is substantially planar and is formed within lateral surface 77 of thrust plate 72 . First sidewall 136 is arcuate and extends from its respective discharge slot 126 to hole 80 in thrust plate 72 . Each second side wall 138 of channel 130 includes U-shaped entrance slot 140 . A portion of oil received by slots 126 from impeller 52 flows into channels 130 and into central hole 80 in thrust plate 72 . The other portion of oil flows into magnetic particle trap cavity 142 as described below.
[0039] Lateral surface 77 of thrust plate 72 is provided with crescent-shaped magnetic particle trap cavity 142 . First sidewall 144 of magnetic particle trap cavity 142 includes a plurality of circumferentially spaced semi-circular inclusions 146 (FIG. 7). Second sidewall 148 of magnetic particle trap cavity 142 is generally smooth and continuous. Magnetic particle trap cavity 142 includes transverse wall 150 provided in lateral surface 77 of thrust plate 72 . Magnetic particle trap cavity 142 is enclosed by upper face 86 of magnetic disk 84 .
[0040] In operation, pump 42 is activated by motor driven shaft 20 urging rotation of impeller 52 and oil in sump 30 (FIG. 1) is drawn, illustrated by arrows 149 in FIG. 4, into suction port 120 of magnetic disk 84 . Thereafter, oil enters suction port 122 provided in thrust plate 72 . Over time it is well understood that a compressor assembly generates debris entrained in the oil and frequently a portion of the debris is in the form of ferrous particles. Ferrous particles, which may be included in the present invention lubricant pump 42 , are attracted to and retained by magnetic disk 84 before the oil enters suction port 122 of thrust plate 72 . Oil then enters annular groove 68 within impeller 52 and is centrifugally flung radially outward through radially positioned grooves 65 between impeller blades 66 . The oil is then urged downwardly into U-shaped discharge slots 126 in thrust plate 72 , and thereafter, a portion of the oil is urged into the pair of arcuate channels 130 which extend toward central hole 80 of the thrust plate 72 . Oil entering central hole 80 of thrust plate 72 via channels 130 is urged upwardly through hole 64 in impeller 52 , into passage 23 of crankshaft 20 , and is ultimately received by the bearing surfaces within compressor mechanism.
[0041] The portion of oil which does not travel through arcuate slots 130 enters magnetic particle trap cavity 142 and is slow moving due to the debris entrained therein. The oil entering magnetic particle trap cavity 142 is flung radially outward into the plurality of inclusions 146 in first sidewall 144 . Oil circulates radially through magnetic particle trap cavity 142 entering one of the U-shaped slots 126 and exiting the other U-shaped slot 126 . Since thrust plate 72 is symmetrical, pump 42 may operate in either rotational direction with similar particle trapping results, i.e., pump 42 is reversible.
[0042] Referring to FIGS. 4 and 5, it may be seen that upper face 86 of magnetic disk 84 overlays arcuate channels 130 and magnetic particle trap cavity 142 of thrust plate 72 . Ferrous particles 87 entering magnetic particle trap cavity 142 are carried with the oil and are attracted to and trapped by upper face 86 of magnetic disk 84 under the influence of magnetic force established by magnetic disk 84 (FIG. 4). Additionally, oil flowing through channels 130 includes ferrous particles which pass over magnetic disk 84 and become attracted and attached to face 86 of magnetic disk. Additional particles and debris, which may include ferrous or non-ferrous particles, are caught within inclusions 146 of magnetic particle trap cavity 142 as oil flows through cavity 142 . Therefore, magnetic particle trap cavity 142 and face 86 of magnetic disk 84 provide a two-stage debris retaining structure, the first stage provided by inclusions 146 within thrust plate 72 , trapping a portion of the debris therein, and a second stage, provided by face 86 of magnetic disk 84 , trapping additional debris, in the form of ferrous particles 87 .
[0043] As best seen in FIG. 4, drive shaft 20 is provided with centrifugal particle trap cavity 155 radially located within a wall defining passage 23 . Specifically, centrifugal particle trap cavity 155 is bound by counterbore 40 and frustoconical surface 156 of impeller stem 56 , on one axial end, and frustoconical surface 160 of the other axial end. Thus, it may be seen that annular, frustoconical surfaces 156 , 160 , and a portion of counterbore 40 in crankshaft 20 , form centrifugal particle trap cavity 155 to capture debris 162 , as it is transported by the oil flowing through passage 23 , shown by flow arrow 149 (FIG. 4). Particles 162 , under the influence of centrifugal force as crankshaft 20 is rotated by motor assembly 14 , are flung into centrifugal particle trap cavity 155 as oil moves through passage 23 . Particles 162 are thereby centrifugally trapped in centrifugal particle trap cavity 155 during compressor operation, and are prevented from thereafter continuing with the oil upwards through passage 23 .
[0044] Referring to FIG. 5, it may be seen that once shaft 20 ceases rotation, at least a portion of particles 162 travel downwardly and rest upon conical surface 156 formed by impeller stem 56 . The remaining particles continue downwardly from second chamber 155 and accumulate at center portion 164 of magnetic disk 84 and some particles may eventually flush back through oil pump 42 and into oil sump 30 or magnetic particle trap cavity 142 . Those having ordinary skill in the art will understand that an abundance of debris entrained in the oil will not plug inventive pump 42 . Rather, magnetic and centrifugal particle trap cavities 142 , 155 are so positioned within the oil circuit such that oil is allowed to pass through pump 42 regardless of whether the magnetic and centrifugal particle trap cavities are replete with debris. Since hermetically sealed compressor assembly 10 of the present invention is manufactured to be non-maintainable, i.e., not to be disassembled for maintenance purposes, it is particularly important that oil pump 42 continues to perform even if a significant amount of debris is accumulated within magnetic and centrifugal particle trap cavities 142 , 155 .
[0045] Referring to FIGS. 2 - 5 , gas vent 166 extends from chamfer 44 of crankshaft 20 to outer surface 46 of crankshaft 20 to provide an escape path for refrigerant gases flashed from the oil in pump 42 . Gases or vapor which are not vented may be detrimental to proper lubricant flow, inasmuch as it may cause an insufficient amount of oil being delivered to the bearing surfaces. Vent 166 provides an escape for these gases to avoid bearing damage.
[0046] While this invention has been described as having exemplary designs, the present invention may be further modified within the spirit and scope of this disclosure. Therefore, this application is intended to cover any variations, uses, or adaptations of the invention using its general principles. For example, aspects of the present invention may be applied to compressors other than reciprocating piston compressors such as rotary and scroll compressor assemblies, for example. Further, this application is intended to cover such departures from the present disclosure as come within known or customary practice in the art to which this invention pertains.
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A hermetic compressor assembly includes a compressor housing having a quantity of liquid lubricant therein. A compressor mechanism is provided within the compressor housing and a drive shaft is selectively rotatable and operably connected to the compressor mechanism. A liquid lubricant displacement element is engaged to the drive shaft and a support member is attached to the compressor housing. A pivotable magnetic member is provided between the liquid lubricant displacement element and the support member and includes a suction port provided therein. The liquid lubricant displacement element is in fluid communication with the quantity of liquid lubricant through the suction port in the magnetic member. At least a portion of any ferrous particles contained in the liquid lubricant are attracted to and retained by the magnetic member as the liquid lubricant is passed through the suction port of the magnetic member.
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FIELD OF INVENTION
This invention relates to electronic data manipulation processes. More specifically, this invention relates to electronic data compression processes.
BACKGROUND
FIG. 1 illustrates a typical LZ data compression method. The LZ compression method of FIG. 1 processes an input data stream 10 to generate a compressed data output stream 20 by comparing an uncompressed portion 13 of input data stream 10 to data in a history buffer 11 of already processed input data. If a data string 12 is located in history buffer 11 which matches current data string 14, data string 14 is then encoded in compressed data stream 20 as a codeword (p o , l o ) 24, corresponding to an offset p o 15 and a data length l o 16. The shorter length of data, such as codeword (p o , l o ) 24 thus replaces longer data string 14 in output compressed data stream 20.
Offset p o 15 is typically a random number that fails within a known range of values determined by the length of history buffer 11. Although the actual value of offset 15 often happens to be a small value, offset 15 also has an upper maximum in that known range of values that increases as the length of history buffer 11 increases. Encoding a variable, such as offset 15, using a single codebook coding method is well known. Typical single fixed length codebook coding method represents offset 15 using a fixed length codeword. A n-bit fixed length codebook codes 2 n source data, encoding decimal equivalents from 0 to (2 n -1) with fixed n number of bits per codeword.
FIG. 2 illustrates two fixed length codebooks, a 3-bit fixed length codebook 30 and a 4-bit fixed length codebook 40. A 3-bit fixed length codebook encodes up to 2 3 or 8 source data, encoding data from 0 to 7 with 3 bits per codeword. The coding range maximum for a 3-bit fixed codebook is therefore equivalent to the decimal numeral 7. A 4-bit fixed length codebook provides a larger codebook than a 3-bit fixed length codebook, since a 4-bit codebook codes 2 4 or 16 source data, providing a coding range from 0-15. It would be desirable to select a small single fixed length codebook to encode offset 15, which is often a small value. However, since the upper range of offset 15 is constantly increasing to correspond to the constantly increasing length of history buffer 11 as the data compression progresses, the single fixed length codebook selected at the outset of data compression should be sufficiently large to encode the maximum possible value of offset 15. Selecting such a large single fixed length codebook is inefficient when the typical offset value is often a small value, and using an unnecessarily large codebook therefore undesirably increases the number of bits per codeword to be stored, thereby also increasing the memory requirements for the stored data.
FIG. 3 illustrates an example of a 3-bit variable length single codebook coding method. As shown in FIG. 3, a 3-bit variable single codebook has a coding range maximum of 4, encoding data from 0 to 4. The codeword format increases from a 2 bit per codeword representation to a 3 bit per codeword representation in one codebook. The variable length codebook allows coding of offset values from 0 to 2 with only two bits, rather than the 3 bits per codeword of a 3-bit fixed codebook, while still allowing coding of data value 3 and 4 in the same codebook when needed. Thus, a variable length codebook provides efficient coding for a variable with recurring smaller values, while increasing the upper maximum range of the codeword representation to allow encoding of a larger value within the upper maximum range when that value occurs. However, like the single fixed length variable codebook approach, a single variable length codebook approach is also inflexible as it would require that the codebook selected at the outset of data compression to be sufficiently large to accommodate the maximum possible offset value corresponding to the growing maximum length of history buffer 11 over time.
In the multiple codebooks phase-in coding method, a set of codebooks of variable lengths is provided. As the coding range maximum of offset 15 increases past the maximum coding range of a particular codebook in that set of provided codebooks, the next larger codebook is then automatically selected, or "phased-in," to encode the next offset value. This approach ensures that if a large offset value occurs, then the newly selected codebook will be able to handle that larger offset value.
The traditional multiple codebooks phase-in coding method is however still not very efficient, since offset 15 is often still a small value even if its maximum possible value may have increased with the increasing length of the history buffer over time. Thus, automatically phasing-in the next larger codebook in response to the current possible maximum value of offset 15, unnecessarily increases the length of the codeword, when the actual value of offset 15 can still be represented by the prior smaller codebook used. Since a significant mount of data is continuously transmitted and stored by the computer during its operation, the effect of reducing a data representation even by one bit per codeword is significant when this data bit reduction is multiplied by the mount of data to be coded to produce a significant, highly sought after, memory saving result. It is therefore desirable to provide an efficient data coding system which minimizes the number of bits required to represent a random variable, such as offset 15 that has an upper maximum that increases over time.
SUMMARY OF THE INVENTION
An improved multi-codebook coding process for coding electronic data received by a computer system is provided. The coding process comprises detecting if that input data exceeds a current coding maximum selected from a set of coding maximums, with the set of coding maximums prioritized from the smallest coding maximum to the largest coding maximum. The coding process selects a codebook from a set of codebooks in response to the step of detecting if the input data is greater than the current coding maximum, and then encoding that input data in accordance to the selected codebook to generate a coded output data.
In a decoding process, the decoding process comprises receiving one or more electronic encoded input data and, for each encoded input data, the decoding process detects whether one or more decode method indicators are associated with that encoded input data. The decoding process then selects a codebook for decoding from a set of codebooks in response to whether one or more decode method indicators are detected, the set of codebooks prioritized from the smallest codebook to the largest codebook. The decoding process then decodes that encoded input data in accordance to the selected codebook to generate a decoded output data.
The coding process described in accordance with the principles of this invention accommodates multiple codebooks having differing coding ranges. It is thus an objective of this invention to maximize the data compression of a computer system by minimizing the number of bits to represent each input data by using a smaller codebook where the input data to be coded is detected to be within the coding range of the smaller codebook. A larger codebook is "phased-in" only where the input data to be coded exceeds the coding range of a smaller codebook.
BRIEF DESCRIPTION OF DRAWINGS
Fig. 1 illustrates an example of a typical compression scheme using Ziv-Lempel coding approach;
FIG. 2 illustrates an example of a 3-bit fixed length codebook and a 4-bit fixed length codebook;
FIG. 2 illustrates an example of a 3-bit variable length codebook;
FIG. 4 illustrates a block diagram of an improved multicodebook coding process provided in accordance with the principles of this invention;
FIG. 5 illustrates a detailed block diagram of the coding process shown in FIG. 4;
FIG. 6 illustrates an alternative embodiment of the coding process shown in FIG. 5;
FIG. 7 illustrates a detailed block diagram of the decoding process shown in FIG. 4; and
FIG. 8 illustrates an example of a format of an output coded data buffer produced by the coding process described in accordance with the principles of this invention.
DETAILED DESCRIPTION
FIG. 4 illustrates an example of an improved multi-codebook coding process constructed in accordance with the principles of this invention. Multi-codebook coding process 100 comprises a coding process 110 for encoding input data stream 101 and a decoding process 120 for decoding coded data stream 102. To code data X, coding process 110 receives an input data stream 10 1 and code input data stream 101 in defined block units. The size of each block unit can be defined according to the user's application and need.
FIG. 5 illustrates a more detailed embodiment of coding process 110. For each block of data, coding process 110 compares each input data X in that block of data with a current coding maximum, R i , from a set of coding maximums. Each coding maximum Ki in the set of coding maximums corresponds to the coding range maximum of an associated codebook in the set of provided codebooks. It is envisioned as within the scope of the principles of this invention that the set of codebooks associated with the set of coding maximums to be either a set of fixed length type codebooks, such as shown in Table 1, or a set of variable length codebooks, such as shown in Table 2, or a combination of both fixed length type codebooks and variable length codebooks. It is also envisioned that the number n of codebooks provided in the set of codebooks is a parameter that can be selected according to the user's application or need, as is also with the desired coding range maximums of each codebook associated with the set of codebooks.
TABLE 1__________________________________________________________________________Codebooks Number of Number of CodingCi Codeword Codewords Bits per Coding Maximum(where n = 3) Format in Ci Codeword Range Ri__________________________________________________________________________C1 Codebook X X X 8 3 0 . . . 7 R1 = 7(3-Bit Fixed(C2 Codebook X X X X 16 4 0 . . . 15 R2 = 15(4-Bit Fixed)C3 Codebook X X X X X 32 5 0 . . . 31 R3 = 31(5-Bit Fixed)__________________________________________________________________________
Table 1 illustrates a set of three fixed length codebooks, C1, C2, and C3, with corresponding set of coding maximums, R1, R2, and R3, prioritized from the smallest coding maximum to the largest coding maximum. Correspondingly, codebook C1, having a 3 bits per codeword format, comprises the smallest coding range, with a coding maximum R1=7. Codebook C2, having a 4 bits per codeword format, comprises the next larger coding range in this set of codebooks, with a coding maximum R2=15. Codebook C3, having a 5 bits per codeword format, comprises the largest coding range in this set of codebooks, with a coding maximum R3=31.
To code a block of input data, coding process 100 in step 111 first initiates index i when current data pointer L is at the beginning of a block of input data 150, e.g., L=0 in input data block 150. (See FIG. 8 ). Current codebook Ci is thus initiated to start with the smallest codebook C1 as the current codebook and current coding range maximum Ri is also correspondingly initiated to R1. Coding process then checks to detect if input data X exceeds current coding maximum R1 associated with the current codebook C1. If input data X does not exceed current coding range maximum, e.g., input data is not greater than R1, then coding process in step 113 instructs the computer to continue coding input data with current codebook C1. Comparing the actual value of input data X to current coding range maximum R1, thus minimizes the codeword stored by avoiding unnecessarily using the next larger codebook in the set of codebooks, if input data X is actually small enough in value to be encoded by the then current codebook C1.
If, however, input data X exceeds the current coding range R1, then coding process 110 instructs the computer in step 114 to insert a codebook indicator, such as an ESCAPE code 222, into an output data stream 200 (FIG. 8 ) and increment index i to select the next larger codebook C2 as current codebook Ci for encoding input data X. Current coding maximum Ri is also thereby increased to the next larger coding maximum, R2. Current coding maximum R2 corresponds to the coding range maximum associated with current codebook C2. Thus, when coding process 110 returns to step 112 to repeat the step of comparing input data X to current coding maximum Ri, X is then compared to R2 to detect if X exceeds R2. Steps 112 and 114 are thus repeated until coding process 110 detects that input data X no longer exceeds current coding maximum Ri, Step 113 then codes input data X with the then corresponding current codebook Ci.
TABLE 2__________________________________________________________________________ Number of Number of CodingCodebooks Codeword Codewords Bits per Coding MaximumCi(j) Format in Ci(j) Codeword Range Ri(j)__________________________________________________________________________C1(j) Codebook(5-Bit Variable)C1(1) 0 X X 4 3 0 . . . 3 R1(1) = 3C1(2) 1 0 X X 4 4 4 . . . 7 R1(2) = 7C1(3) 1 1 X X X 8 5 8 . . . 15 R1(3) = 15C2(j) Codebook(7-Bit Variable)C2(1) 0 X X 4 3 0 . . . 3 R2(1) = 3C2(2) 1 0 X X 4 4 4 . . . 7 R2(2) = 7C2(3) 1 1 0 X X X 8 5 8 . . . 15 R2(3) = 15C2(4) 1 1 1 1 X X X 8 7 16 . . . 23 R2(4) = 23__________________________________________________________________________
FIG. 5 together with FIG. 6 illustrate an example of coding process 110 wherein the set of codebooks comprises a set of variable length codebooks, such as the set of variable length codebooks Ci(j) shown in Table 2. The coding steps with a set of variable length codebooks are similar to the coding steps with a set of fixed length codebooks as shown in FIG. 5. Coding process 110 first initializes index i in step 111 and then in step 112 detects whether input data X exceeds current coding maximum R1, associated with the then current codebook C1. If input data X does not exceed current coding maximum R1 then, in step 113, coding process 110 selects current codebook C1. Since C1 is a variable length codebook, coding step 113 as shown in FIG. 6 further comprises comparing input data X with a set of sub-coding maximums R1(j), where j ranges from 1 to n, with n equivalent to the maximum number of sub-codebooks C1(j) associated with current codebook C1. The set of current sub-codebook coding maximums R1(j) is also prioritized from the smallest coding maximum R1(1) to the largest coding maximum R1(3 ). Coding process 113 first initializes index j to select C1(1) and R1(1) and then continues processing input data X by comparing input data X to current sub-codebook coding maximums R1(1). In step 117, coding process detects whether input data X exceeds R1(1). If X is within the coding maximum of R1(1), e.g., X is less than 3, then X is encoded with sub-codebook C1(1) in step 118. If, however, X exceeds R1(1), e.g., X is greater than 3, then, in step 119, coding process increments index j to select the next larger coding maximum R1(2) as the current coding maximum R1(j) and returns to step 117 to compare X to this next larger current coding maximum R1(2) to detect whether X exceeds that next larger coding maximum. Step 117 is thus repeated until input data X is detected not to exceed R1(j), whereupon corresponding current sub-codebook C1(j) is then selected to code X in step 118, and coding process then returns to step 108 (FIG. 5).
FIG. 7 illustrates a detailed embodiment of decoding process 120. Thus, when decoding process 120 detects the beginning of a new block of coded data Y, decoding process 120 initializes index i to select the smallest codebook C1 from a set of codebooks Ci in step 122, the set of codebooks Ci prioritized from the smallest codebook C1 to the largest codebook C3. Decoding process 120 then detects in step 123 whether each encoded data Y in that block of coded data 200 comprises one or more ESCAPE codes 222 prior to each codeword 220 (see FIG. 8). If no ESCAPE code 222 is detected before codeword 220, decoding step 124 instructs the computer to decode codeword 220 using current codebook C1.
If, however, an ESCAPE code is detected, decoding process 120 in step 125 then increments index i and selects the next larger codebook, C2, as current codebook Ci. Decoding process 120 then returns to step 123 to repeat of detecting for an ESCAPE code, and repeats the decoding process from step 123 until no further ESCAPE code is detected. Thus, for example, if two ESCAPE codes precede coded data Y, decoding process 120 first increments Ci to C2 in step 125 upon detecting the first ESCAPE code in step 123. Decoding process then returns to step 123 to repeat the step of detecting for another ESCAPE code. Upon detecting the second ESCAPE code, decoding process in step 125 selects the next larger codebook, C3, as current codebook Ci for decoding. When no further ESCAPE code is subsequently detected upon returning to step 123, decoding process 120 then decodes coded data Y with the then current codebook C3.
In an alternative embodiment, where the set of codebooks comprises a set of variable length codebooks, upon identifying current codebook Ci to decode coded data Y, decoding process 120 then selects an appropriate sub-codebook Ci(j) according to a prefix 210 associated with coded data Y. For example, referring to the set of variable length codebooks of Table 2, upon identifying C1 for decoding coded data Y, if prefix 210 comprises "0", then decoding process 120 selects Ci(1) to decode Y. If prefix "10" is detected as the first two bits of codeword 220, then C1(2) is selected to decode coded data Y.
The improved multiple-codebooks phase-in coding process described in accordance with the principles of this invention accommodates multiple codebooks having differing coding ranges. This process maximizes data compression by minimizing the number of bits required to represent each input data by using a smaller codebook where the input data to be coded is detected to be within the coding range of the smaller codebook. A larger codebook is "phased-in" only where the input data to be coded actually does exceed the coding range of a smaller codebook.
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An improved multi-codebook phase-in coding process for coding electronic data wherein for each received electronic input data, the coding process detects whether that input data exceeds a current coding maximum, then selecting a codebook coding method from one or more codebook coding methods in response to detecting whether that input data exceeds the current coding maximum, and then encoding that input data in accordance to the selected codebook coding method to generate a coded output data. A corresponding codebook indicator is inserted into a generated coded output data stream to indicate which codebook method to use to decode the coded output data. During decoding, the decoding process detects for a decode method indicator associated with each encoded input data, and decodes in accordance to a decode method corresponding to the detected decode method indicator to generate a decoded output data.
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CROSS REFERENCE TO RELATED APPLICATION
This is a continuation-in-part application of application Ser. No. 10/966,905, now U.S. Pat. No. 7,378,187, issued May 27, 2008 and filed Oct. 14, 2004, which claims priority to and the benefit of Korea Patent Application No. 10-2003-0071948 filed on Oct. 15, 2003 in the Korean Intellectual Property Office, the entire content of both of which is incorporated herein by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a secondary battery, and more particularly, to a structure of a cap assembly forming a top of a secondary battery and a method of fabricating the same.
2. Description of the Related Art
As is generally known in the art, secondary batteries are rechargeable and can be fabricated in a smaller size with a larger capacity than primary batteries. Secondary batteries may be classified into nickel-hydrogen (Ni-MH) batteries, lithium (Li) batteries, lithium ion (Li-ion) batteries, and polymer lithium (PLI) batteries according to the materials of the secondary batteries, or into cylinder type batteries and square type batteries according to their appearances.
According to a typical method of fabricating a secondary battery, an electrode assembly including a positive electrode plate, a negative electrode plate and a separator is seated in a can generally made from aluminum or an aluminum alloy. Electrolyte is injected into the can, and the can assembly is then sealed. Each can has an electrode terminal which is formed at an upper portion of the can and is insulated from the can. The electrode terminal has a positive or negative polarity determining a polarity of the can. In addition, each can includes a positive temperature coefficient (PTC) element, a thermal fuse, and a protection circuit module (PCM).
The secondary battery employs an electrode structure in a “jelly-roll” configuration formed by winding a positive electrode plate, a negative electrode plate, and a separator interposed between the positive electrode plate and the negative electrode plate, together. The shape of the battery determines the shape of the jelly-roll employed by the battery. That is, a cylinder type battery employs a jelly-roll wound in a cylindrical shape, and a square type battery employs a jelly-roll wound in a polygonal shape having angular corners and flat sides.
FIG. 1 is a sectional view of a conventional secondary battery having a typical construction. As shown in FIG. 1 , a cylinder type secondary battery includes electrode assembly 110 for generating potential difference, cylinder-type can 120 for receiving electrode assembly 110 , cap assembly 130 assembled with a top of cylinder-type can 120 , so as to prevent electrode assembly 110 from being separated from cylinder-type can 120 , and electrolyte 140 injected in cylinder-type can 120 , so as to enable movement of ions between electrodes of electrode assembly 110 . Cap assembly 130 has various safety devices provided at cap assembly 130 .
Cylinder-type can 120 has clamp portion 121 bent inward so as to push cap assembly 130 inward and a bead portion 122 depressed inward so as to push cap assembly 130 upward.
Cap assembly 130 includes conductive safety vent unit 131 , printed circuit board 132 , PTC element 133 , and positive electrode cap 134 . Conductive safety vent unit 131 has a bottom welded to a positive electrode lead 111 and has a convex portion which is inverted when the battery is excessively charged or abnormally heated. Printed circuit board 132 is disposed above and is electrically and mechanically connected to conductive safety vent unit 131 . Printed circuit board 132 has a circuit which is cut off when the convex portion of conductive safety vent unit 131 is inverted. PTC element 133 is disposed above and is electrically and mechanically connected to printed circuit board 132 . PTC element 133 is electrically cut off when heated exceeding a predetermined temperature. Positive electrode cap 134 is disposed above and is electrically and mechanically connected to PTC element 133 . Positive electrode cap 134 allows current to flow to the exterior. Insulating gasket 135 surrounds circumferential portions of conductive safety vent unit 131 , current breaker 132 , PTC element 133 , and positive electrode cap 134 , stacked on each other, and insulates them from cylinder-type can 120 .
However, in cap assembly 130 of the conventional cylinder-type secondary battery, conductive safety vent unit 131 , printed circuit board 132 , PTC element 133 , and positive electrode cap 134 are simply stacked on each other, and central portion 135 a , lower dip portion 135 b , and upper dip portion 135 c of insulating gasket 135 are simply in contact with the circumferential portion of cap assembly 130 including conductive safety vent unit 131 , printed circuit board 132 , PTC element 133 and positive electrode cap 134 , stacked on each other. Therefore, insulating gasket 135 cannot sufficiently seal the gap between the interior and the exterior of the can and may allow internal gas of the can to leak through a nip between cap assembly 130 and insulating gasket 135 when the internal pressure has excessively increased.
SUMMARY OF THE INVENTION
In accordance with the present invention an integrated cap assembly of a secondary battery and a method of fabricating the same is provided wherein the cap assembly includes a cap lamination and an insulating gasket surrounding and clamping the cap lamination with an increased tightness, the cap lamination may include a conductive safety vent unit, a printed circuit board, a PTC element, and a positive electrode cap, the safety vent unit may include a safety vent, contact plate connected to an electrode lead of electrode assembly in the secondary battery and an insulating plate which makes the safety vent and the contact plate meet only at an electric connection portion.
Also in accordance with the present invention an integrated cap assembly of a secondary battery and a method of fabricating the same is provided which can simplify the process of fabricating the secondary battery, thereby increasing the productivity and reducing the manufacturing cost
Further in accordance with the present invention an integrated cap assembly of a secondary battery is provided which includes a cap lamination and a gasket integrated with each other through injection-molding in a state that a peripheral portion of the cap lamination is inserted in the gasket, wherein the cap lamination may include a conductive safety vent unit, a printed circuit board, a PTC element, and a positive electrode cap. In an exemplary embodiment a groove and/or a hole is formed at a portion of at least one element of the cap lamination being inserted in the inner side of an insulating gasket, the portion may be a peripheral portion of a lowermost element of the cap lamination, so that a portion of the insulating gasket is inserted in the hole or the groove, thereby enhancing the assembling force between the cap lamination and the insulating gasket.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a sectional view of a conventional cylinder-type secondary battery.
FIG. 2 is a sectional view of a cap assembly according to an exemplary embodiment of the present invention.
FIG. 3 is a sectional view of a cap assembly according to another embodiment of the invention.
FIG. 4 is a sectional view of a cap assembly according to yet another embodiment of the invention.
FIG. 5 is a sectional view of a cap assembly according to still another embodiment of the invention.
FIG. 6 is a sectional view of a cap assembly according to yet another embodiment of the invention.
FIG. 7 is a flowchart showing a process for integrally molding a cap assembly according to an exemplary embodiment of the present invention.
DETAILED DESCRIPTION
Referring now to FIG. 2 , an exemplary embodiment of a cap assembly according to the present invention includes a cap lamination and insulating gasket 235 . The cap lamination includes conductive safety vent unit 231 , printed circuit board 232 , PTC element 233 , and positive electrode cap 234 .
Conductive safety vent unit 231 seals a can of the secondary battery and can be bent outward (upward in the drawing) by a pressure generated in the secondary battery. Conductive safety vent unit 231 has a central portion which is deformed or convex inward (downward in the drawing) in a normal state. The downward convex or deformed portion of conductive safety vent unit 231 is electrically connected with a positive electrode tab extending from a positive electrode plate of an electrode assembly placed in the can of the secondary battery.
Printed circuit board/current breaker 232 is disposed above conductive safety vent unit 231 and transfers electric current supplied from the positive electrode tab to positive electrode cap 234 . Printed circuit board/current breaker 232 has a current-interrupting means which is broken and interrupts electric current flow by the deformation of conductive safety vent unit 231 when the internal pressure of the battery exceeds a predetermined value due to abnormal operation such as excessive charging, etc. Printed circuit board/current breaker 232 is usually made from an epoxy-based resin. Printed circuit board/current breaker 232 includes a traverse extending over and across the deformed portion of conductive safety vent unit 231 and its ring-shaped member connected to opposite ends of the traverse. The traverse has a breakable portion which can be tom by the force applied by the deformed portion of conductive safety vent unit 231 when the deformed portion of conductive safety vent unit 231 is inverted. The breakable portion is a weakened portion having slits formed through central and end portions of the traverse. The breakable portion may have either a single kind of at least two slits, or combination of slits and grooves.
PTC element 233 is a current regulator which instantly increases the resistance to regulate or interrupt current flow when the temperature of the battery increases beyond a safety limit. PTC element 233 is optional in a cap assembly of a secondary battery according to the present invention.
Positive electrode cap 234 has a plurality of pores. Positive electrode cap 234 is an element which may come into contact with an external terminal.
The cap lamination including the elements as described above is assembled with insulating gasket 235 . In order to assemble the cap lamination with insulating gasket 235 , the cap lamination is inserted in and is integrally formed with insulating gasket 235 when insulating gasket 235 is molded. Then, a portion of the edges of the cap lamination is inserted into insulating gasket 235 . Edges of each element of the cap lamination integrally molded in insulating gasket 235 , i.e., each of conductive safety vent unit 231 , Printed circuit board/current breaker 232 , PTC element 233 , and positive electrode cap 234 , are individually integrated with insulating gasket 235 . Therefore, the cap lamination and insulating gasket 235 are completely integrated with each other without any gap between them. Here, when some elements such as PTC element 233 are omitted in the cap lamination, only the other elements of the cap lamination are stacked on each other and then inserted in insulating gasket 235 while insulating gasket 235 is molded.
Further, groove H, which in exemplary embodiments may be an annular through-hole or a recess, is formed at a peripheral portion of Printed circuit board/current breaker 232 , which is the lowermost element of the cap lamination. As a result, when insulating gasket 235 is molded, a portion of insulating gasket 235 is inserted in groove H, thereby enhancing the assembling force between the cap lamination and insulating gasket 235 . In one exemplary embodiment, groove H is wedge shaped having an upper or rear portion wider than a lower or inlet portion thereof. Here, groove H may have not only a frusto-conical shape but also various shapes including shapes of polygonal prisms, such as triangular prisms, rectangular prisms, pentagonal prisms, etc. Further, although FIG. 2 shows groove H formed at the lowermost element of the cap lamination, a groove, hole or recess may be formed in and/or through the lower two elements or all the elements of the cap lamination.
FIG. 3 to FIG. 6 are sectional views of a cylinder-type cap assembly according to other exemplary embodiments of the present invention.
FIG. 3 shows a contact plate 336 which has a through-hole 3361 and is connected to an electrode lead (not shown) of an electrode assembly, placed at the lowermost layer of the cap assembly.
Conductive safety vent unit 331 has a ring-shaped peripheral portion separated from the contact plate 336 by the insulating plate 337 . The conductive safety vent unit 331 , which is placed above the contact plate 336 , also has a central portion formed downward convexly so that it is contact with the contact plate 336 .
PTC 333 and a positive electrode cap 334 are mounted above conductive safety vent unit 331 .
The cap lamination assembly may be integrally formed with a gasket 335 , its peripheral portion of the cap lamination assembly being covered by the gasket when the gasket is formed through injection-molding.
Also, the cap lamination assembly and the gasket 335 are integrally inserted in the upper portion of a can and become part of the cylinder-type secondary battery through a crimping process.
In the gasket injection process, a portion of the gasket 335 is directed into a wedge-shaped through-hole 3363 formed in the contact plate 336 and solidified, thereby enhancing the physical assembling force between the gasket and the cap lamination assembly.
The through-hole 3363 may be formed such that the diameter of its upper part is the same as the diameter of its lower part. Alternatively, the through-hole 3363 may have a conical shape.
If heating in the interior of the secondary battery raises the interior pressure of the battery to an abnormal level, the pressure on the through-hole 3361 will push the downward convex portion of conductive safety vent unit 331 upward to cut off contact between the conductive safety vent and the contact plate 336 . Thus electric current between an electrode lead (not shown) and the positive electrode cap 334 will be interrupted.
Additionally, PTC 333 works independently of conductive safety vent unit 331 to turn off the electric current between the electrode lead (not shown) and the positive electrode cap 334 .
FIG. 4 shows an exemplary embodiment of a cap assembly similar to the cap assembly shown in FIG. 3 . However, the conductive safety vent unit 331 has an extension part 4311 formed on a peripheral portion thereof, the extension part extending around a lower contact plate 436 . The extension part 4311 may be deeply embedded in the interior part of an insulating gasket 435 in the exemplary embodiment of FIG. 4 .
A hole 4363 for strengthening contact between a cap assembly and the insulating gasket 435 is formed in the peripheral portion of the contact plate 436 .
If the extension part 4311 is bent inward, the extension part may form a groove together with the lower side of the peripheral portion of the contact plate 436 , and the interior of the groove can be filled with the insulating gasket 435 .
The exemplary embodiment of a cap lamination assembly as shown in FIG. 5 is similar to the exemplary embodiment of FIG. 3 .
However, a peripheral portion of a contact plate 536 having a through-hole 5361 at the lowermost layer of a cap lamination assembly and being connected to an electrode lead (not shown) of an electrode assembly is bent upward. A peripheral portion of an insulating plate 537 above the contact plate 536 is also convexed upward.
Conductive safety vent unit 531 , which has a peripheral portion not in contact with the contact plate 536 , and a central portion formed convexly so as to contact the contact plate is placed above the insulating plate.
A positive electrode cap 534 are mounted above conductive safety vent unit 531 , and a PTC 533 may be mounted there as well.
In this exemplary embodiment, the insulating plate 536 , conductive safety vent unit 531 , PTC 533 , and the positive electrode cap 534 are placed in a fixed position above the contact plate 536 and the insulating plate 537 of the lowermost layer.
The cap lamination assembly is also integrally formed with a gasket 535 , its peripheral portion being covered by the gasket when the gasket is formed through injection-molding as described above.
Also, the cap lamination assembly and the gasket 535 inserted in the upper portion of the can, and become part of the cylinder-type secondary battery through the crimping process.
The exemplary embodiment of FIG. 6 is also substantially similar to the cap assembly of FIG. 3 .
However, a contact plate 636 and an insulating plate 637 are formed so as to correspond to and be attachable to the central portion of conductive safety vent unit 631 . Thus, the thickness of the lamination assembly and the length of the secondary battery may be reduced.
Also, a peripheral portion of conductive safety vent unit 631 itself has holes 6313 for strengthening assembly with an insulating gasket 635 . Additionally, the contact plate 636 has a hole 6361 allowing it to operate with conductive safety vent unit 631 .
As a positive electrode cap 634 , PTC 633 , the contact plate 636 , and conductive safety vent unit 631 having the insulating plate 637 are laminated and the gasket 635 is injected therein, a portion of the gasket becomes embedded in hole 6313 and solidifies. Thus, the lamination assembly becomes integrally formed with the insulating gasket 635 .
An electrode lead (not shown) of an electrode assembly is welded to the contact plate 636 , and the lamination assembly is inserted into the upper part of the cylinder-type cap through crimping to complete assembly of the secondary battery.
FIG. 7 is a flowchart showing a process for integrally molding a cap assembly according to an exemplary embodiment of the present invention. As shown in FIG. 7 , the method of injection-molding a cap assembly according to the present invention includes: aligning and stacking elements of a cap lamination on each other (S 31 ); picking up and transferring the cap lamination (S 32 ); inserting and supporting the cap lamination in a mold (S 33 ); injecting a molding material, thereby injection-molding a gasket with the cap lamination (S 34 ); and taking the cap assembly out of the mold (S 35 ).
In the element aligning and stacking step (S 31 ), conductive safety vent unit 231 , printed circuit board 232 , PTC element 233 , and positive electrode cap 234 , which constitute the cap lamination, are aligned and sequentially stacked one after another. Then, the aligned and stacked cap lamination is supported and held by a holder, such as a pneumatically-operated forced pin, etc. Here, the forced pin may have a shape of a dip and may be preferably from the same material as that of the gasket.
In the cap lamination pick up and transfer step (S 32 ), the cap lamination having been supported and held by a forced pin, etc., is picked up and held by a dual pin, tweezers, etc., of an inserting jig and is then moved to the mold by a robot control operation.
In the cap lamination inserting and supporting step (S 33 ), the cap lamination moved to the mold is inserted into the mold and is then held by a holding pin, etc., in order to perform injection-molding of the gasket. Here, the holding pin may be made from comparable material as that of the gasket.
In the injection-molding step (S 34 ), the gasket is injection-molded in such a manner that edges of the gap lamination inserted and held in the mold are partially inserted in the gasket. Here, a hole or recess is formed at a lower element the cap lamination, and the molten gasket is inserted in the hole or recess during the injection-molding, thereby enhancing the assembling force between the cap lamination and the gasket. The gasket may be made from polymer resin, which is an insulating material, such as polypropylene, etc.
In the step of the cap assembly take-out step (S 35 ), the cap assembly including the cap lamination and the gasket, which are integrally injection-molded, is taken out of the mold and is then dropped on an outputting conveyer.
As described above, the present invention provides an integrated cap assembly for a secondary battery, thereby highly increasing tightness between a cap lamination of the cap assembly, including conductive safety vent unit 131 , printed circuit board 132 , PTC element 133 , and positive electrode cap 134 , and an insulating gasket surrounding and clamping the cap lamination. Further, a process of forming a cap assembly of a secondary battery according to the present invention enables the secondary battery to be assembled by only one apparatus, thereby greatly reducing the number of necessary apparatuses, the manufacturing time, the manufacturing cost, etc., for the fabrication of the secondary battery, and thereby increasing productivity.
Although exemplary embodiments of the present invention have been described for illustrative purposes, those skilled in the art will appreciate that various modifications, additions and substitutions are possible, without departing from the scope and spirit of the invention as disclosed in the accompanying claims.
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An integrated cap assembly of a secondary battery. A cap lamination forms a top portion of the secondary battery and serves as a connection terminal while the secondary battery is charged or discharged. A gasket is molded integrally with the cap lamination in such a manner that a peripheral portion of the cap lamination is inserted in the gasket, the gasket insulating the cap lamination from a can of the secondary battery and sealing a gap between the cap lamination and the can.
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FIELD OF THE INVENTION
The present invention relates to compounds and formulations useful for improving the toughness of adhesive compositions and methods for use thereof. In a particular aspect, the present invention relates to epoxy-based resin formulations having improved fracture toughness. In another aspect, the present invention relates to methods for improving the fracture toughness of epoxy-based resin formulations. In still another aspect, the present invention relates to methods for preparing toughening agents useful for improving the fracture toughness of epoxy-based resin formulations.
BACKGROUND OF THE INVENTION
Toughness is the ability of a material to absorb energy and undergo large permanent set without rupture. For many engineering adhesive applications, toughness is often the deciding factor. Plastics, because of their inherent brittleness, have been modified in a variety of ways in efforts to improve the toughness thereof. Epoxy resins, for example, which form a versatile glassy network, exhibit excellent resistance to corrosion and solvents, good adhesion, reasonably high glass transition temperatures (T g ) and adequate electrical properties. Unfortunately, however, the poor fracture toughness of epoxy resins oftentimes limits the usefulness thereof.
The impact strength as well as most other physical properties of crosslinked epoxy resins is controlled by the chemical structure and ratio of the epoxy resin and hardener, by any added fillers, and by the curing conditions used. Unfortunately, crosslinked, glassy epoxy resins with relatively high T g (>100° C.) are brittle. The poor impact strength of high glass transition epoxy resins limits the usage of epoxies as structural materials and in composites.
Indeed, current commercially available underfill epoxy adhesives are excessively brittle and tend to fail prematurely in such applications as chip scale packaging (CSP) and related applications as a result of poor fracture toughness. Conventional toughening agents (e.g. carboxyl terminated butadiene, i.e., CTBN) are frequently unsuitable as additives in these adhesives because they adversely affect the capillary flow properties of the uncured adhesive.
Accordingly, there is a need for toughening agents that are effective for improving the toughness of adhesive formulations, especially in formulations requiring good capillary flow properties.
SUMMARY OF THE INVENTION
In accordance with the present invention, there are provided toughening agents which are useful for improving the performance properties of epoxy-based adhesive formulations. For example, epoxidized polyacrylates have been found to be useful toughening agents of component level underfill adhesive compositions. Invention materials are generally liquid rubbers which provide improved fracture toughness while maintaining satisfactory capillary flow properties. Invention materials can be synthesized in neat (solventless) reactions from readily available low-cost raw materials and isolated in high yields. They have a branched structure with terminal epoxide functional groups. The polyacrylate is typically obtained as a mixture of epoxidized polymer, chain extended poly-oligomer and unreacted monomer. Invention materials are compatible with common epoxy formulations and may be used without purification. At low levels of incorporation, they provide adhesives that meet the minimum fracture toughness (Gq>2.0 lb/in) and capillary flow specifications (i.e., flow, by capillary force, a distance of 20 mm through a 2-mil gap between a pair of microscope slides in <180 seconds at 120° C.) for many commercial underfill applications.
In accordance with a further embodiment of the present invention, there are provided adhesive compositions comprising invention compounds and methods for use thereof.
In additional embodiments of the present invention, there are provided methods for the preparation of invention toughening agents, methods for adhesively attaching a device to a substrate, and assemblies comprising first article(s) adhered to second article(s).
BRIEF DESCRIPTION OF THE FIGURES
FIG. 1 illustrates the synthesis of an epoxidized poly(alkyl acrylate-co-acrylic acid) by reaction of bisphenol F diglycidyl ether (BPF-DGE) with a copolymer prepared by copolymerization of alkyl acrylate and acrylic acid in the presence of mercaptoacetic acid as a chain transfer agent.
FIG. 2 presents a partial structure of an extended epoxidized poly(butyl acrylate) resin according to the present invention. The branching that arises from the multi-functional acrylate is not shown in the figure.
FIG. 3 presents the normalized FTIR absorbency for the reaction of carboxyl functional polyacrylate with multi-functional epoxy monomers, indicating formation of β-hydroxyester during reaction of carboxylic acid terminated polyacrylate and bisphenol F diglycidyl ether (BPF-DGE) epoxy monomer.
FIG. 4 illustrates the average epoxide equivalent weight (EEW) of epoxidized polyacrylate as a function of the reaction stoichiometry.
FIG. 5 illustrates the dependence of product viscosity on the equivalent weight ratio of epoxy monomer to the carboxylic acid functionalized polyacrylate, BPF-DGE/CBB.
FIG. 6 presents a GPC chromatogram of CBB-3098 (short dashes), BPF-DGE epoxy monomer (RE 404S; long dashes) and the reaction product of these two materials (YL253945; solid line).
FIG. 7 illustrates the variation of Gq as a function of rubber concentration added as 4/1 BPF-DGE/CBB mixture. Error bars represent the standard deviation of an average of 7 specimens. Dashed line indicates the minimum required value.
FIG. 8 illustrates the variation of Gq as a function of CBB/BPF-DGE equivalent weight ratio.
DETAILED DESCRIPTION OF THE INVENTION
In accordance with the present invention, there are provided toughening agents comprising an epoxy-extended polyacrylate, wherein the polyacrylate from which the epoxy-extended polyacrylate is derived has a number average molecular weight in the range of about 1000 up to about 10,000, an average functionality of at least about 2.2, and a polydispensity in the rage of about 1.05 up to about 5. Presently preferred toughening agents according to the present invention are liquid, typically having a viscosity in the range of about 5 up to about 500 Pascal-seconds at 25° C. (1 milliPascal-second=1 centipoise), with viscosities in the range of about 20 up to about 200 Pascal-seconds at 25° C. being presently preferred.
As employed herein, “functionality” refers to the number of functional equivalents (determined by suitable means, e.g., by acid-base titration in the case of a carboxylic acid) times the number average molecular weight divided by the weight of the sample being analyzed is the calculated average number of functional groups per chain of the polyacrylate.
As employed herein, “polydispensity” (also known as “polydispersity index” and “molecular weight distribution”) refers to the ratio of weight average molecular weight/number average molecular weight for a subject polymer. This value provides an indication of the broadness of the molecular weight distribution of the subject polymer. Thus, for a monodisperse polymer where the weight average molecular weight equals the number average molecular weight, the value will be 1. As the breadth of molecular weight distribution increases, the polydispersity will be greater than 1.
Invention toughening agents can be prepared from polyacrylates bearing a variety of functionalities, e.g, carboxylic acids, amines, anhydrides, hydroxy groups, thiol groups, phenolic groups, and the like. As noted above, the polyacrylates employed for the preparation of invention toughening agents have a functionality of at least about 2.2, with a functionality of at least about 2.5 (and no greater than about 5) being presently preferred.
Presently preferred toughening agents according to the present invention are those wherein the epoxy-extended polyacrylate is prepared by reacting a carboxylic acid functionalized polyacrylate with a multi-functional epoxy monomer. Exemplary polyacrylates contemplated for use in the practice of the present invention include the poly-functional or branched polymers prepared as disclosed in JP 00344823A (S. Okamota et al Jap. Patent Appl. P2000-128911A to Soken Chemical and Engineering Co. Ltd. (2000)), incorporated by reference herein in its entirety (e.g., a copolymer prepared employing a 10:1 ratio of methyl acrylate to trimethylolpropane triacrylate in the presence of mercaptopropionic acid chain transfer agent), or from carboxylic acid functionalized branched polyacrylates prepared by polymerization of blends of mono acrylates and divinyl branching agents in the presence of carboxylic acid functionalized chain transfer agents and/or carboxylic acid functionalized initiators by a process similar to that described by P. A. Costello et al in Polymer 2002, 43, 245–254.
Presently preferred polyacrylates contemplated for use in the practice of the present invention are further characterized by one or more of the following parameters: being a liquid at room temperature, having a number average molecular weight in the range of about 1000 up to about 5000, having as the principle repeating unit n-butyl acrylate, 2-ethylhexyl acrylate, isooctyl acrylate, and the like, functionalized with carboxylic acid groups via such monomers as acrylic acid, methacrylic acid, maleic acid, maleic anhydride, carboxylic acid functionalized chain transfer agents, carboxylic acid functionalized initiators, carboxylic acid functionalized co-monomers, and the like.
Multi-functional epoxy monomers contemplated for use in the preparation of invention toughening agents include bisphenol F diglycidyl ether, bisphenol A diglycidyl ether, 4-vinyl-1-cyclohexene diepoxide, butanediol diglycidyl ether, neopentylglycol diglycidyl ether, 3,4-epoxycyclohexylmethyl-3,4-epoxycyclohexanecarboxylate, limonene diepoxide, hexanediol diglycidyl ether, trimethylolpropane triglycidyl ether, aniline diglycidyl ether, diglycidyl ether of propylene glycol, cyanuric acid triglycidyl ether, ortho-phthalic acid diglycidyl ether, diglycidyl ester of linoleic dimer acid, dicyclopentadiene diepoxide, diglycidyl ether of tetrachloro bisphenol A, 1,1,1-tris(p-hydroxypenyl)ethane glycidyl ether, tetra glycidyl ether of tetrakis(4-hydroxyphenyl)ethane, epoxy phenol novolac resins, epoxy cresol novolac resins, tetraglycidyl-4,4′-diaminodiphenylmethane, and the like.
When functional polyacrylates contemplated for use herein are contacted with multi-functional epoxy monomers for the preparation of invention toughening agents, it is preferred that a stoichiometric excess of the multi-functional epoxy monomer be employed in the preparation of the epoxy-extended polyacrylate. It is especially preferred that a sufficient excess of the multi-functional monomer be employed so as to prevent gellation of the reaction mixture.
In accordance with another embodiment of the present invention, invention toughening agents further comprise unreacted multi-functional epoxy monomer. Thus, as little as a few percent by weight of the unreacted epoxy monomer may be present as part of the invention toughening agent, with as much as 50 percent by weight, or more, of the invention toughening agent comprising unreacted epoxy monomer from which the epoxy-extended polyacrylate is prepared.
The epoxy extension can be linked to the above-described polyacrylate materials by any of the following structures:
—Z—, —W—, —Z—W—, —W—Z—, —W—Z—W—,
and combinations of any 2 or more thereof, wherein: each Z is independently alkylene, substituted alkylene, cycloalkylene, substituted cycloalkylene, heterocyclic, substituted heterocyclic, oxyalkylene, substituted oxyalkylene, alkenylene, substituted alkenylene, arylene, substituted arylene, alkarylene, substituted alkarylene, aralkylene or substituted aralkylene, and each W is independently ester, reverse ester, thioester, reverse thioester, amide, reverse amide, silyl, carbonate, or carbamate.
As employed herein, “alkyl” refers to hydrocarbyl radicals having 1 up to about 20 carbon atoms, preferably 2–10 carbon atoms; and “substituted alkyl” comprises alkyl groups further bearing one or more substituents selected from alkoxy, cycloalkyl, substituted cycloalkyl, heterocyclic, substituted heterocyclic, aryl, substituted aryl, heteroaryl, substituted heteroaryl, aryloxy, substituted aryloxy, halogen, cyano, nitro, amido, C(O)H, acyl, oxyacyl, carboxyl, carbamate, sulfonyl, sulfonamide, sulfuryl, and the like.
As employed herein, “cycloalkyl” refers to cyclic ring-containing groups containing in the range of 3 up to about 8 carbon atoms, and “substituted cycloalkyl” refers to cycloalkyl groups further bearing one or more substituents as set forth above.
As employed herein, “alkenyl” refers to straight or branched chain hydrocarbyl groups having at least one unit of ethylenic unsaturation, i.e., a carbon-carbon double bond, and having in the range of 2 up to about 12 carbon atoms, and “substituted alkenyl” refers to alkenyl groups further bearing one or more substituents as set forth above.
As employed herein, “unit of ethylenic unsaturation” refers to unsaturation comprising localized (i.e., non-aromatic) carbon-carbon double bonds, as shown below:
As employed herein, “cycloalkenyl” refers to cyclic ring-containing groups containing in the range of 3 up to about 8 carbon atoms, wherein the cyclic ring-containing group contains at least one carbon-carbon double bond. “Substituted cycloalkenyl” refers to cycloalkenyl groups further bearing one or more substituents as set forth above. Cycloalkenyl groups as defined herein also refer to bicycloalkenyl groups, such as, for example, 2.2.1.-bicycloheptene, and the like.
As employed herein, “aryl” refers to aromatic groups having in the range of 6 up to about 14 carbon atoms and “substituted aryl” refers to aryl groups further bearing one or more substituents as set forth above.
As employed herein, “alkylene” refers to divalent hydrocarbyl radicals having 1 up to about 20 carbon atoms, preferably 2–10 carbon atoms; and “substituted alkylene” comprises alkylene groups further bearing one or more substituents as set forth above.
As employed herein, “cycloalkylene” refers to divalent cyclic ring-containing groups containing in the range of 3 up to about 8 carbon atoms, and “substituted cycloalkylene” refers to cycloalkylene groups further bearing one or more substituents as set forth above.
As employed herein, “alkenylene” refers to divalent, straight or branched chain hydrocarbyl groups having at least one carbon-carbon double bond, and having in the range of 2 up to about 12 carbon atoms, and “substituted alkenylene” refers to alkenylene groups further bearing one or more substituents as set forth above.
As employed herein, “arylene” refers to divalent aromatic groups having in the range of 6 up to about 14 carbon atoms and “substituted arylene” refers to arylene groups further bearing one or more substituents as set forth above.
As employed herein, “alkarylene” refers to an arylene group bearing an alkyl substituent and “substituted alkarylene” refers to alkarylene groups further bearing one or more substituents as set forth above.
As employed herein, “aralkylene” refers to an alkylene group bearing an aryl substituent and “substituted aralkylene” refers to aralkylene groups further bearing one or more substituents as set forth above.
As employed herein, “oxyalkylene” refers to the moiety —O-alkylene-, wherein alkylene is as defined above, and “substituted oxyalkylene” refers to oxyalkylene groups further bearing one or more substituents as set forth above.
As employed herein, “heterocyclic” refers to cyclic (i.e. ring containing) groups containing one or more heteroatoms (e.g. N, O, S, or the like) as part of the ring structure, and having in the range of 3 up to 20 carbon atoms, and “substituted heterocyclic” refers to heterocyclic groups further bearing one or more substituents as set forth above.
Invention toughening agents can be readily prepared in a variety of ways, e.g., a neat mixture of the polyacrylate and a multi-functional epoxy monomer can be subjected to a temperature in the range of about 100 up to about 150° C. for a time in the range of about 1 up to about 24 hours in the substantial absence of a catalyst. Preferably, reaction is carried out in a stoichiometric excess of epoxy monomer, which excess can optionally be removed when the reaction is complete, or can be retained as part of the reaction mixture and added directly to the epoxy resin to be modified.
In accordance with still another embodiment of the present invention, there are provided methods to improve the fracture toughness of an epoxy-based adhesive composition, the methods comprising adding to the adhesive composition an effective amount of an invention toughening agent. As little as about 2 weight percent invention toughening agent, up to about 25 weight percent invention toughening agent can be employed in the practice of the present invention.
In accordance with yet another embodiment of the present invention, there are provided adhesive formulations comprising:
a curable epoxy resin, a curing agent, at least one toughening agent according to the invention; and optionally, a filler.
In one aspect of the invention, the above-described adhesive formulations contain substantially no latent curing agent; and the cure onset temperature of the curable epoxy resin is less than about 220° C. Such formulations are especially useful in non-fluxing underfill applications.
In another aspect of the present invention, the performance properties (e.g., toughness) of underfill sealant compositions is improved by adding invention toughening agents thereto. Such formulations typically comprise an epoxy resin component, a secondary amine-based adhesion promoting component and a curative based on the combination of a nitrogen containing compound and a transition metal complex. Reaction products of these compositions demonstrate improved adhesion, improved resistance to moisture absorption, and improved resistance to stress cracking.
Typically, the composition includes about 60 to about 95.8 weight percent of the epoxy resin component (which includes up to about 10 weight percent of invention toughening agent), about 5 to about 30 weight percent of the secondary amine-based adhesion promoting component, and about 0.2 to about 10 weight percent of the curative, of which about 80 to about 98 weight percent is comprised of the nitrogen containing compound and about 2 to about 20 weight percent is comprised of the transition metal complex.
The epoxy resin component of the present invention may include any common epoxy resin, which may have at least one multifunctional epoxy resin.
Examples of such epoxy resins include C 4 -C 28 alkyl glycidyl ethers; C 2 -C 28 alkyl- and alkenyl-glycidyl esters; C 1 -C 28 alkyl-, mono- and poly-phenol glycidyl ethers; polyglycidyl ethers of pyrocatechol, resorcinol, hydroquinone, 4,4′-dihydroxydiphenyl methane (or bisphenol) F, such as RE-404-S or RE-410-S available commercially from Nippon Kayuku, Japan), 4,4′-dihydroxy-3,3′-dimethyldiphenyl methane, 4,4′-dihydroxydiphenyl dimethyl methane (or bisphenol A), 4,4′-dihydroxydiphenyl methyl methane, 4,4′-dihydroxydiphenyl cyclohexane, 4,4′-dihydroxy-3,3′-dimethyldiphenyl propane, 4,4′-dihydroxydiphenyl sulfone, and tris(4-hydroxyphenyl)methane; polyglycidyl ethers of transition metal complex chlorination and bromination products of the above-mentioned diphenols; polyglycidyl ethers of novolacs; polyglycidyl ethers of diphenols obtained by esterifying ethers of diphenols obtained by esterifying salts of an aromatic hydrocarboxylic acid with a dihaloalkane or dihalogen dialkyl ether; polyglycidyl ethers of polyphenols obtained by condensing phenols and long-chain halogen paraffins containing at least two halogen atoms; N,N′-diglycidyl-aniline; N,N′-dimethyl-N,N′-diglycidyl-4,4′-diaminodiphenyl methane; N,N,N′,N′-tetraglycidyl-4,4′-diaminodiphenyl methane; N,N′-diglycidyl-4-aminophenyl glycidyl ether; N,N,N′,N′-tetraglycidyl-1,3-propylene bis-4-aminobenzoate; phenol novolac epoxy resin; cresol novolac epoxy resin; and combinations thereof.
Among the commercially available epoxy resins suitable for use herein are polyglycidyl derivatives of phenolic compounds, such as those available under the tradenames EPON 828, EPON 1001, EPON 1009, and EPON 1031, from Shell Chemical Co.; DER 331, DER 332, DER 334, and DER 542 from Dow Chemical Co.; GY285 from Ciba Specialty Chemicals, Tarrytown, N.Y.; and BREN-S from Nippon Kayaku, Japan. Other suitable epoxy resins include polyepoxides prepared from polyols and the like and polyglycidyl derivatives of phenol-formaldehyde novolacs, the latter of which are available commercially under the tradenames DEN 431, DEN 438, and DEN 439 from Dow Chemical Company. Cresol analogs are also available commercially ECN 1235, ECN 1273, and ECN 1299 from Ciba Specialty Chemicals. SU-8 is a bisphenol A-type epoxy novolac available from Shell Chemicals (formerly, Interez, Inc.). Polyglycidyl adducts of amines, aminoalcohols and polycarboxylic acids are also useful in this invention, commercially available resins of which include GLYAMINE 135, GLYAMINE 125, and GLYAMINE 115 from F.I.C. Corporation; ARALDITE MY-720, ARALDITE MY-721, ARALDITE 0500, and ARALDITE 0510 from Ciba Specialty Chemicals and PGA-X and PGA-C from the Sherwin-Williams Co. And of course combinations of the different epoxy resins are also desirable for use herein.
As noted above, the epoxy resin component of the present invention may include any common epoxy resin, at least a portion of which is a multifunctional epoxy resin. Ordinarily, the multifunctional epoxy resin should be included in amount within the range of about 20 weight percent to about 100 weight percent of the epoxy resin component.
A monofunctional epoxy resin, if present, should ordinarily be used as a reactive diluent, or crosslink density modifier. In the event such a monofunctional epoxy resin is included as a portion of the epoxy resin component, such resin should be employed in an amount of up to about 20 weight percent, based on the total epoxy resin component.
In choosing epoxy resins for the epoxy resin component of the compositions of the present invention, consideration should also be given to viscosity and other properties thereof.
Additional polymerizable co-reactants contemplated for optional use in the practice of the present invention include, for example maleimides, nadimides, itaconamides, cyanate esters, vinyl ethers, acrylates, styrenes, and the like.
The secondary amine-based adhesion promoting component should have at least two secondary amines available for reaction. For instance, the secondary amine-based adhesion promoting component may be represented as within the following structure I:
where R and R 1 may be the same or different and may be selected from C 1-12 alkyl, C 1-12 alkenyl, C 5-12 cyclo or bicycloalkyl, C 6-18 aryl, and derivatives thereof, and
may be selected from C 1-12 alkylene, C 1-12 alkenylene, C 5-12 cyclo or bicycloalkylene, C 5-12 cyclo or bicycloalkenylene, C 6-18 arylene, and derivatives thereof.
The secondary amine-based adhesion promoting component should be used in the inventive compositions in an amount within the range of about 5 to about 30 weight percent, with about 13 to about 20 weight percent being particularly desirable, depending of course on the identity of the chosen secondary amine-based adhesion promoting component.
As employed herein, the term “curing agents” refers to polymerization promoters, co-curing agents, catalysts, initiators or other additives designed to participate in or promote curing of the adhesive formulation. With respect to epoxide-based adhesive formulations, such curing agents include polymerization promoters and catalysts such as, for example, anhydrides, amines, imidazoles, amides, thiols, carboxylic acids, phenols, dicyandiamide, urea, hydrazine, hydrazide, amino-formaldehyde resins, melamine-formaldehyde resins, amine-boron trihalide complexes, quaternary ammonium salts, quaternary phosphonium salts, tri-aryl sulfonium salts, di-aryl iodonium salts, diazonium salts, and the like, as well as combinations of any two or more thereof, optionally also including a transition metal complex. Presently preferred curing agents and catalysts for epoxide-based formulations include anhydrides, amines, imidazoles, and the like.
Transition metal complexes contemplated for use herein may be chosen from a variety of organometallic materials or metallocenes as can be readily identified by those of skill in the art.
As readily recognized by those of skill in the art, curing agents contemplated for use in the practice of the present invention will vary with the reactive functionality(ies) present, the presence of optional co-reactant(s), and the like. Typically, the quantity of curing agent will fall in the range of about 1 weight % up to about 50 weight % of the total composition, with presently preferred amounts of curing agent falling in the range of about 5 weight % up to about 40 weight % of the total composition.
Initiators contemplated for use with epoxide-based adhesive formulations include hydroxy functionalized compounds such as, for example, alkylene glycols. Preferred alkylene glycols include ethylene glycols and propylene glycols.
Fillers contemplated for optional use in the practice of the present invention may optionally be conductive (electrically and/or thermally). Electrically conductive fillers contemplated for use in the practice of the present invention include, for example, silver, nickel, gold, cobalt, copper, aluminum, graphite, silver-coated graphite, nickel-coated graphite, alloys of such metals, and the like, as well as mixtures thereof. Both powder and flake forms of filler may be used in the adhesive compositions of the present invention. Preferably, the flake has a thickness of less than about 2 microns, with planar dimensions of about 20 to about 25 microns. Flake employed herein preferably has a surface area of about 0.15 to 5.0 m 2 /g and a tap density of about 0.4 up to about 5.5 g/cc. It is presently preferred that powder employed in the practice of the invention has a diameter of about 0.5 to 15 microns. If present, the filler typically comprises in the range of about 30% up to about 70% by weight of the adhesive formulation.
Thermally conductive fillers contemplated for optional use in the practice of the present invention include, for example, aluminum nitride, boron nitride, silicon carbide, diamond, graphite, beryllium oxide, magnesia, silica, alumina, and the like. Preferably, the particle size of these fillers will be about 20 microns. If aluminum nitride is used as a filler, it is preferred that it be passivated via an adherent, conformal coating (e.g., silica, or the like).
Electrically and/or thermally conductive fillers are optionally (and preferably) rendered substantially free of catalytically active metal ions by treatment with chelating agents, reducing agents, nonionic lubricating agents, or mixtures of such agents. Such treatment is described in U.S. Pat. No. 5,447,988, which is incorporated by reference herein in its entirety.
Optionally, a filler may be used that is neither an electrical nor thermal conductor. Such fillers may be desirable to impart some other property to the adhesive formulation such as, for example, reduced thermal expansion of the cured adhesive, reduced dielectric constant, improved toughness, increased hydrophobicity, and the like. Examples of such fillers include perfluorinated hydrocarbon polymers (i.e., TEFLON™), thermoplastic polymers, thermoplastic elastomers, mica, fumed silica, fused silica, glass powder, and the like.
Flexibilizers (also called plasticizers) contemplated for optional use in the practice of the present invention include branched polyalkanes or polysiloxanes that lower the T g of the formulation. Such flexibilizers include, for example, polyethers, polyesters, polythiols, polysulfides, and the like. If used, flexibilizers typically are present in the range of about 0.5% up to about 30% by weight of the formulation.
Dyes contemplated for optional use in the practice of the present invention include nigrosine, Orasol blue GN, phthalocyanines, and the like. When used, organic dyes in relatively low amounts (i.e., amounts less than about 0.2% by weight) provide contrast.
Pigments contemplated for optional use in the practice of the present invention include any particulate material added solely for the purpose of imparting color to the formulation, e.g., carbon black, metal oxides (e.g., Fe 2 O 3 , titanium oxide), and the like. When present, pigments are typically present in the range of about 0.5 up to about 5 weight %, relative to the weight of the base formulation.
In accordance with another embodiment of the present invention, there are provided methods for adhesively attaching a device to a substrate, such methods comprising dispensing an invention adhesive formulation onto a substrate and/or a device or between the substrate and the device to form an assembly, and exposing the assembly to conditions sufficient to cure the adhesive.
Conditions suitable to cure invention adhesive formulations comprise subjecting invention adhesive formulations to a temperature of at least about 120° C. but less than about 190° C. for about 0.5 up to about 60 minutes. This rapid, short duration heating can be accomplished in a variety of ways, e.g., with an in-line heated rail, a belt furnace, a curing oven, or the like.
In accordance with yet another embodiment of the present invention, there are provided assemblies produced by the above-described methods.
In accordance with a further embodiment of the present invention, there are provided methods for adhesively attaching a first article to a second article, such methods comprising:
(a) applying an invention formulation to the first article, (b) bringing the first and second article into intimate contact to form an assembly wherein the first article and the second article are separated only by the adhesive composition applied in step (a), and thereafter, (c) subjecting the assembly to conditions suitable to cure the adhesive formulation.
In accordance with yet another embodiment of the present invention, there are provided assemblies produced by the above-described methods.
In accordance with a still further embodiment of the present invention, there are provided methods for encapsulating electronic components, such methods comprising:
applying an invention formulation to the component, and curing the formulation.
In accordance with yet another embodiment of the present invention, there are provided assemblies produced by the above-described methods.
In accordance with a still further embodiment of the present invention, there are provided methods for encapsulating electronic components, such methods comprising curing a formulation according to the invention after application of the formulation to the component.
In accordance with yet another embodiment of the present invention, there are provided assemblies produced by the above-described methods.
In accordance with a still further embodiment of the present invention, there are provided articles comprising an electronic component adhesively attached to a circuit board. wherein the electronic component is adhesively attached to the board by a cured aliquot of invention formulation.
In accordance with still another embodiment of the present invention, there are provided articles comprising an electronic component adhesively attached to a circuit board, wherein the electronic component is adhesively attached to the board by a cured aliquot of invention formulation.
Those of skill in the art recognize that many different electronic packages would benefit from preparation using the invention formulations described herein. Examples of such packages include ball grid arrays, super ball grid arrays, IC memory cards, chip carriers, hybrid circuits, chip-on-board, multi-chip modules, pin grid arrays, CSPs, and the like.
The invention will now be described in greater detail by reference to the following non-limiting examples.
EXAMPLES
Materials:
All starting materials and solvents were purchased from the Aldrich Chemical Company, and were used without further purification, unless otherwise specified.
CBB-3098, a carboxylic acid functionalized poly(butyl acrylate) co-polymer, was supplied by Esprix Technologies.
Chemical analyses:
Proton Nuclear Magnetic Resonance analyses (1H NMR) were performed on a Varian 300 Hz Gemini Spectrophotometer. Infrared spectra (IR) were recorded on a Perkin-Elmer Spectrum One FTIR Spectrophotometer. Epoxy equivalent weight (EEW) measurements were performed according to standard titrometric methodology, using a 0.15 g sample and 0.1N HClO 4 /HOAc titrant. Acid determinations were also measured according to standard titrometric methodology, using 1N methanolic KOH titrant.
Example 1
Synthesis of Epoxidized Acrylate
Epoxidized polybutylacrylates were synthesized by heating carboxylic acid terminated poly (butyl acrylate, CBB, with access bisphenol F diglycidyl ether (BPF-DGE) and isolated as mixtures in the unreacted epoxy monomer. Under these conditions, the free carboxylic acid is esterified to give the corresponding β-hydroxyester by a ring opening reaction of one or more of the epoxide groups as shown in FIG. 1 . The reaction conditions used are similar to those typically employed for the epoxy modification of CTBN resins (see R. S. Drake et al, in Epoxy Resin Chemistry II, ACS Symposium Series 221, R. S. Bauer, ed., American Chemical Society, Washington D.C. 1983, p 1).
Gellation is avoided in the reaction by employing a large excess of the diepoxide monomer. The reaction product is a mixture of epoxidized polyacrylates and unreacted BPF-DGE. The amount of unreacted monomer was estimated from the 1 H NMR spectrum by comparing the integral ratio of epoxide group proton at δ=3.3 (—CH—O—) to the normalized aromatic signal δ=6.8–7.1 before and after the reaction. The formation of the product was also confirmed by the emergence of a strong hydroxyl peak in the IR spectrum at ˜3500 cm −1 . The reaction composition contains, in addition to the simple adduct represented by the structure in FIG. 1 , small amounts of extended polymer resulting from the reaction of an initial epoxidized adduct with further carboxylic acid functionalized polyacrylate as shown in FIG. 2 .
The reaction was carried out at CBB/BPF-DGE equivalent weight ratios 1/4, 1/7 and 1/10 (corresponding to approximate mole ratios=0.11, 0.06 and 0.04 respectively) (see experimental details). Neither catalysts nor solvents were employed. The progress of the reaction was followed by the emergence of the hydroxyl absorbance peak at 3507 cm −1 in the infrared spectrum of the reaction mixture, as shown in FIG. 3 .
Using the absorbance at 1612 cm −1 as an internal standard, the conversion of the polyacrylate to the corresponding β-hydroxyester was quantified in terms of the ratio of absorbance bands A 3507 /A 1612 .
The reaction proceeds rapidly during the first hour and more slowly thereafter. It is essentially complete within 3 hours after which no further increase in hydroxyl absorbance with observed. The analyses of products from several different reaction batches are listed in Table 1.
A typical procedure is as follows (run #4, Table 1): A mixture of carboxylic acid terminated poly (butyl acrylate), CBB-3098 (113.172 g; 0.18 equivalents of carboxylic acid) and bisphenol F diglycidylether (BPF-DGE) (105.679 g; 0.72 equivalents of epoxide) was heated at 140° C. for 6 hours to give a light yellow colored viscous liquid (213.438 g; 98% yield). The epoxide equivalent weight (EEW) was 594 (see Table 1 for additional details).
TABLE 1
Analysis of various BPF-DGE/CBB reaction mixtures
Run
BPF-DGE/CBB
Epoxy
Viscosity
Mole fraction
#
EW ratio in feed
EW
(mPa · s, 25° C.)
Unreacted epoxy
1
10
278
17,400
0.81
2
7
353
30,000
0.83
3
4
623
136,000
0.42
4
4
594
183,000
0.52
5
4
514
148,000
0.56
6
4
562
118,500
0.62
There is clearly a strong inverse correlation between the epoxy equivalent weight of the final product and the equivalent weight ratio of epoxide monomer to CBB polymer ( FIG. 4 ). Runs #3, 4, 5 and 6 were performed under almost identical conditions and in these experiments, a reasonably good reproducibility of epoxide equivalent weight was observed (±8% of the mean value; standard deviation of EEW for runs #3, 4, 5 and 6 is 46.7).
Similarly, the viscosity of the final mixture was observed to decrease with increasing EW ratio of CBB/BPF-DGE ( FIG. 5 ). In this case, identical runs, i.e. #3, 4, 5 and 6, were observed to vary in final viscosity by ±19% of the mean value (standard deviation of viscosity measurements for runs #3, 4, 5 and 6 is 27,427). The variability of these data can be attributed in part to small differences in the reaction temperature and mixing efficiency from variable batch sizes of the different reaction runs (50–1000 g).
From the NMR analysis of the products and stoichiometry of the reaction mixtures can be estimated. The composition of the various polymers and the results are shown in Table 2.
TABLE 2
Estimated composition of various BPF-DGE/CBB mixtures.
BPF-
Epoxidized
Unreacted
Poly BA
Run
DGE/CBB
rubber
BPF-DGE
rubber
#
Ratio
(%)
(%)
(%)
1
10
48
52
27
2
7
55
45
35
3
4
91
9
48
4
4
86
14
48
5
4
84
16
48
6
4
81
19
48
GPC analysis was carried out on the reaction product from run #6 along with the starting materials bis-F epoxy monomer (RE404) and polyacrylate (CBB). The results, presented in FIG. 6 , show the polymeric component of the mixture does not have a well defined maximum in its molecular weight distribution, but is clearly higher in molecular weight and has increased polydispersity compared to the starting polyacrylate (Mn=1,680; MWD=1.59). This result is consistent with the structures proposed above. The presence of residual unreacted epoxy monomer is also clearly evident from the chromatogram (component eluting at ˜18.3 mL; Mp=290). An independent external calibration of RE404 epoxy monomer concentration versus peak area was also performed. From this the concentration of unreacted monomer in the product mixture was found to be 14.4% by weight, which is in very good agreement with the 19% value estimated by NMR analysis (see Table 2).
Example 2
Preparation of Prototype Underfill Adhesive Formulations
Bisphenol F diglycidyl ether epoxy monomer (RE404), toughening agent, Co(AcAc) 3 (added as 1% premix in RE404), Unilink 4100, A-137 and silica were blended together using a mechanical mixer and vacuum treated at room temperature for about 30 minutes to remove small amounts of volatile materials present in the A-137 silane. The mixture was then heated to 100° C. (to promote silylation of silica filler) and cooled to room temperature. A-1100 silane and imidazole catalyst were then added and the mixture stirred for a further 10 minutes. The composition was vacuum treated to remove air bubbles and used immediately or stored at −20° C. until needed.
Formulations containing different levels of 4/1 epoxidized poly (butyl acrylate) BPF-DGE/CBB adducts were prepared as shown in Table 3. All of the compositions contain the same stoichiometric balance of curing agents and catalysts to epoxide monomers, although there are small variations in the amounts of silica used.
TABLE 3
Formulations containing BPF-DGE/CBB mixture as a
toughening agent
Component
A
B
C
D
B
F
4/1 BPF-DGE/CBB
0
8.28
13.59
24.39
0
0
7/1 BPF-DGE/CBB
0
0
0
0
13.80
0
10/1 BPF-DGE/CBB
0
0
0
0
0
12.87
BPF-DGE
25.24
21.49
19.11
14.26
17.16
16.67
1% Co premix
8.78
8.36
7.98
7.39
8.16
3.10
N,N′-bis-isobutyl-p-
3.29
3.09
3.00
2.66
3.04
8.29
phenylenediamine
octyl triethoxy silane
0.39
0.37
0.36
0.32
0.37
0.38
Silica, SO-E5
60.33
56.50
54.19
49.36
55.64
56.84
3-aminopropyl
0.64
0.60
0.57
0.53
0.60
0.60
triethoxysilane
2-propyl imidazole
1.33
1.31
1.20
1.09
1.23
1.25
Formulation A, which does not contain added rubber, was included in the tests for comparative purposes. Formulations B–F contain various amounts of different BPF-DGE/CBB mixtures. In formulations B, C and D, the amount of specific additive, 4/1 BPF-DGE/CBB, and hence the % rubber is varied. In formulations B, E and F, the equivalent ratio is varied, while the rubber concentrations are maintained at similar levels. Samples of each formulation were cured as already described and cut specimens subjected to fracture toughness testing. Fracture toughness testing was measured in terms of the critical energy release rate, Gq, and the stress intensity factor, Kq (both of which are discussed in greater detail below). The results are summarized in Table 4. Note that % rubber indicates the amount of CBB polyarcylate component and not the amount of epoxidized adduct used in the above formulations.
TABLE 4
Fracture toughness test results for underfill adhesive containing
various BPF-DGE/CBB rubbers as toughening agents.
CBB/BPF-
Rubber
Gq
Kq
Formulation
DGE ratio
(weight %)
(lb/in)
(MPa√m)
A
0
0
1.52 ± 0.20
1.42 ± 0.18
B
0.25
4.0
2.23 ± 0.14
1.53 ± 0.06
C
0.25
6.6
2.54 ± 0.19
1.59 ± 0.10
D
0.25
11.8
4.16 ± 0.31
1.59 ± 0.07
E
0.14
4.8
2.09 ± 0.11
1.46 ± 0.03
F
0.10
4.8
1.63 ± 0.18
1.31 ± 0.05
Comparing the results of formulations A, B, C and D, the fracture toughness, Gq, increases linearly with the amount of added polyacrylate rubber as indicated in FIG. 7 . The minimum specification value for fracture toughness (Gq) of 2.0 lb/in and flow, by capillary force, a distance of 20 mm through a 2-mil gap between a pair of microscope slides in <180 seconds at 120° C., is obtained when the rubber concentration (as % polyacrylate component) exceeds about 3% by weight and continues to increase to a loading of 12%.
The Kq value also increases with the amount of added rubber but reaches a plateau value of 1.59 Mpa✓m at a loading of about 7%.
Comparing the results of formulations A, B, E and F, the fracture toughness, Gq, increases by a small but significant amount as the polyacrylate/epoxy equivalent weight ratio in the CBB/BPF-DGE adduct is increased ( FIG. 8 ). Since the amount of polyacrylate rubber in formulations B, E and F does not vary significantly (4–5% range), it can be concluded that the structure and composition of the adduct influences the fracture toughness. This effect can be attributed to the higher molecular weight between crosslinks for adducts prepared at higher CBB/epoxy ratios. As the amount of CBB in the adduct is increased, the epoxide equivalent weight of the product is enhanced due to formation of higher molecular weight CBB/epoxy products (see Table 1). In addition, the concentration of extended polymer in the final mixture increases as the ratio of CBB/epoxy in the reaction mixture increases (see Table 2). The overall effect of increasing CBB/epoxy ratio is to increase the molecular weight between crosslinks in the cured adhesive, which for a series of epoxidized butadiene-acrylonitrile copolymers, is known to enhance fracture toughness (see A. Kinloch in Rubber - Toughened Plastics, Advances in Chem. Series 222, C. Riew ed., American Chemical Society, Washing D.C. 1987, p 67).
Example 3
Physical and Materials Testing
Viscosity measurements were performed on a Brookfield Model DV-111 Programmable Rheometer at 25° C. Capillary flow measurements were performed by allowing material to flow 20 mm at 120° C. through a 2-mil gap between a pair of microscope slides. Fracture toughness testing was carried out according to ASTM D5045-99 (area method) employing samples that were 3 mm thick. The critical energy release rate (Gq) and stress intensity factor (Kq) were determined in an Instron mechanical tester at a loading rate of 10 mm/minute using three-point bend geometry and a crack induced from a single edge cut notch (2.5 mm). Specimens for fracture toughness measurements were prepared as follows: a pair of glass plates (20.5×12.5×0.4 cm 3 ) was treated with release agent and heated at 121° C. for one hour. The treated plates were assembled into an open-topped mold by means of a U-shaped Teflon gasket/spacer (3.0 mm in thickness) and held together by means of external clamps. The mold was filled with the adhesive formulation and heated to 90° C. under reduced pressure to remove all air bubbles (10–30 minutes). The adhesive was then cured in situ by heating at 100° C. for 1 hour and 140° C. for 2 hours. The cured product was removed from the mold, cut into test coupons (12.5 mm×63.5 mm) which were edge-sanded and measured. Dynamic mechanical analysis (DMA) was performed on a Rheometric RDA II according to ASTM D5279-95 (torsion mode; frequency=10 rad/s and strain=0.19%).
Underfill adhesives are generally applied to component parts by capillary filling after the chip components have been assembled and aligned with the requisite conductive receptors located on the substrate. To enable reasonable production rates and to ensure component reliability the adhesive is required to fill the bondline gap quickly and completely. The underfill adhesive should flow, by capillary force, a distance of 20 mm through a 2-mil gap between a pair of microscope slides in ≦180 seconds at 120° C. The formulated products described above were tested to determine if they conformed to this specification. The results are presented in Table 5.
TABLE 5
Capillary flow results for toughened underfill formulations
Weight %
Flow time
Formulation
Toughening Agent
rubber
(seconds)
B
4/1 BPF-DGE/CBB
4.0
140
D
4/1 BPF-DGE/CBB
11.8
240
Formulations containing the epoxidized polyacrylate were tested at low and high levels of added rubber (formulations B and D). At a rubber loading of 4% the product meets the flow requirement, but fails when the rubber concentration is increased to 12%.
These data can be understood in part on the viscosity differences between the various toughening agents. The average viscosity of the polyacrylate 4/1 BPF-DGE/CBB is 146,000 mPa.s at 25° C. (see Table 1). This material is, therefore, expected to significantly increase the formulation viscosity at high loadings and consequently reduce the capillary flow rates.
Adhesive formulations containing some of the invention toughening agents were evaluated by DMA. The formulations employed in this work were similar to those described above (BPF-DGE, curing agents, catalysts) but without added silica (samples containing silica were found to be too stiff to enable accurate analysis by the method employed). Five formulations containing different amounts of different toughening agents were prepared and evaluated. The results are presented in Table 6. Analyses were conducted over the temperature range −100° C. to +175° C. The glass transition of the unmodified formulation (D−1) was observed at 122° C. with a small secondary transition at −76° C. Addition of ˜11% polyacrylate, 10/1 BPF-DGE/CBB (formulation D=2) had no significant effect on the Tg or storage modulus of the cured composition. However, a small increase in the ratio tan δ β /tan δ α was observed which may be indicative a small increase in phase separation compared to the control sample. Increasing the polyacrylate loading to ˜23% (D−3) resulted in a significant reduction of Tg and a sizable reduction in the stiffness (G′). A beta-transition was not observed in this sample.
TABLE 6
DMA analysis of toughened epoxy formulations
Formulation
D-1
D-2
D-3
% toughening agent
0
11.2
23.4
Glass transition, Tg (° C.)
122
116
102
β-transition (° C.)
−76
−79
N/D
Tan δ β /tan δ α
0.10
0.12
—
Storage modulus, G′
1.6
1.7
1.2
At 25° C. (Gpa)
Storage modulus, G′
66
87
N/D
at 140° C. (Mpa)
D-1: no added toughening agent;
D-2: epoxidized polyacrylate 10/1 BPF-DGE/CBB
D-3: epoxidized polyacrylate 4/1 BPF-DGE/CBB;
N/D: not determined
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In accordance with the present invention, there are provided toughening agents which are useful for improving the performance properties of epoxy-based adhesive formulations. For example, epoxidized polybutylacrylates have been found to be useful toughening agents of component level underfill adhesive compositions. Invention materials are generally liquid rubbers which provided improved fracture toughness while maintaining satisfactory capillary flow properties. Invention materials can be synthesized in neat (solventless) reactions from readily available low-cost raw materials and isolated in high yields. They have a branched telechelic structure with terminal epoxide functional groups. The polyacrylate is typically obtained as a mixture of epoxidized polymer, chain extended polyoligomer and unreacted monomer. Invention materials are compatible with common epoxy formulations and may be used without purification. At low levels of incorporation, they provide adhesives that meet the minimum fracture toughness (Gq>2.0 lb/in) and capillary flow specifications (flow time<180 seconds) for many commercial underfill applications. In accordance with a further embodiment of the present invention, there are provided adhesive compositions comprising invention compounds and methods for use thereof. In additional embodiments of the present invention, there are provided methods for the preparation of invention toughening agents, methods for adhesively attaching a device to a substrate, and assemblies comprising first article(s) adhered to second article(s).
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BACKGROUND OF INVENTION
1. Field of the Invention
The present invention relates to a method for use in the manufacturing of a fluid dynamic pressure bearing, and more particularly to a method of filling an oil a bearing gap.
2. Background Art
Various fluid dynamic pressure bearings have been proposed for high rotational precision motors. Examples of such motors include spindle motors of recording disk drives, and motors used to drive polygon mirrors in laser beam printers. Generally, fluid dynamic pressure bearings utilize fluid pressure of lubricating fluid such as oil or the like interposed between a shaft and a sleeve which are rotatable relative to one another.
FIG. 1 shows one example of a motor using such a fluid dynamic pressure bearing. A motor using the conventional fluid dynamic pressure bearing comprises a pair of radial bearing sections 4 , 4 , formed so as to be spaced apart from each other in the axial direction, between an outer peripheral surface of a shaft 2 that is integrally formed with a rotor 1 and an inner peripheral surface of a sleeve 3 in which the shaft 2 is rotatably inserted. Further, a pair of thrust bearing sections 7 , 7 are disposed respectively between an upper surface of a disk-like thrust plate 5 that projects from the outer peripheral surface of one edge section of the shaft 1 in the outward direction of the radius direction and a flat surface of a step portion formed on the sleeve 2 , and between the lower surface of the thrust plate 5 and a thrust bush 6 that closes one opening of the sleeve 2 .
A bearing gap that is a series of minute gaps is formed between the shaft 2 and the thrust plate 5 and between the sleeve 3 and the thrust bush 6 . Oil 9 serving as lubricating fluid is continuously retained in the bearing gap without a break.
Herringbone grooves 41 , 41 and 71 , 71 formed by joining a pair of spiral grooves are formed at the radial bearing sections 4 , 4 and the thrust bearing sections 7 , 7 , whereby maximum dynamic pressure is produced according to the rotation of the rotor 1 at the central section of the bearing section where a joint section of the spiral groove is positioned, thereby holding a load acted on the rotor 1 .
The motor described above has a taper seal section 8 in the vicinity of the upper edge section of the sleeve 3 that is positioned opposite to the thrust bearing sections 7 , 7 in the axial direction, so that the surface tension of the oil and the atmospheric pressure are balanced to form an interface. Specifically, the internal pressure of the oil in this taper seal section 8 is maintained at a pressure substantially equal to the atmospheric pressure.
The following method has been proposed for filling the oil 9 retained between the thrust plate 5 and the shaft 2 and between the sleeve 3 and the thrust bush 6 of the bearing section having the above-mentioned construction. Firstly, a vacuum chamber having the oil stored therein is pressure-reduced, and then, with this state, a stirring machine in the oil is operated to perform a stirring and degassing. After the pressure in the vacuum chamber that supports the bearing is reduced to a vacuum level, the oil is supplied to the bearing-supporting vacuum chamber, and suitable amount of oil is placed at the bearing opening such as the taper seal section 8 or the like of the bearing section under a reduced pressure environment. Thereafter, the environment in the bearing-supporting vacuum chamber is returned to the atmospheric pressure, thereby filling the oil in the bearing gap of the fluid dynamic pressure bearing by utilizing the atmospheric pressure.
However, even in the oil filling method as described above, the oil often bubbles during the filling process. This is because it is extremely difficult, particularly in a mass production process in a factory, to remove the dissolved air to a degree of not forming air bubbles even by stirring and degassing the oil under the reduced pressure. The oil bubbling during the oil filling process hinders a smooth supply from the vacuum chamber having the oil stored therein to the bearing-supporting vacuum chamber. Further, when bubbling occurs at the stage where the oil reaches the bearing-supporting vacuum chamber, the oil may be scattered in a spraying manner in the oil vacuum chamber, thereby staining the bearing and the inside of the chamber with the oil.
The degassing level of the oil is somewhat enhanced by exposing the oil under the reduced pressure environment and performing stirring and degassing. However, effective degassing cannot be carried out by degassing under a state where the oil is stored in the vacuum chamber, since the area exposed to the reduced pressure environment to the volume of the oil, i.e., the surface area of the oil is limited. In this case, it is possible to increase the area to the volume of the oil by using a large-sized vacuum chamber, or by decreasing the amount of oil stored in the chamber. However, these are not realistic solutions since they deteriorate productivity by increasing the size of the oil filling device or by increasing an oil replenishing frequency.
SUMMARY OF INVENTION
The present invention aims to provide a method for use in the manufacturing of a fluid dynamic pressure bearing that can prevent or reduce the likelihood of air bubbles during an oil filling process.
In the method of an embodiment according to the present invention, a first vacuum chamber, that stores oil and performs a degassing, is pressure-reduced, and at least at the time of completing the pressure-reduction, the pressure in the first vacuum chamber is made smaller than the pressure in a second vacuum chamber at the time of the operation of supplying the oil into a bearing. This provides that higher pressure is applied on the oil upon the operation of supplying the oil than upon the operation of degassing the oil. The higher pressure restrains the occurrence of air bubbles in the oil at the supplying operation.
According to another embodiment of the present invention, even after the first vacuum chamber is pressure-reduced to obtain a pressure not more than a predetermined pressure, the reduced-pressure state is kept, and with this state, oil is supplied to a second vacuum chamber to thereby fill in the bearing. The predetermined pressure in the first vacuum chamber is smaller than the pressure in a second vacuum chamber at the time of the operation of supplying the oil into a bearing. The first vacuum chamber is kept to be pressure-reduced, whereby a more perfect degassing of oil can be attained.
In the present invention, a valve mechanism or pump mechanism for sending the oil to the second vacuum chamber may be disposed on the way of a pipe that joins the first vacuum chamber and the second vacuum chamber. The oil can be sent to the second vacuum chamber by this valve or pump against the pressure difference. Thereby the oil is supplied to the second vacuum chamber more certainly.
In the present invention, gravity may be used for supplying the oil. This can provide a smooth supply of oil. For example, supposing that the density of the oil is about 1 g/cm 3 , the pressure can be increased by 1000 Pa due to the height difference of 10 cm. Making a suitable height difference enables to supply oil to the second vacuum chamber against the pressure difference between the first vacuum chamber and the second vacuum chamber. Combining the valve mechanism to this can provide an accurate supply of oil.
In the present invention, oil may be dripped into the first vacuum chamber. Oil is dripped, whereby the surface per volume exposed to the reduced pressure environment is temporarily increased, thereby promoting the degassing. Further, droplets of oil impinging on the bottom of the chamber or on the liquid level of the stored oil become a more minute splash. This phenomena also assists the degassing of oil.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1 is a constructional view of a motor having a fluid dynamic pressure bearing; and
FIG. 2 is a conceptual view of an oil filling apparatus corresponding to an embodiment of the invention.
DETAILED DESCRIPTION
A manufacturing method of a fluid dynamic pressure bearing device according to an embodiment of the present invention will be explained with reference to drawings. It should be noted that the fluid dynamic pressure bearing 10 of FIG. 2 is the same as that shown previously described in FIG. 1 , and accordingly a detailed description thereof is omitted below to avoid redundancy in the description.
In the method according to the embodiment, a valve B 1 is firstly opened and a vacuum pump P 1 is operated, whereby air in a first vacuum chamber 100 that is an oil tank is exhausted to be pressure-reduced to a predetermined degree of vacuum PL 1 . After the reduced pressure level in the first vacuum chamber 100 is confirmed to reach the degree of vacuum PL 1 , a valve B 2 is opened to thereby start a supply of oilL from an oil supplying chamber 102 to the first vacuum chamber 100 . At this time, a capillary 104 for supplying the oilL from the oil supplying chamber 102 to the first vacuum chamber 100 has a needle shape having a diameter to a degree in which the oiIL is retained by a capillary phenomena. Further, pressure PL 2 in the oil supplying chamber 102 is kept to be slightly higher than the reduced pressure level PL 1 in the first vacuum chamber 100 . Accordingly, the oiIL retained in the capillary 104 is dripped as droplets into the first vacuum chamber 100 due to the pressure difference between the first vacuum chamber 100 and the oil supplying chamber 102 .
The oilL is naturally dripped into the first vacuum chamber 100 with its internal pressure higher than the reduced pressure level PL 1 due to the pressure difference between the reduced pressure level PL 1 in the first vacuum chamber 100 and the pressure PL 2 in the oil supplying chamber 102 . Therefore, the oilL enters into the first vacuum chamber 100 from the capillary 104 as a droplet, and at the same time, air dissolved in the oilL expands by a cavitation phenomena to form air bubbles. However, the oilL is dripped from the capillary 104 having a diameter to a degree in which the capillary phenomena is acted, whereby the volume of the oilL dripping as a droplet is extremely small. On the other hand, the entire surface of the dripped oilL is exposed to the vacuum environment under the reduced pressure level PL 1 , so that air bubbles are easily opened in the first vacuum chamber 100 , thereby degassing the oil L.
Droplets of oilL impinging on the bottom of the first vacuum chamber 100 or on the liquid level of the oilL previously dripped and stored in the first vacuum chamber 100 become a more minute splash to be scattered, thereby further promoting the degassing. Therefore, the degassing process of the oilL by the drip that also uses the vacuum degassing as described above is more efficient compared to the conventional degassing process using only the vacuum degassing or the degassing process using both the vacuum degassing and the degassing by stirring. Thereby the air dissolved in the oil is surely eliminated.
When the oilL of a predetermined amount is stored in the first vacuum chamber 100 , the fluid dynamic pressure bearing 10 having no oil filled therein is inserted into a second vacuum chamber 106 , that is an oil injecting chamber, from an opening not shown and is placed at the predetermined position. After the opening is closed, a valve B 3 is opened, and then, a vacuum pump P 2 start to exhaust air in the second vacuum chamber 106 and the bearing gap of the fluid dynamic pressure bearing 10 . When reaching a reduced pressure level PL 3 set in advance, the valve B 3 is closed and the vacuum pump P 2 is stopped to thereby start the filling of the oil L. It should be noted that the pressure in the second vacuum chamber 106 can be reduced by using the vacuum pump P 1 that is used for pressure-reducing the first vacuum chamber 100 .
In order to perform the filling of the oil L, an oil injecting opening 108 is firstly positioned above the taper seal section 8 of the fluid dynamic pressure bearing 10 by moving in parallel or by rotating a movable member 110 . Thereafter, a valve B 4 is opened to supply the degassed oil stored in the first vacuum chamber 100 via a pipe 112 . In this case, a needle valve 114 (for example, BP- 107 D manufactured by Ace Giken Co., Ltd.) is operated in order to accurately send a first amount of oil V 1 set in advance to the oil injecting opening 108 .
Then, the oilL supplied from the first vacuum chamber 100 to the needle valve 114 is dripped into the taper seal section 8 of the fluid dynamic pressure bearing 10 from the oil injecting opening 108 . Next, a valve B 5 is opened for a predetermined time to flow in dust-proof open air by filter means or the like, and then, the atmospheric pressure in the second vacuum chamber 106 is increased from the reduced pressure level PL 3 . At this time, the bearing gap of the fluid dynamic pressure bearing 10 is in a state of being sealed by the oilL dripped into the taper seal section 8 , so that the pressure in the bearing gap is kept to be the reduced pressure level PL 3 . Therefore, a pressure difference occurs between the pressure in the bearing gap and the increased pressure in the second vacuum chamber 106 , by which the amount of dripped oil V 1 is pressed into the bearing gap.
Subsequently, a camera 116 is moved to a position where the inside of the taper seal section 8 can be observed by moving in parallel or rotating a movable member 118 , observing the amount of the oilL filled in the bearing gap by the above-mentioned process. A second amount of oil V 2 , that is an adding amount of oil required to supply an optimum amount of oilL to the fluid dynamic pressure bearing 10 , is determined based upon the result of this observation Then, the valve B 3 is opened again and the vacuum pump P 2 is operated, whereby the air in the vacuum chamber 106 is exhausted to reduce the pressure therein to the reduced pressure level PL 3 . After this pressure-reduction is completed again, the second oil amount V 2 is filled again in the bearing gap by the same manner as the filling process of the oil amount V 1 .
The fluid dynamic pressure bearing 10 to which the filling of the predetermined amount of oilL is completed as described above is taken away from the second vacuum chamber 106 from the opening section not shown. Although the above-mentioned explanation is made about the case where the filling of the oilL to the fluid dynamic pressure bearing 10 is performed two times, it can be carried out three times or more. Further, the oil is filled in the bearing gap in a somewhat greater amount than the predetermined oil filling amount, and the excessive filling amount may be absorbed and collected by confirming the interface position of the oilL in the taper seal section 8 by the camera 116 .
The important point in the filling of the oilL to the bearing gap is that the pressure in the first vacuum chamber 100 is surely reduced to be lower than the pressure in the second vacuum chamber 106 , i.e., the relationship of the reduced pressure level PL 1 >reduced pressure level PL 3 is established, at the time of completing the pressure-reduction.
In case where the relationship between the reduced pressure level PL 1 and PL 3 in each vacuum chamber 100 and 106 is such that the reduced pressure level PL 1 <reduced pressure level PL 3 , i.e., in case where the pressure in the first vacuum chamber 100 is higher than the pressure in the second vacuum chamber 106 , upon supplying the oilL to the second vacuum chamber 106 from the first vacuum chamber 100 , slightly remaining air in the oilL forms air bubbles by a cavitation phenomena due to the pressure difference, thereby spouting out in the second vacuum chamber 106 from the oil injecting opening 108 . In case where the fluid dynamic pressure bearing 10 is applied as a bearing device for a motor in a hard disk drive device or the like used under a clean environment, the spouting oilL kept to be adhered pollutes the clean environment. Therefore, it is required to wipe the inside of the second vacuum chamber 106 or the surface of the fluid dynamic pressure bearing 10 . Moreover, in case where the bubbling phenomena is caused in the pipe 112 , the oilL is broken by the air bubbles in the pipe 112 , so that the oilL cannot smoothly be supplied toward the oil injecting opening 108 . These problems cause a serious reduction in productivity of the fluid dynamic pressure bearing 10 .
On the other hand, the relationship of PL 1 >PL 3 is established between the reduced pressure level PL 1 in the first vacuum chamber 100 and the reduced pressure level PL 3 in the second vacuum chamber, whereby the oilL is transported toward the side where the pressure is higher (the degree of vacuum is lower) successively during the oil filling process, thereby being capable of surely preventing the occurrence of bubbling phenomena. In this case, the pressure in the second vacuum chamber 106 wherein the oil is filled into the bearing gap of the fluid dynamic pressure bearing 10 is reduced to be not more than 1000 Pa, and more preferably to be about 1000 Pa, whereby air is prevented to be melted again in the oilL when the oilL is dripped from the oil injecting opening 108 into the taper seal section 8 of the fluid dynamic pressure bearing 10 to thereby be filled in the bearing gap. Therefore, the filling process of the oilL is completed without deteriorating the degassing level of the oil L. Accordingly, the occurrence of air bubbles can be restrained even after the operation is started with the fluid dynamic pressure bearing 10 built in as a bearing device of a motor.
It should be noted that, in this case, the reduced pressure in the first vacuum chamber 100 whose pressure is reduced to the reduced pressure level PL 1 that is higher than the reduced pressure level PL 3 in the second vacuum chamber 106 is preferably set to be not more than 30 Pa. Setting the reduced pressure level PL 1 in the first vacuum chamber 100 to be higher as described above makes it possible to enhance the degassing level in the degassing process of the oilL by the above-mentioned dripping.
Although the embodiment of the manufacturing method of the fluid dynamic pressure bearing according to the present invention has been explained above, the invention is not limited to the embodiment. Various modifications or amendments are possible without departing from the scope of the invention, and further, the invention can be applied to fluid dynamic pressure bearings having various configurations.
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Oil which will serve as a lubricating fluid of a fluid dynamic pressure bearing is degassed in a first environment under a first pressure which is lower than atmospheric pressure. First and second members of the bearing are place in a second environment under a pressure lower than atmospheric pressure and higher than the pressure in the first environment. The degassed oil is supplied to the gap between bearing surfaces of the first and second members while the first and second members are in the second environment under pressure lower than atmospheric pressure and higher than the pressure in the first environment. Subsequently the pressure in the second environment is increased to force the oil into the gap between the bearing surfaces of the first and second members of the hydrodynamic fluid.
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FIELD OF THE INVENTION
This invention relates to a log infeeder, e.g., for feeding logs to chip-and-saw apparatus, and more particularly to a mechanism for adjusting the height of the infeeder.
BACKGROUND OF THE INVENTION
Maximizing the production of lumber from each log is a major objective of sawmills of today. Many different types of machinery or apparatus are applied to this task. An example is the chip-and-saw apparatus. A log is scanned and a computer determines a precise rectangular cross section extended lengthwise down the log that can be derived from the log and the precise cuts that can be made to maximize the production of lumber from that cross section. The log is then passed through a series of chippers that discriminately removes the wood of the log periphery to generate the desired cross section. Included is a bottom chipper that squares (or flattens) the log bottom, side chippers that square the log sides, and a top chipper that squares the log top, all precisely in accordance with the dictated rectangular cross section determined by the computer.
The chippers have to be adjusted relative to each log to be sawn in order to accomplish the desired flattening (or opening) of the sides. Typically the bottom chipper is fixed and the log infeed or conveyor path, as defined by the height of the infeed table is raised or lowered relative to the bottom chipper. The side chippers are moved in and out relative to a center line and the log infeed path is laterally adjusted to align the log with that center line. The top chipper is raised and lowered as needed.
The mechanism to which the present invention is directed is that mechanism which raises and lowers the infeed table or conveyor. Logs being arranged on the table can weigh several thousand pounds and the weight of the conveyor mechanism which supports the log can weigh additional thousands of pounds. The mechanism which adjusts the height of this very large weight must be rapid and precise. The log conveyance path defined by the table cannot be altered except in height and side way shifting, i.e., the entire table must be equally raised so as to be retained in a parallel plane.
The mechanism to achieve this task has progressed through several stages. In an early version of the table lift mechanism, the conveyor structure is supported on a series of lateral shafts hereafter referred to as lifting shafts. The lifting shafts were supported at each end on a pivotal crank arm, the connection to the crank arm being offset a precise distance from the crank arm's pivotal axis. Simultaneous pivoting of all of the crank arms simultaneously raise or lower the lifting shafts which in turn raise or lower the table, with every position of the table retained in a parallel plane.
As previously mentioned, each lifting shaft was supported on a set of crank arms. The crank arms of each set were connected through their pivotal axis by a pivoting shaft. Pivoting one crank arm of a set would apply torque to the pivot shaft resulting in rotation of the pivot shaft to pivot the other pivot arm of the set.
To insure simultaneous and equal movement of all the crank arm sets supporting the lifting shafts, a single actuator was utilized. A cylinder was coupled to one crank arm of a set. A rigid rod coupled the cylinder actuated crank arm to one crank arm of the next crank arm set and the additional crank arm sets would be coupled to the previous crank arm set by additional rods in the same manner.
The cylinder engaging one of the opposed crank arms connected together by the pivoting shaft, is controlled by the computer to actuate pivotal movement of the crank arms and corresponding raising and lowering of the infeed table.
The problem with the above-described mechanism is that the single actuator applies excessive torque to the pivotal shaft. Failure of the pivotal shaft and/or various connecting means used for connecting the crank arm and pivoting shaft are common.
A second version was developed whereby the pivotal shaft was eliminated and an actuator was applied to a crank arm on each side of the table. The problem with this design was the precise timing required of the actuators. The slightest difference in actuation is intolerable, as everything is tied together by support beams and the huge forces applied to the crank arms at each side causes severe damage when not equally applied.
BRIEF DESCRIPTION OF THE INVENTION
Applicant's solution to the problem was in the first instance to revert back to the single actuating cylinder. To avoid the torque problems, i.e., the torque being applied to a pivot shaft, a lifting beam connects the two crank arms and the actuating cylinder is connected to the lifting beam at a mid-point between the crank arms. The force thus applied to the lifting beam is a bending force which is readily accommodated by the beam, and both crank arms are equally forced by the actuating cylinder to the same precise pivotal position.
A secondary benefit is accomplished by providing the actuated crank arms at one end of the table and a second pair of crank arms at the other end, also interconnected by a lifting beam. A cable extended between the midpoints of the lifting beams, couple the two pairs of crank arms. The arrangement of the actuating cylinder is such that a pulling force is applied to the cable for raising the table whereas lowering thereof is accomplished by the weight of the table directed counter to the lifting force. This counter force maintains the cable always in tension. The cable insures that if something does prevent lowering of the crank arm at the opposite end, the cable will simply relax rather than buckle a rigid connecting rod as has happened on occasion in the past. The cable otherwise accomplishes the task equally as well as the rigid rod and is less expensive.
The invention will be more fully understood upon reference to the detailed description and drawings which follow.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a view in diagram form of an infeed table for logs;
FIG. 2 is a view as viewed on view lines 2--2 of FIG. 1;
FIG. 3 is a view as viewed on view lines 3--3 of FIG. 1; and
FIG. 4 is a perspective view of a lift mechanism of the infeed table of FIG. 1.
DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 illustrates an infeed table 10 for receiving and feeding logs to a log processing unit. In this embodiment, the infeed table receives and feeds logs to a chipper/saw line. Other embodiments will of course comprise cutting tools other than a chipper/saw line. Basically the infeed table 10 has a chain-type conveyor 12 for receiving and transporting a log 14. Hold down rollers 16 are provided to apply pressure to the top of a log to hold the log in position on the chain-type conveyor 12. As the log 14 is transported by the chain-type conveyor 12, it is scanned by a scanner unit 18. The scanner 18 scans the profile of the log and determines the position of the log 14 on the chain conveyor 12. The data from the scanner 18 is input to a computer 20 and the computer will establish the ideal cant that may be obtained from the log 14, it will establish the center line of the ideal cant in reference to the chain conveyor 12 and will control the lift and shift mechanism, which will later be detailed, for shifting the infeed table 10 transverse to the travel direction of the log 14 and for elevating or lowering the table 10 to position the log 14 in the proper attitude for a subsequent processing unit. In this embodiment, the next processing unit is a chipper unit as is illustrated in FIGS. 1 and 2.
In this embodiment, the bottom chipper 26 is in a fixed position and is not adjustable either upwardly or laterally. The side chippers 28 and 30 are adjustably movable toward and away from a center line 32 (FIG. 2). A top chipper 34 is adjusted upwardly and downwardly to accommodate the diameter of the log 14. FIG. 2 illustrates a log 14 and a resulting cant 14a that will be produced by the chipper unit. Since the bottom chipper 26 is in a fixed position, the log 14 received on the chain conveyor 12 may require repositioning either upwardly or downwardly to present the log 14 in the proper attitude to the chipper unit. Thus, the infeed table 10 will be raised (lifted) or lowered as determined by the computer. Similarly the infeed table 10 will be laterally shifted to align the log 14 with a known reference. In this embodiment, the bottom chipper 26 produces a spline on the resulting cant 14A. The log 14 is laterally shifted (in either direction) to produce the spline at the desired location on the cant 14A. It will be appreciated that other references may be utilized to position the log 14 particularly when the infeed table 10 is feeding the log 14 to other log processing units.
The infeed table 10 is supported on lift and shift mechanisms 40, 42 illustrated in FIGS. 1 and 4 with the lift and shift mechanism 42 being further illustrated in FIG. 3. In this embodiment, there are two lift mechanisms, i.e., 40 and 42. However, it will be appreciated that additional lift and shift mechanisms may be provided to facilitate elevating and shifting the infeed table 10. The number of lift and shift mechanisms utilized will depend in part on the length of the infeed table 10, the structural makeup of the infeed table 10, the weight of the infeed table 10 plus the weight of the largest log contemplated and so forth.
Each of the lift and shift mechanisms 40, 42 has a base plate 50. Pedestals 52 are fixedly mounted near each end of the base plates 50. A housing 54 is provided on the top of each pedestal 52 and is arranged to receive a pivot shaft 56. A pivot shaft 56 is provided on each lift and shift mechanism 40 and 42. Each of shafts 56 extends from one bearing housing 54 on one pedestal 52 to the other bearing housing 54 on the opposite pedestal 52. The pivot shafts 56 are rotatably mounted in the opposed housings 54 on each of the pedestals 52.
The lift and shift mechanism 40 has a crank arm 58 mounted to the pivot shaft 56 adjacent each of the pedestals 52. The crank arms 58 may or may not be non-rotatable with reference to the pivot shaft 56 and the shaft itself may be replaced with a pair of pivot pins at each pedestal. A support shaft 60 is rotatably and slidably mounted in bores 62 provided in each of the crank arms 58. The mounted support shaft 60 is substantially parallel to the mounted pivot shaft 56 and is offset at a distance from the pivot shaft 56. The support shaft 60 may be moved longitudinally in the bores 62 of the crank arms 58 as indicated by arrow 61. The infeed table 10 is fixedly mounted on the support shaft 60 between the spaced-apart crank arms 58.
Refer to FIG. 3 which illustrates the table 10 fixedly mounted to the support shaft 60 of the lift and shift mechanism 42 at 100. Only one of the table mounts is illustrated, however the opposite side of the table 10 is mounted to the shaft 60 in the same manner. The table 10 is similarly mounted to the support shaft 60 of the lift and shift mechanism 40. Conventional openings 106 are provided in the infeed table 10 to permit extending the pivot shafts 56 of the lift and shift mechanisms 40, 42 through the table 10 and to permit lifting and lowering the table 10 without interfering with the pivot shafts 56. The infeed table 10 is fixedly attached to the support shaft 60 and thus as the support shaft 60 is moved longitudinally in the bores 62, the infeed table 10 will be moved laterally with respect to the flow path (indicated by arrow 39 in FIG. 1) of the infeed table 10.
A lift beam 70 is extended between the crank arms 58 and is fixedly attached to each of the crank arms 58. The lift beam 70 is substantially parallel to the pivot shaft 56 and is preferably offset a greater distance from the pivot shaft 56 than the support shaft 60 is offset from the pivot shaft 56. The lift beam 70 has a bracket 72 arranged to couple an end 74 of a cable assembly 76. Another bracket 82 is provided for coupling the lift beam 70 to a cylinder rod 84 of a cylinder 86. Trunnion blocks 88 (FIG. 1) are mounted to the base plate 50 and are arranged to support the cylinder 86 in a conventional manner.
The cylinder 86 as its rod 84 is extended and retracted will thus pivot the crank arms 58 on the pivot shaft 56 extending between the pedestals 52 and since the support shaft 60 is offset from the pivot shaft 56, the support shaft 60 which is connected to and supports the infeed table 10 will elevate (lift) and lower the infeed table 10 as the crank arms 58 are pivoted on the pivot shaft 56. The infeed table 10 will thus be elevated and lowered by the appropriate pivoting of the crank arms 58. In this embodiment, fluid power is applied to the cylinder 86 to elevate (lift) the table 10 and the fluid is controllably released from the cylinder 86 to lower the table 10. The weight of the table 10 is sufficient to lower the table 10 by gravity, however, by controlling the release of the fluid the rate of lowering and the position to which it is lowered is controlled.
The lift and shift mechanism 42 as shown in FIGS. 1, 3 and 4 is similarly arranged and has crank arms 90 mounted on the pivot shaft 56 that extends between the opposed housings 54 on the pedestals 52. The pivot shaft is rotatably mounted in the housings 54 mounted on the pedestals 52.
Another support shaft 60 is extended between the crank arms 90 and is rotatably slidably mounted in the bores 62 provided in the crank arms 90. The support shaft 60 is substantially parallel to and offset at a distance from the pivot shaft 56. The support shaft 60 is fixedly attached to the infeed table 10 at 100 (FIG. 3).
A lift beam 96 is extended between the crank arms 90 and is fixedly attached to the crank arms 90. The lift beam 96 is substantially parallel to and offset at a distance from the pivot shaft 56. The lift beam 96 has a bracket 98 arranged for coupling an end 80 of the cable assembly 76.
The lift and shift mechanism 40 is thus mechanically coupled to the lift and shift mechanism 42 by the cable assembly 76. The cable assembly 76 includes a turn buckle 78 for adjusting the length of the cable assembly 76 so that the crank arms 90 of the lift and shift mechanism 42 will be pivoted in unison with the crank arms 58 of the lift and shift mechanism 40. The infeed table 10 will thus be elevated and lowered uniformly.
Each of the support shafts 60 of the lift and shift mechanisms 40, 42 are coupled to individual cylinders 102 (FIG. 3) for moving the support shafts 60 longitudinally in either direction in the bores 62 in their corresponding crank arms 58 and 90 of the lift and shift mechanisms 40, 42. The cylinders 102 are mounted on brackets 104 extending from the crank arms 58, 90 of the lift and shift mechanisms 40, 42. The cylinders 102 and brackets 104 are not illustrated in FIGS. 1 and 4 for drawing clarity. The cylinders 102 will move the support shafts 60 longitudinally as indicated by arrow 61 in FIG. 4. The cylinders 102 on the lift and shift mechanisms 40, 42 are preferably coupled to move in unison such that the infeed table 10 will uniformly be moved in either direction transverse to the product flow direction (indicated by arrow 39 in FIG. 1).
A log 14 which most often has been rotated to a horns down position is received on the chain-type conveyor 12 as illustrated in FIGS. 1 and 3. Typically the infeed table 10 has a known centering mechanism (generally designated by the numeral 15 in FIG. 1) that will substantially center the log 14 on the chain-type conveyor 12. The log 14 is supported on the chain 12 as best seen in FIG. 3. As the log 14 is transported by the chain-type conveyor 12, the log will pass the scanner system 18. The scan data from the scanner 18 is input to the computer 20 and the computer 20 will determine the ideal or optimum cant 14a that may be obtained from the log 14 as best seen in FIG. 2. The scan data from the scanner 18 also provides the computer with information about the position of the log 14 on the chain 12 and therefore will determine the position of the center line of the ideal cant 14a and also will determine the bottom edge 14c (surface) of the ideal cant 14a. From the input data, the computer will control the lift and shift mechanisms 40, 42 to properly position the infeed table 10 with relation to the chipper unit. The computer 20 will control the operation of the cylinder 86 to elevate (lift) or lower the infeed table 10 as required to place the intended bottom surface 14c of the ideal cant 14a in relation to the bottom chipper unit 26. The computer 20 will also control the operations of the cylinders 102 to shift the infeed table 10 laterally in either direction to adjust the position of the log 14 so that the spline generated in the cant 14A by the bottom chipper 26 will be at the desired location. The log 14 will thus be properly positioned according to the ideal cant 14a that is to be produced from the log 14 and the chain-type conveyor 12 will propel the log 14 into the chipper unit whereat the bottom, sides and top of the log 14 will be chipped away by the chipper unit and thus will produce the cant 14a.
The lift and shift mechanisms 40, 42 provide a uniform lifting and lowering motion to the infeed table 10. As seen in the figures, the force applied to the lifting beam 70 of the lift and shift mechanism 40 and the lifting beam 96 of the lift and shift mechanism 42 is applied near their center points and thus are only subject to a bending moment rather than a torsional twisting moment. This will apply a uniform force to each of the crank arms 58 and 90 of the lift and shift mechanisms 40, 42. The lift and shift mechanism 42 is mechanically coupled to the lift and shift mechanism 40 by the cable assembly 76 and thus the lifting and lowering of the infeed table 10 is accomplished by a single actuator, i.e., cylinder 86. By utilizing a cable assembly 76 to couple the lift and shift mechanism 42 to the lift and shift mechanism 40, there is a reduced chance to any damage to the coupling mechanism as the table 10 is lowered. Should the portion of the infeed table 10 that is supported by the lift and shift mechanism 42 fail to lower as the cylinder 86 is actuated to lower the infeed table 10, the cable assembly 76 will simply relax rather than being subject to a bending or twisting force that is commonly experienced with solid couplings that would couple the lift and shift mechanism 42 to the lift and shift mechanism 40.
Those skilled in the art will recognize that modifications and variations may be made without departing from the true spirit and scope of the invention. The invention is therefore not to be determined by the embodiments described and illustrated but is to be determined by the appended claims.
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A mechanism for elevating and/or shifting a log infeed table to position a log received on the infeed table for a subsequent operation. The mechanism has sets of opposed paired crank arms pivotally mounted on supports. The infeed table is mounted on supporting shafts extending between the crank arms with the supporting shaft offset from the pivot axis of the crank arms. The crank arms are pivoted by an actuator coupled to a beam extended between one pair of the crank arms. All of the sets of paired crank arms have their beams coupled together by flexible couplings such that all of the sets of crank arms will pivot in unison. As the crank arms are pivoted by the actuator, the infeed table is raised or lowered. The supporting shafts are slidably movable in the cranks arms. Separate actuators are provided to move the supporting shaft in the crank arms to shift the infeed table transverse to the flow path of the infeed table.
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BACKGROUND AND SUMMARY OF THE INVENTION
[0001] Exemplary embodiments of the invention relate to method for carrying out a process of parking a vehicle by means of a driver assistance system. The method involves detecting objects in an environment of the vehicle and their respective relative positions with respect to the vehicle. A target position and a trajectory to the target position are then determined by considering the detection of the environment and relative position. Subsequently, the parking process along the determined trajectory is carried out by means of a control device, wherein the trajectory is adapted during the implementation of the parking process, considering the continuously detected environment objects.
[0002] The parking spaces and garages for vehicles are often designed to be small due to the limited parking situation in cities and car parks. If a vehicle is parked, for example, in a parking space between two stationary vehicles at the sides, the doors of the vehicle can often only be opened at a comparatively small angle and the vehicle user can only leave the parked vehicle with difficulty.
[0003] In the last few years, automatic and autonomous solutions have been developed to address this problem. Therein, the user of the vehicle can disembark in front of the parking space and can then initiate the autonomous parking procedure via radio. For this there are two solutions. In the first solution, the vehicle can only be moved straight forwards and straight backwards. In the second solution, the parking space and the surroundings of the vehicle are detected by means of suitable sensor devices. The vehicle can park autonomously in this detected parking space.
[0004] German patent document DE 102 06 763 A1 discloses a method to park a vehicle in which the obstacles in the environment of the vehicle are detected. Both the distances of the vehicle to the obstacles and the length or width of a parking space are determined. Sensors are used both for parking space determination and for distance measurement. In the case of falling below a predetermined distance to an obstacle, a warning signal is emitted to the driver.
[0005] European patent document EP 1 249 379 A2 discloses a method to bring a motor vehicle into a target position in which the motor vehicle is brought into a start position close the target position that is aimed for. After a first activation on the part of the driver, the surroundings of the motor vehicle are continuously scanned and the current vehicle position is continuously determined. A trajectory to the target position is determined by means of the determined surroundings and positional information. To drive the trajectory, control information is generated to bring the motor vehicle into the target position. After a second activation on the part of the driver, the control command that depends on the control information is emitted to the drive train, the brake system and the steering of the motor vehicle. Thus, the motor vehicle drives into the target position independently of the driver. The activation on the part of the driver can take place outside the motor vehicle.
[0006] German patent document DE 10 2009 041 587 A1 discloses a driver assistance device that includes a control device that emits control signals to a drive and steering device of the motor vehicle and initiates an implementation of an autonomous parking process. By means of a remote control, commands can be given to the control device from outside the vehicle. After receiving a predetermined interruption command, a parking process of the motor vehicle that has already begun can be interrupted. At least one camera is coupled to the control device and obtains image data over a surrounding region of the motor vehicle. The control device sends the image data obtained by the camera or image data calculated from this to the remote control. The remote control depicts this image data by means of complex display and operation units.
[0007] German patent document DE 10 2011 003 231 A1 discloses a method and a device to automatically carry out a driving maneuver with a motor vehicle. The method comprises the following steps: (a) detection of the surroundings of the motor vehicle with a first detection system whilst driving past a parking space, (b) calculation of a trajectory, along which the motor vehicle is moved during the driving maneuver, by means of the surroundings data detected in step (a), (c) automatic movement of the motor vehicle along the trajectory to carry out the driving maneuver, wherein the surroundings of the motor vehicle are detected with a second detection system that is different from the first whilst the motor vehicle is moved. The data detected by the first detection system is transferred to a portable control device. Using the portable control device, it is possible to monitor the driving maneuver even outside the vehicle. The driver can interrupt the driving maneuver, comfortably disembark and subsequently continue the driving maneuver from outside the vehicle. Here the interruption of the driving maneuver is controlled by the driver and not by the vehicle.
[0008] German patent document DE 10 2009 046 674 A1 discloses a method to support a process of parking a motor vehicle in a parking position by means of a parking device. The parking device has at least one sensor device, which sensor device is formed at least to detect the contours of the parking position, wherein the method has at least the following steps: driving into a region in front of at least one parking position with the motor vehicle and detection of the region by the sensor device, initiation of a driving reaction by the driver of the motor vehicle, which is formed in such a way that the intention of the driver of the motor vehicle to park the motor vehicle in a parking position is recognized by the parking device, recognition of the arrangement of the parking position by the sensor device relative to the motor vehicle, instant detection of the contours of the parking position by the sensor device and guiding of the motor vehicle to the parking position by the parking device. Here, a selection of different parking trajectories or arrangements within the parking position is offered to the user.
[0009] German patent document DE 10 2005 046 827 A1 discloses a method for parking support in which in the case of an at least partial positioning of the vehicle in a parking space, said positioning not yet having been completed, the dimensions of the parking space are determined and a trajectory of the vehicle to complete the parking process is determined. Here, different trajectories are offered to the driver for selection.
[0010] With the device and method that has been known until now, the user of the vehicle has the possibility to select different trajectories for the parking process, but no possibility for selection to carry out a determined parking maneuver. Additionally, the vehicle assistance system does not offer the driver the possibility to choose between parking processes with the driver in the vehicle and outside the vehicle.
[0011] Exemplary embodiments of the present invention are directed to optimizing a parking process such that it can be carried out particularly reliably and in a user friendly manner.
[0012] In accordance with the invention, at the beginning of the parking process a selection possibility between at least two parking maneuvers is made available to the user of the driver assistance system in the vehicle. The first parking maneuver is a direct parking maneuver; therein a parking process from the start position directly to the target position, known in prior art, is carried out. For the further parking maneuver, a break point is determined along the trajectory and this break point allows the user to disembark.
[0013] In comparison to the direct parking maneuver, in the further parking maneuver, not only is a trajectory to the target position determined, but also a break point along the trajectory. The vehicle is stopped at this break point. That is, when carrying out the parking process the vehicle does not drive automatically into the target position as in the direct parking maneuver, but stops at a suitable break point before the target position during driving of the trajectory. In order to determine this break point, both the fixed objects, such as, for example, a wall, and the moving objects, such as, for example, pedestrians, are continuously considered in the surroundings. Thus, a narrow parking space, a narrow garage or a parking space that is difficult to drive into, such as parking spaces next to a wall, a hedge or similar, where it is made difficult for a user to disembark, can be used.
[0014] Preferably, the break point for the disembarking of a user is determined such that the target position is reached in one stroke, so without change of driving direction, during the continuation of the parking process. This is referred to below as one-stroke parking.
[0015] In order to bring a vehicle into a target position along a determined trajectory, several changes in direction from forward drive and backward drive of the vehicle are often carried out during the parking process. This is referred to as parking with multiple-stroke maneuvering processes. If the user starts such a parking process, an exact monitoring of the entire parking process by the user is of great importance. Therein it must be considered that not all obstacles are recognized with a determined environment recognition device. For example, thin bars cannot be recognized with certainty by means of an ultrasound sensor. Additionally, the complete vehicle contour, such as, for example, outer mirrors or a loaded roof, must be monitored with certainty. Above all, in multi-stroke maneuvering processes, the user must always be informed in which direction the vehicle will drive in the next stroke. A complex operation and display concept is necessary for this. Provided the user is located outside the vehicle, he must change his position, if necessary, during a change of direction of the vehicle in order to see the region in front of or behind the vehicle.
[0016] This monitoring is significantly simplified if necessary changes in direction from forward and backward drive of the vehicle are carried out before the break point and are monitored by a user in the vehicle. The user can actively intervene at any time.
[0017] Preferably, the completion of the parking process is activated by a user of the vehicle after the break point. Here it would also be conceivable to offer another selection possibility between different parking maneuvers to the user of the vehicle assistance system.
[0018] Thus the user of the vehicle receives the possibility to check the current parking situation and continue the parking process by a renewed activation. This is advantageous because the desire of the user is considered in a particularly simple way.
[0019] Preferably, the completion of the parking process is initiated and carried outside the vehicle out after the break point. The continuation of the parking process after the break point can be initiated and ended by a user situated outside the vehicle.
[0020] A parking maneuver controlled from outside is particularly advantageous if a very narrow parking space is present in which the vehicle still fits, however a disembarking of a user would no longer be possible. Thus, narrow parking spaces can also be supported by the system. The customer use of a vehicle assistance system can thus be considerably increased. Additionally, a limited parking area, such as, for example, a car park, can be made better use of.
[0021] A further advantage of the activation of the continuation of the parking process from outside is that the user can comfortably disembark. The user can the parking process from outside without great monitoring effort, above all if the vehicle is driven into the target position in one stroke, without changing the driving direction. If the activation of the continuation of the parking process from outside is only enabled after the break point, i.e. only for one-stroke parking, simple operating devices can be used for this.
[0022] Preferably, in this method, the break point of the vehicle is determined for the disembarking of a user such that the vehicle doors can be opened without collision with the detected objects. Thus, a comfortable and safe disembarking of the user is possible.
[0023] Preferably, the trajectory and the break point for the disembarking of a user are determined and adapted such that a predetermined distance is maintained to the detected objects. For example, if these objects are further vehicles, then a predetermined distance is maintained. This distance to be maintained considers, for example, the case in which a vehicle door of the further vehicle is opened. The vehicle, which moves during the parking process or stands at the break point, may not collide with the open door. Overall, safety distances to objects along the trajectory during the parking process or the break process can be provided such that a collision-free implementation of the parking process is supported.
[0024] In one development of the method, the trajectory and the break point for the disembarking of a user are determined and adapted such that the seat occupation of the vehicle is considered.
[0025] Therein, for example, the positioning of the vehicle in a parking space or next to a lateral limit is adapted depending on a seat occupation of the vehicle. The lateral distances of the vehicle to objects, for example, other vehicles, which limit the parking space or break point laterally, can be selected such that the respective vehicle user can disembark from the vehicle without problem. If only a driver sits in the vehicle, a correspondingly shorter distance to an object limiting the parking space or the break point can be selected than on the passenger side. This enables an optimum use of a narrow parking space.
[0026] Preferably the completion of the parking process is initiated by the user after the break point, either by means of a mobile operating unit or by means of a voice control device or by means of a gesture recognition device.
[0027] Preferably if the enabling of the activation of the continuation of the parking process occurs from outside the vehicle only after the break point, i.e., only for single-stroke parking, a simple operating device can be used. This can, for example, be implemented by means of a simple mobile operating unit having two operating elements with which the forward and backward driving is activated separately. Likewise, the forward or the backward driving can be implemented simply by voice command or two different hand signals.
[0028] Finally it is preferable that the driving direction of the vehicle is displayed during the parking process by a lighting device on the vehicle. A light signal can be used in order to clarify the driving direction of the vehicle to the user situated outside the vehicle. For this purpose, for example, the front indicators can be controlled for the forward driving and the rear indicators for the backward driving.
[0029] Thus, a simple mobile operating device can be used. A complex display device that depicts the driving direction of the vehicle can be dispensed with. A user who is situated outside the vehicle can always direct his view to the vehicle and thus better monitor the parking process.
[0030] Preferably, the flashing frequency of the lighting device of the vehicle varies depending on the distance to the detected objects. The distance to the next recognized obstacle is communicated to the user via the flashing frequency. The shorter the distance, the faster the lights flash.
[0031] This enables a particularly simply depiction of the driving direction and the distance to the next detected object.
BRIEF DESCRIPTION OF THE DRAWING FIGURES
[0032] There are now different possibilities to design and develop the teaching of the present invention in an advantageous way. For this purpose reference is made to the following explanation of the embodiment. One embodiment of the method according to the invention is depicted in the drawing. Herein are shown, in schematic depiction,
[0033] FIG. 1 top view onto a parking situation, wherein a vehicle is maneuvered backwards into a perpendicular parking space;
[0034] FIG. 2 top view onto a parking situation, wherein a vehicle is maneuvered forwards into a parallel parking space;
DETAILED DESCRIPTION
[0035] FIG. 1 shows a parking situation in a schematic depiction in which a vehicle 1 is maneuvered backwards into a parking space 2 . The vehicle 1 is situated on a road 3 that is navigable in the x direction. The parking space 2 borders the road 3 in such a way that a longitudinal axis 4 of the parking space 2 runs in the y direction and thus perpendicularly to a longitudinal axis of the road 3 . The parking space 2 is directly limited on each side, for example by a vehicle 5 and wall 6 . An additional object, for example a post or a pedestrian 7 , is situated to the side, in front of the parking space 2 .
[0036] The parking space 2 is recognized while driving the vehicle 1 past the parking space 2 . The objects 5 , 6 and 7 in the environment of the vehicle 1 are detected. Subsequently, two parking maneuvers: “Direct Parking” or “Parking with Break Point” are determined by considering the environment and relative position detection and are offered to the user in the vehicle 1 for selection.
[0037] If the user in the vehicle selects the first parking maneuver “Direct Parking”, then a trajectory 8 for the parking process from the start position 9 to the target position 10 in the parking space 2 is determined. Subsequently an at least partially autonomous control of the vehicle 1 along the trajectory 8 occurs using a control device, wherein the trajectory 8 is adapted during the implementation of the parking maneuver by considering the continuously detected environment objects 5 , 6 and 7 .
[0038] If the user in the vehicle selects the second parking maneuver “Parking with Break Point”, then, in comparison to “Direct Parking”, a trajectory 12 is determined with a break point 11 . The parking process is carried out from the start position 9 to the break point 11 and the vehicle 1 is stopped at the break point 11 .
[0039] This break point 11 is always determined if the width of the parking space 2 is below a determined limit value, for example, smaller than the total width of the vehicle 1 including open side doors. Therein, the position of the break point 11 along the trajectory 12 must be determined such that the user of the vehicle 1 has enough space to comfortably and safely disembark.
[0040] Furthermore, the determination and adaptation of the break point 11 occurs such that all required changes in driving direction from forward driving and backward driving of the vehicle are carried out before the break point 11 . After stopping at the break point 11 , the vehicle 1 is then driven into the target position 10 in one stroke, without a change in driving direction. The trajectory 12 is divided into two partial trajectories 13 , 14 by the break point 11 . The first partial trajectory 13 comprises all required changes to the driving direction from forward driving and backward driving of the vehicle. The parking process is stated by a user inside the vehicle 1 . The user remains sitting in the vehicle 1 and monitors the parking process while the vehicle 1 drives at least partially automatically from the start position 9 along the trajectory 13 to the break point 11 . The completion of the parking process, which is initiated from outside the vehicle 1 , is enabled from the break point 11 .
[0041] If the user of the vehicle 1 disembarks at the break point 11 , then the user has the possibility to check the current parking situation from the outside. The user can activate the completion of the parking process from outside the vehicle 1 . Therein the user monitors the entire implementation and can, if necessary, interrupt the implementation at any time. The second partial trajectory 14 does not comprise any change of driving direction, i.e. only forward or backward driving. After the activation of the user, the vehicle 1 ends the parking process along the trajectory 14 and parks the vehicle 1 in the target position 10 .
[0042] FIG. 2 shows a parking situation in a schematic depiction in which a vehicle 1 is maneuvered forwards into a parking space 2 . The vehicle 1 is situated on a road 3 that is navigable in the x direction. The parking space 2 borders the road 3 in such a way that a longitudinal axis 4 of the parking space 2 runs in the x direction and thus is parallel to a longitudinal axis of the road 3 . The parking space 2 is directly limited on each side by, for example, a vehicle 5 and walls 6 and 15 .
[0043] If the second parking maneuver “Parking with a Break Point” is selected from the possible parking maneuvers, then a trajectory 12 is determined with a break point 11 . The parking process is carried out from the start position 9 to the break point 11 and the vehicle 1 is stopped at the break point 11 . Therein the parking space 2 can be driven into such that at the beginning of the parking process, no complete trajectory 12 to the target position is detected, but a short trajectory within the region that is able to be detected by environment detection, i.e., the vehicle advances.
[0044] The determination and adaptation of the trajectory 12 and of the break point 11 are determined such that the vehicle 1 is directed in parallel to a longitudinally-extended object, depicted here as a wall 15 . At the same time, the position of the break point 11 is determined such that the user of the vehicle 1 has enough space to disembark comfortably and safely. Here, for example, the break point 11 can be determined such that the lateral distance of the vehicle to the vehicle 5 and to the wall 15 is larger than the total width of the vehicle 1 including open doors.
[0045] As in FIG. 1 , the trajectory 12 comprises a break point and two partial trajectories 13 , 14 . The first partial trajectory 13 comprises all required changes in driving direction from forward driving and backward driving of the vehicle. The parking process is started by a user inside the vehicle 1 . The passenger, for example, disembarks at the break point 11 and activates the completion of the parking process outside the vehicle 1 . The driver remains sitting in the vehicle 1 and monitors the parking process, while the vehicle 1 drives along the partial trajectory 14 into the target position 10 in one stroke.
[0046] Furthermore, in the case of the determination and adaptation of the trajectory 12 and of the break point 11 , the seat occupation of the vehicle 1 can be considered. The positioning of the vehicle 1 in a parking space 2 or at the break point 11 can be adapted depending on a seat occupation of the vehicle 1 . As in the case shown in FIGS. 1 and 2 , the passenger disembarks at the break point 11 ; therefore the partial trajectory is adapted such that less space is left on the passenger side to the object 6 or 15 than on the driver side. For a case in which the driver's seat is also not occupied, the vehicle 1 can be driven at a low minimum distance up to the corresponding objects such as, for example, 5 in FIG. 1 .
[0047] The foregoing disclosure has been set forth merely to illustrate the invention and is not intended to be limiting. Since modifications of the disclosed embodiments incorporating the spirit and substance of the invention may occur to persons skilled in the art, the invention should be construed to include everything within the scope of the appended claims and equivalents thereof.
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A method for performing an automatic parking process of a vehicle involves offering a user a selection between at least two parking maneuver for implementing by a driver assistance system in the vehicle. The first parking maneuver is a direct parking maneuver in which an automatic parking process is performed from the start position directly to the target position along the trajectory. The second parking maneuver involves providing a break point the parking trajectory so that a user can disembark the vehicle at the break point and prior to the target position.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional Application Serial No. 60/201,292 filed by T. P. Weihs et al. on May 2, 2000 and entitled “Reactive Multilayer Foils”. It is related to U.S. patent application Ser. No. ______ filed by M. E. Reiss et al. concurrently herewith and entitled “Method of Making Reactive Multilayer Foil and Resulting Product” and U.S. patent application Ser. No. ______ filed by T. P. Weihs et al. concurrently herewith and entitled “Freestanding Reactive Multilayer Foils”. These three related applications are incorporated herein by reference.
GOVERNMENT INTEREST
[0002] This invention was made with government support under NSF Grant Nos. DMR-9702546 and DMR-9632526, and The Army Research Lab/Advanced Materials Characterization Program through Award No. 019620047. The government has certain rights in the invention.
FIELD OF THE INVENTION
[0003] This invention relates to reactive multilayer structures, and, in particular, to reactive multilayer structures that can be easily processed to produce ductile reaction products.
BACKGROUND OF THE INVENTION
[0004] Reactive multilayer coatings are useful in a wide variety of applications requiring the generation of intense, controlled amounts of heat in a planar region. Such structures conventionally comprise a succession of substrate-supported coatings that, upon appropriate excitation, undergo a self-propagating exothermic chemical reaction that spreads across the area covered by the layers. While we will describe these reactive coatings primarily as sources of heat for welding, soldering or brazing, they can also be used in other applications requiring controlled local generation of heat such as propulsion and ignition.
[0005] Many methods of bonding require a heat source. The heat source may be external or internal to the structure to be joined. An external source is typically a furnace that heats the entire unit to be bonded, including the bodies (bulk materials) to be joined and the joining material. An external heat source often presents problems because the bulk materials can be sensitive to the high temperatures required for joining. The bulk materials can also be damaged in cooling from high temperatures due to mismatches in thermal contraction.
[0006] Internal heat sources often take the form of reactive powder. Reactive powders are typically mixtures of metals or compounds that react exothermically. Such powders, developed in the early 1960s, fostered bonding by Self-Propagating, High-Temperature Synthesis (SHS). However, the energy released and its diffusion is often difficult to control in SHS reactions. As a result, bonding by powders may be unreliable or insufficient.
[0007] Reactive multilayer structures, which were subsequently developed, reduced the problems associated with reactive powder bonding. These structures are typically comprised of thin coatings that undergo exothermic reactions. See, for example, T. P. Weihs, Handbook of Thin Film Process Technology , Part B, Section F.7, edited by D. A. Glocker and S. I. Shah (IOP Publishing, 1998); U.S. Pat. No. 5,538,795 issued to Barbee, Jr. et al. on Jul. 23, 1996; and U.S. Pat. No. 5,381,944 to D. M. Makowiecki et al. on Jan. 17, 1995. As compared to reactive powders, reactive multilayer structures permit exothermic reactions with more controllable and consistent heat generation. The basic driving force behind such reactions is a reduction in atomic bond energy. When the series of reactive layers is ignited, the distinct layers mix atomically, generating heat locally. This heat ignites adjacent regions of the structure, thereby permitting the reaction to travel the entire length of the structure until all the material is reacted.
[0008] The individual layer thickness in the foils defines the average diffusion distance that is required for materials to mix in these exothermic reactions. An exothermic reaction in a multilayer foil can self-propagate far more easily and far faster at room temperature than the same reaction in a powder compact because the layers are many orders of magnitude smaller than the powders. Individual layer thicknesses typically range from 1-1000 nm while typical powder diameters range from 10 to 100 μm. Consequently, reaction velocities in foils typically range from 1-30 m/s while reaction in powders range from 0.01 to 0.1 m/s. An additional advantage for multilayer foils is that the thicknesses of their individual layers are far more uniform, consistent, and controllable than diameters of corresponding powders. Thus, reaction properties are more easily controlled and modified. Lastly, while reactive foils are fully dense and free of contaminants at interfaces between its reactants, reactive powder compacts are rarely fully dense and often contain many contaminants at reactant/reactant interfaces due, for example, to oxide coatings on the particles. Both the lack of full density and the presence of contaminants can limit reaction kinetics and velocities compared to reactive foils.
[0009] While a clear improvement over powders, reactive multilayer structures encountered their own difficulties. For example, when attached to a substrate, the reactive foils often debond or delaminate from their substrates upon reaction. This debonding is caused by inherent reactive foil densification during reaction and by non-uniform thermal expansion on heating and contraction during cooling. In the case of joining, it significantly weakens the bonding joint. More significantly, most reactive coatings react to produce a brittle intermetallic compound, which can be detrimental at the center of a joint, lowering its fracture toughness and causing it to behave in a brittle fashion when deformed. Consequently, internal or external stresses can cause catastrophic mechanical failure of the joint.
[0010] To date, most research and development of self-propagating reactions in foils has been directed primarily to formation reactions wherein two or more elements (A/B) mix and react to form a compound product (AB x ). While such reactions may produce large heats of reaction, many difficulties are encountered in fabricating and using the requisite foils. The reactants are typically expensive or are brittle, hard to deposit and difficult to use. Many of the foils are subject to unwanted ignition. Moreover, many of the reactions produce brittle final products.
[0011] These difficulties can be illustrated by the problems with foils having B, C or Si layers. Table 1, which lists pertinent conventional formation reactions, shows that many of these reactions combine a transition metal such as Ti, Zr, Hf, V, Nb, Ta, Ni, Pd, or Pt with a light element such as B, C, Si, or Al. It also shows that the borides, carbides, and silicides generally have higher heats than the aluminides. (The two exceptions are very expensive due to the use of Pd and Pt, and therefore have very limited commercial potential.) Thus reactive foils with high heats of reaction generally employ reactions that form borides, carbides, or silicides.
TABLE 1 Thermodynamic Data for Formation Reactions that Can Self-propagate in Reactive Foils at Room Temperature Heat of Adiabatic Reaction Reaction Phase of Reaction (kJ/mol) Temperature (° C.) Reaction Product Ti + 2B to TiB 2 −108 2920 Liquid Zr + 2B to ZrB 2 −108 3000 Liquid H + 2B to HfB 2 −110 3370 Liquid V + 2B to VB 2 −68 2297 Solid Nb + 2B to NbB 2 −72 2282 Solid Ta + 2B to TaB 2 −63 2400 solid Ti + C to TiC −93 3067 liquid Zr + C to ZrC −104 3417 liquid Hf + C to HfC −105 3830 liquid V + C to VC −50 1957 Solid Nb + C to NbC −69 2698 Solid Ta + C to TaC −72 2831 Solid 5Ti + 3Si to Ti 5 Si 3 −72 2120 liquid 5Zr + 3Si to Zr 5 Si 3 −72 2250 liquid 5Hf + 3Si to Hf 5 Si 3 −70 2200 liquid 5V + 3Si to V 5 Si 3 −58 1519 solid 5Nb + 3Si to Nb 5 Si 3 −57 2060 solid 5Ta + 3Si to Ta 5 Si 3 −42 1547 solid Ti + Al to TiAl −36 1227 solid Zr + Al to ZrAl −45 1480 liquid Hf + Al to HfAl −46 Ni + Al to NiAl −59 1639 liquid Pd + Al to PdAl −92 2380 liquid Pt + Al to PtAl −100 2800 liquid
[0012] Unfortunately, reactive foils with B, C or Si are difficult to fabricate and use. As compared with aluminum, for example, foils with B, C or Si are more likely to delaminate or fracture during vapor deposition. When deposited at the relatively low temperatures required for making reactive multilayer foils, B, C and Si deposit in an amorphous state. Consequently the deposited layers are subject to considerable growth stresses. Thus, multilayer foils with amorphous layers of B, C and Si have a higher driving force to delaminate. In addition, multilayer foils with amorphous layers of B, C or Si are more susceptible to fracture, cracking, and delaminating than foils with Al layers.
[0013] An additional difficulty in fabricating foils with B, C, or Si is that these materials sputter deposit at very slow rates, far slower than Al. Since sputter deposition is a preferred method of fabricating reactive multilayer foils, slow sputter rates are a severe limitation on the eventual commercialization of these foils.
[0014] Reactive foils that contain B, C, or Si, also tend to be brittle and unstable. The amorphous layers of B, C or Si in these foils have a lower fracture toughness than the alternative Al layers, so the multilayer foils will be more susceptible to fracture and cracking during handling. This susceptibility makes cutting and patterning the foils difficult and raises the likelihood of unwanted ignition during handling due to fracture or cracking. In addition, since transition elements diffuse rapidly into amorphous layers, faster than into Al at a similar temperature, foils based on B, C, or Si will also have lower thresholds for ignition, which also makes them more susceptible to unwanted ignition.
[0015] Lastly, when any of the above formation reactions are completed, the final reaction product is brittle at room temperature. Thus, future handling or use of this product, whether in a joint, a propellant, or a combustion reaction, can be degraded. In the particular case of joining, the presence of a brittle boride, carbide, silicide, or aluminide at the interface between the two components is bound to lower the fracture strength, fracture resistance, and fatigue resistance of the joint. Accordingly, there is a need for new reactive multilayer foils that can be easily processed and handled and can be easily used to produce ductile, reliable bonding.
SUMMARY OF THE INVENTION
[0016] In accordance with the invention, a reactive multilayer structure comprises alternating layers of materials that exothermically react by a self-propagating reduction/oxidation reaction or by a self-propagating reduction/formation reaction. This combination of a reduction reaction and either an oxidation or formation reaction can lead to ductile reaction products and is frequently accompanied by the generation of large amounts of heat. As compared with conventional multilayer foils, the new multilayer structures are easier to fabricate, easier to handle, and produce more reliable bonds.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] The nature, advantages, and various additional features of the invention can be seen by consideration of the various illustrative embodiments now to be described in detail in connection with the accompanying drawings. In the drawings:
[0018] [0018]FIG. 1 is a schematic diagram of a reactive multilayer structure in accordance with the invention;
[0019] [0019]FIG. 2 is a schematic diagram of a reactive foil with particle composite geometry in accordance with the invention; and
[0020] [0020]FIG. 3 illustrates bonding using the ductile metal reaction product of a multilayer structure as a joining material.
[0021] It is to be understood that these drawings are for purposes of illustrating the concepts of the invention and, except for graphical illustrations, are not to scale.
DETAILED DESCRIPTION
[0022] In accordance with a preferred embodiment of the invention, a reactive multilayer structure (generically referred to herein as a “foil”) is provided as a local heat source in a variety of applications such as a process for joining materials together. As illustrated in FIG. 1, the reactive foil ( 14 ) with a layered structure is made up of alternating layers 16 and 18 . The foil contains two materials, which in their simplest form consist of an element α and an oxide or compound βΓ x , where α, β and Γ can designate any element and x can be an integer or a fraction. The foil will react by the element (α) reducing the initial oxide or compound (βΓ x ) and forming a more stable oxide or compound αΓ y and the element β. This combination of a reduction and either an oxidation or a formation reaction leads to the release of heat. Examples include reactions wherein a reactive element like Al (or Si, Ti, Zr, or Hf) reduces an oxide with a low heat of formation (e.g., Fe 2 O 3 , CuO, or ZnO) and forms a metal (Fe, Cu, or Zn) plus an oxide, Al 2 O 3 (or SiO 2 , TiO 2 , ZrO 2 , or HfO 2 ) that has a very high heat of formation. Examples also include a reactive element(s) such as Ti, (or Zr and Hf) that reduces a compound with a low heat of formation, such as NiB, and then subsequently forms a metal (Ni) plus a compound (TiB 2 , or ZrB 2 or HfB 2 which has a high heat of formation.
[0023] [0023]FIG. 2 illustrates an alternate form of a reactive multilayer structure which we will call a composite particle foil 50 wherein one of the reactive materials is in the form of particles 52 (e.g. spheres, disks or fibers). The other reactive material can be in the form of layers establishing a matrix 54 for the particles. The structure 50 can use the same materials and the same reactions as the foil 14 of FIG. 1.
[0024] The materials (α/βΓ x ) used in the reactive structures ( 14 , 50 ) are preferably chemically distinct. In one preferred embodiment, layers 16 , 18 ( 52 / 54 ) alternate between Al and an oxide with a low heat of formation (e.g., Fe 2 O 3 , CuO, or ZnO). In another embodiment, layers 16 , 18 ( 52 , 54 ) alternate between a reactive early transition element such as Ti, Zr, or Hf and a boride, silicide, or carbide compound with a low heat of formation such as (NiB, FeB, FeSi, Cu 3 Si, Ni 3 C, Fe 3 C). In yet another embodiment, layers 16 , 18 ( 52 , 54 ) alternate between Pt, Pd or alloys of these elements and an aluminide compound with a low heat of formation such as (CuAl 2 , TiAl 3 ) In another preferred embodiment, the initial compounds comprise metallic elements that are ductile such as Fe, Cu, or Ni, so that the final product consists of this ductile metal and a hard compound. Preferably, the pairs of materials α, βΓ x , are chosen so that the reactions form stable compounds with large negative heats of reaction and high adiabatic reaction temperatures. These reactions will self-propagate in a manner similar to the formation reactions described in T. P. Weihs, “Self-Propagating Reactions in Multilayer Materials,” Handbook of Thin Film Process Technology (1997), which is incorporated herein by reference in its entirety.
[0025] When a multilayer structure 14 , 50 is exposed to a stimulus (e.g., a spark or energy pulse) neighboring atoms from the two materials mix. The change in chemical bonding caused by this mixing results in a reduction in atomic bond energy, thus generating heat in an exothermic chemical reaction. This chemical bonding occurs as layers with α-αbonds (i.e., layer 16 , 52 ) and layers with β-Γ bonds (i.e., layer 18 , 54 ) are exchanged for α-Γ and β-β bonds, thereby reducing the chemical energy stored in the foil, and generating heat. As FIGS. 1 and 2 further illustrate, the heat that is generated diffuses through foil 14 , 50 (in a direction from reacted section 30 through reaction zone 32 to unreacted section 34 ) and initiates additional mixing of the reactants. As a result, a self-sustaining/self propagating reaction is produced through the structure 14 , 50 . With sufficiently large and rapid heat generation, the reaction propagates across the entire structure 14 , 50 at velocities that can exceed 10 m/s. As the reaction does not require additional atoms from the surrounding environment (as would, for example, oxygen in the case of combustion), the reaction makes foils 14 or 50 self-contained sources of energy capable of emitting bursts of heat and light, rapidly reaching temperatures above 1400 K and a local heating rate reaching as high as 10 9 K/s. This energy is particularly useful in applications such as propulsion, joining, and ignition requiring production of heat rapidly and locally.
[0026] When a reaction propagates across a multilayer structure 14 , 50 as illustrated in FIGS. 1 and 2, the maximum temperature of the reaction is typically located at the trailing edge of the reaction zone 32 . This may be considered the final temperature of reaction, which can be determined using the heat of reaction (ΔH rx ), the heat lost to the environment (ΔH env ), the average heat capacity of the sample (C p ), and the mass of the product (M). Another factor is whether or the not reaction temperature exceeds the melting point of the final product. If the melting point is exceeded, then some heat is absorbed in the state transformation from solid to liquid of at least part of the product. With reduction/oxidation and reduction/formation reactions very often the metallic component in the product can melt due to the high reaction temperatures, while the stable compound may not. The final temperature of reaction may be determined using the following formulas (where T o is the initial temperature, ΔH mm is the enthalpy of melting of the final metallic phase, T m is the melting temperature of the final metallic phase in the product, ΔH mc is the enthalpy of melting of the final compound phase, and T mc is the melting temperature of the final compound phase in the product),
T f =T o −(Δ H rx +ΔH env )/( C p M )
[0027] If no melting of final product occurs;
T f =T mm
[0028] If the metallic phase in the product melts only partially;
T f =T o (Δ H rx +ΔH env +ΔH mm )/( C p M)
[0029] If the metallic phase in the product completely melts.
[0030] T f =T mc
[0031] If the compound phase in the product melts only partially; and
T f =T o (Δ H rx +ΔH env +ΔH mm +ΔH mc )/( C p M )
[0032] If the metallic and compound phases in the product melt completely.
[0033] Intricately related to the heat of the foil reaction is the velocity of the propagation of the reaction along the length of foil 14 , 50 . The speed at which the reaction propagates depends, in particular, on how rapidly the atoms diffuse normal to their layering or particles (FIG. 1 or 2 ) and how rapidly heat is conducted along the length of foil 14 , 50 . However, now at least three elements are involved in the reaction α, β, and Γ compared to simple formation reactions that can involve only two elements. But, only one of the elements must diffuse to complete the reduction/oxidation or reduction/formation reactions. In most cases the diffusion of O, Si, B, or C between the layers (or particles and matrix) will control the rate of the reaction. The propagation velocity is a strong function of the foil's multilayer thickness or average particle thickness. As the thickness of individual layers 16 , 18 (or particles 54 ) decreases, the diffusion distances are smaller and atoms can mix more rapidly. Heat is released at a higher rate, and, therefore, the reaction travels faster through the foil structure. Reactive foils typically have diffusion distances that range from 1-1000 nm while reactive powder compacts typically have diffusion distances that range from 10-100 μm. Hence, reaction rates and reaction velocities are many times faster in foils than in powder compacts.
[0034] In accordance with a preferred embodiment of the invention, reactive multilayer foils 14 , 50 may be fabricated by physical vapor deposition (PVD), chemical vapor deposition, electrochemical methods, electroless methods, mechanical methods, or some combination of these methods. A magnetron sputtering technique, for example, may be used to deposit the materials α/βΓ x on a substrate (shown in FIG. 1 in dashed outline form as layer 35 ) as alternating layers 16 , 18 . Substrate 35 may be rotated over two isolated sputter guns in a manner well known in the art to effectuate the layering of materials α/βΓ x into alternating layers 16 , 18 .
[0035] The vapor streams from the two sputter guns or the two electron beam hearths are isolated from one another during deposition of a reactive multilayer foils 14 . This isolation reduces intermixing and unwanted reaction of the elements being deposited. It is important to isolate the two vapor streams from one another to prevent loss of the energy of the reaction during deposition.
[0036] Substrate 35 is shown in dashed outline form to indicate that it is a removable layer that facilitates fabrication of the reactive foil 14 as a freestanding foil. Substrate 35 may be any substrate (e.g., Si, glass, or other underlayer) having the characteristics of providing sufficient adhesion so as to keep the foil layers on the substrate during deposition, but not too adhesive to prevent the foil from being removed from the substrate following deposition.
[0037] In accordance with a preferred embodiment, an additional wetting layer (e.g., tin) may be used as an interface layer between the first layer of foil ( 16 or 18 ) and the substrate 35 to provide the necessary adhesive. When no wetting layer is employed, selection of the appropriate material αor βΓ x as the first layer deposited on the substrate will ensure that the necessary adhesive requirements are met. When a reactive foil using Al/Cu 2 O as materials α/βΓ x , is to be fabricated, for example, without a wetting layer, the exemplary reactive foil would be deposited on a substrate such as Si with the first layer being Al deposited on the substrate. Al is preferably selected as the first layer in such case because Al will sufficiently adhere to Si during depositing, but will allow peeling off of the substrate after the foil is formed.
[0038] A fabricated foil 14 may have hundreds to thousands of alternating layers 16 and 18 stacked on one another. Individual layers 16 and 18 preferably have a thickness ranging from 1-1000 nm. In a preferred embodiment, the total thickness of foil 14 may range from 10 μm to 1 m.
[0039] Another preferred method of fabricating is to deposit material in a codeposition geometry. Using this method, both material sources are directed onto one substrate and the atomic fluxes from each material source are shuttered to deposit the alternate layers 16 and 18 . Again, care must be taken to isolate the two physically distinct atomic fluxes from each other.
[0040] In accordance with a preferred embodiment, the degree of atomic intermixing of materials α/βΓ x that may occur during deposition should be minimized. This may be accomplished by depositing the multilayers onto cooled substrates, particularly when multilayers 16 and 18 are sputter deposited. To the extent that some degree of intermixing is unavoidable, a relatively thin (as compared to the alternating unreacted layers) region of pre-reacted material 20 will be formed. Such a pre-reacted region 20 , nevertheless, is helpful in that it serves to prevent further and spontaneous reaction in foil 14 .
[0041] As illustrated in FIGS. 1 and 2, the reactive foil 14 or 50 can have a layered or particle composite geometry. While a layered geometry will typically result from vapor deposition of a reactive foil, another preferred embodiment of this invention is the mechanical formation of α/βΓ x reactive foils. In this method, sheets of α and βΓ x are stacked, inserted in a removable protective jacket, and then deformed into a multilayer sheet, as by swaging and rolling. The jacket is then removed. This mechanical processing can result in either a layered or particle composite geometry and generally is less expensive than vapor deposition. For further detail concerning mechanical processing, see U.S. application Ser. No. ______, filed by M. Reiss et al. concurrently herewith and entitled “Method of Making Reactive Multilayer Foil and Resulting Product” which is incorporated here by reference.
[0042] Reactive foils in accordance with the invention may be adapted for use in a variety of applications. In one preferred application, the foils may be used to ignite another reaction that releases a signal, more heat, or a gas, as in a combustion or propulsion application. In this case, a freestanding foil can be inserted into a metastable material to be ignited, with all sides of the foil being covered by the metastable material.
[0043] [0043]FIG. 3 illustrates another preferred application of the invention wherein the reactive structures react to form a ductile composite product 40 that contains particles 42 or layers of a hard oxide or compound in a matrix 41 of a ductile metal. The ductile metal 41 can be a simple element such as Cu, Ni, or Fe or it could be a ductile alloy of two or more elements. In a preferred embodiment, these reactive structures can be used in the joining of two bodies or components ( 43 , 44 ). In these applications, the reactive multilayer is positioned between the two bodies ( 43 , 44 ) to be joined, the bodies are pressed against the reactive multilayer, and the latter is ignited. The ductile metallic product 41 resulting from the self-propagating reaction can serve as a solder or braze that flows and wets the surfaces of the bodies, and consequently forms a strong joint. Thus, reactive multilayers described in the present invention essentially enable a braze-free room-temperature joining process. This process provides significant advantages over known reactive joining methods which require braze of solder material to be deposited on, or positioned next to the free-standing foil and/or on the surfaces of the components.
[0044] In another embodiment of the invention, the foils are fabricated using inexpensive materials such as Al and CuO, Fe 2 O 3 or ZnO. These materials are less expensive than many of the elements used to fabricate reactive foils with very exothermic formation reactions (as opposed to reduction/oxidation or reduction/formation reactions) such as Ti, Zr, Hf, or Nb.
[0045] Preferred embodiments of the invention are useable as freestanding reactive foils 14 with increased total thickness. The total thickness of such a reactive foil depends upon the thickness and number of the elemental layers (e.g., 16 and 18 ) utilized to form the foils. Foils that are less than 10 μm are very hard to handle as they tend to curl up on themselves. Foils on the order of 100 μm are stiff, and thus, easily handled. Thicker foils also minimize quenching. In joining applications, for example, using reactive foils, there is a critical balance between the rate at which the foil generates heat and the rate at which that heat is conducted into the surrounding braze layers and the joint to be formed. If heat is conducted away faster than it is generated, the reaction will be quenched and the joint cannot be formed. The thicker foils make it harder to quench the reaction because there is a larger volume generating heat and the same surface area through which heat is lost.
[0046] Thicker foils can be utilized with reaction temperatures that are lower, generally leading to more stable foils. Foils with high formation reaction temperatures (as opposed to reduction/oxidation or reduction/formation temperature) are generally unstable and brittle and therefore are dangerous and difficult to use. Brittle foils, for example, will crack easily leading to local hot spots (through the release of elastic strain energy and friction) that ignite the foil. Cutting such brittle foils (e.g., for specific joint sizes) is very difficult to do as they are more likely to crack into unusable pieces or ignite during the cutting process.
[0047] In accordance with a preferred embodiment, the thicker reactive foils are on the order of 10 μm to 1 cm. Although a number of different systems may be employed to create the thick freestanding reactive foils, a unique process in selecting the fabrication conditions is advantageous. In accordance with a preferred embodiment, for example, deposition conditions such as sputter gas and substrate temperature are advantageously chosen so that stresses remain sufficiently low in the films of the foil as they are grown in the system. Since the stress in the film times its thickness determines with the driving force for delamination, the product of stress and thickness should be kept below 1000 N/m. Stresses often arise in the films during the fabrication process. As the films grow thicker, they are more likely to peel off their substrates or crack their substrates than thinner films, thereby ruining the final foil production. By characterizing the stresses on the films and selecting conditions to minimize the stresses, the fabrication process can be completed without the peeling off (or cracking) of the substrate.
[0048] Utilizing one or more embodiments of the invention, a number of different applications can now be performed more effectively and efficiently. For example, freestanding reactive foils can be incorporated directly into solid propellants, enabling the uniform and complete combustion of components within the foil with extremely large releases of heat. Alternatively, a number of materials can now be joined more efficiently. Semiconductor devices may be bonded to circuit boards or other structures, using reduction/oxidation reactions where the final metallic product serves as a braze or solder material to join the components.
EXAMPLES
[0049] The invention may now be more clearly understood by consideration of the following examples:
Example 1
[0050] Al/CuO/Cu Composites
[0051] Electrodeposition of Cu from standard cupric sulphate solution is alternated, with electrodeposition of CuO (or Cu 2 O) from a 3 M copper lactate, 0.4 M cupric sulphate solution (pH>10 by addition of NaOH). The alternating layers can be fabricated either by moving the substrate from one bath to another or by draining and refilling the same bath with different solution. Rotation of the substrate during deposition and the suspension of a large volume percent of aluminum particles in the either or both solutions enables the aluminum particles to be incorporated in the electrodeposited matrix.
[0052] Instead of an electrodeposited multilayer structure, the pH of the copper lactate solution can be modified such that Cu and CuO are deposited simultaneously. The oxygen content can be controlled by optimizing the pH, current density, and electrolyte concentrations.
[0053] The aluminum particles can be 100 micron diameter down to 100 nm diameter. Cold rolling of the electrodeposited foils will create pancake structures with much smaller average diffusion lengths. Swaging will create oblong particles which can then be roll flattened for even further reduction in diffusion distances.
[0054] It is to be understood that the above-described embodiments are illustrative of only some of the many possible specific embodiments, which can represent applications of the principles of the invention. Numerous and varied other arrangements can be made by those skilled in the art without departing from the spirit and scope of the invention.
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In accordance with the invention, a reactive multilayer structure comprises alternating layers of materials that exothermically react by a self-propagating reduction/oxidation reaction or by a self-propagating reduction/formation reaction. This combination of a reduction reaction and either an oxidation or formation reaction can lead to ductile reaction products and is frequently accompanied by the generation of large amounts of heat. As compared with conventional multilayer foils, the new multilayer structures are easier to fabricate, easier to handle, and produce more reliable bonds.
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This application claims the benefit of priority to U.S. Provisional Application Ser. No. 61/935,474 filed Feb. 4, 2014, the entire disclosure of which is incorporated herein by reference.
FIELD OF INVENTION
This invention relates to posts for mailboxes and fences, and in particular to devices, apparatus, kits, systems and methods for protecting sides of new or existing posts with easily attachable panels made from a durable material, and for providing marking surfaces, such as addresses for the posts, as well as a surface for applying desirable colors and indicia designs thereon.
BACKGROUND AND PRIOR ART
Many mailboxes are mounted on wooden type posts, such as a rectangular or circular cross-sectional post. Cutting grass and weeds about the base of these posts are often done with automated cutting tools such as line trimmers, often referred to as WEED WACKERS™. These trimmers are able to trim edges of lawns by a motor driven flexible wire or plastic or nylon type cord. Often the trimmer lines constantly striking the posts cause unsightly indentations such as grooves and cuts into the surface areas of the posts. The indentations can often attract dirt and debris that can also become discolored and tend to shorten the lifespan of the posts.
Another problem with wooden posts is that it can be difficult to place indicia such as street addresses, etc., since tape type lettering and numbering often does not stick to the wooden surfaces. Nailing numbers and address indicia would not be desirable since the nails and fasteners can split the wood and further reduce the post lifespan over time.
Other types of posts such as wooden fence posts can also have similar problems where rotating trimmer lines also cause unsightly indentations, that also can become discolored, and can shorten the lifespan of the posts over time.
Thus, the need exists for solutions to the above problems with the prior art.
SUMMARY OF THE INVENTION
A primary objective of the present invention is to provide devices, apparatus, kits, systems and methods for protecting sides of posts such as wooden mailbox posts and wooden fence posts with easily attachable plastic panels.
A secondary objective of the present invention is to provide devices, apparatus, kits, systems and methods for marking surfaces on wooden mailbox posts and/or wooden fence posts for addresses and for desirable colors and indicia designs thereon.
A third objective of the present invention is to provide devices, apparatus, kits, systems and methods for protecting sides of wooden posts from nicks, cuts and scrapes from lawn maintenance equipment and further improves the appearance the property.
A fourth objective of the present invention is to provide devices, apparatus, kits, systems and methods for protecting sides of plastic posts protect the plastic post from scuffs and damage using replaceable panels without having to replace the expensive plastic posts.
A fifth objective of the present invention is to provide devices, apparatus, kits, systems and methods for protecting sides of posts that are made of a durable material to protect and decorate the mailbox, deck, pergola, fence, garden, and utility and recreation posts.
A sixth objective of the present invention is to provide devices, apparatus, kits, systems and methods for protecting sides of posts with panels having a moisture protection barrier to protect the post from mold and mildew.
A seventh objective of the present invention is to provide devices, apparatus, kits, systems and methods for protecting sides of posts with panels have hinged corners to allow movement to better-fit cracked, warped or misshapen posts.
An eighth objective of the present invention is to provide devices, apparatus, kits, systems and methods for protecting sides of posts with panels having corners that are rounded and enhanced to reduce ware and damage to the lawn maintenance equipment.
A ninth objective of the present invention is to provide devices, apparatus, kits, systems and methods for protecting sides of posts with panels having sides made smooth with a non-abrasive surface to reduce ware and damage to the lawn maintenance equipment.
A tenth objective of the present invention is to provide devices, apparatus, kits, systems and methods for protecting sides of posts with panels that are interchangeable, so that panels with different sizes, colors, designs, indicia, and the like, are attachable to one another.
A eleventh objective of the present invention is to provide devices, apparatus, kits, systems and methods for protecting sides of posts with panels that come in different widths and heights to protect and cover the entire post, so that panels with different colors, designs, indicia, and the like, are attachable to one another.
An embodiment of the post protector, can include a plurality of planar plastic rectangular or circular panels, each panel having a top edge, a bottom edge, a left side edge and a right side edge, with the top edge being parallel to the bottom edge, and the left edge being parallel to the right edge, where each of the panels having a hook portion on one of the left side edge and the bottom side edge, and where each of the panels having a protruding portion along an opposite side edge to the side edge having a hook portion, wherein the plurality of panels are interconnected with one another by fitting the protruding portion of each panel into the hook portion of an adjacent panel adaptable to form a barrier about a post to be protected.
Each panel can be formed from plastic with the hook portion and protruding portion molded into the plastic.
The plurality of rectangular or circular or curved panels can include one or multiple panels adapted to form a rectangular or circular or circular base about the post.
The underlying post can be a mailbox post. The underlying post can be a fence post.
Each of the panels can include different colors. The panels can include designs or indicia screen printed on the panels. Alternatively, the panels can include addresses, such as streets and building numbers. The indicia and/or designs can be engraved on the panels, and/or painted and/or screen printed and/or formed in other ways typical in the art.
A method of protecting posts, can include the steps of providing a plurality of planar plastic rectangular or circular panels, each panel having a top edge, a bottom edge, a left side edge and a right side edge, with the top edge being parallel to the bottom edge, and the left edge being parallel to the right edge, providing a hook portion along one of the left side edge or the right side edge of each panel, providing a protruding portion along another side edge of the panel opposite to the side edge having the having a hook portion, and attaching the plurality of panels about a post by sliding the protruding portions of one panel into the hook portions on an adjacent edge until a full perimeter circumference about the post is protected.
Each of the plastic panels can include the hook portion and the protruding portion molded on the panels. The plurality of panels can include three panels, or four panels or more panels
Further objects and advantages of this invention will be apparent from the following detailed description of the presently preferred embodiments which are illustrated schematically in the accompanying drawings.
BRIEF DESCRIPTION OF THE FIGURES
FIG. 1A is an exploded view of the attachable post panels for the invention with hook portions and protrusion portions that slidably attach with one another.
FIG. 1B is another view of the attachable panels being able to snap to one another.
FIG. 1C shows another view of the panels of FIG. 1B with hook portion of last panel snapably attaching to protrusion portion of adjacent panel.
FIG. 1D shows multiple panels of the preceding figures assembled and attached together.
FIG. 2A shows the panels of FIG. 1 ready to assemble to a lower end of a mailbox post.
FIG. 2B the panels of FIG. 2A almost assembled about a lower end of a mailbox post.
FIG. 2C shows extended length panels of FIG. 2A almost assembled about a lower end of a mailbox post.
FIG. 3 is a top view of one of the panels of the preceding figures.
FIG. 4 is a front view of the panel of FIG. 3 .
FIG. 5 is a top view of another embodiment of another panel for the invention.
FIG. 6 is a front view of the panel of FIG. 5 .
FIG. 7 is a top cross-sectional view along arrows 7 Y of FIG. 2B showing the assembled panels attached about a post.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Before explaining the disclosed embodiments of the present invention in detail it is to be understood that the invention is not limited in its applications 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.
In the Summary above and in the Detailed Description of Preferred Embodiments and in the accompanying drawings, reference is made to particular features (including method steps) of the invention. It is to be understood that the disclosure of the invention in this specification includes all possible combinations of such particular features. For example, where a particular feature is disclosed in the context of a particular aspect or embodiment of the invention, that feature can also be used, to the extent possible, in combination with and/or in the context of other particular aspects and embodiments of the invention, and in the invention generally.
In this section, some embodiments of the invention will be described more fully with reference to the accompanying drawings, in which preferred embodiments of the invention are shown. This invention may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will be thorough and complete, and will convey the scope of the invention to those skilled in the art. Like numbers refer to like elements throughout, and prime notation is used to indicate similar elements in alternative embodiments.
A list of components referenced in the figures will now be described.
1 post protector 10 first panel 14 ribs and/or moisture strips 12 rounded hook end with open slit 16 bent protruding portion end with enlarged head 20 second panel 22 rounded hook end with open slit 26 bent protruding portion end with enlarged head 30 third panel 32 rounded hook end with open slit 36 bent protruding portion end with enlarged head 40 fourth panel 42 rounded hook end with open slit 46 bent protruding portion end with enlarged head 100 post for mailbox 200 elongated panel post protector 210 first panel 220 second panel 230 third panel 240 fourth panel 310 another embodiment panel with different shaped protruding end 312 rounded hook end with open slit 314 ribs and/or moisture strips 316 sideways bent protruding portion
The invention embodiments can be used and sized in height and width to fit about various types of rectangular or circular cross-section posts, such as but not limited to posts being 4″×4″, 4″×6″, “6×6”, and the like, as well as other sizes and the like.
Each of the posts sizes can have respective sized panels, such as having a width of approximately 4″ and a height of approximately 4 & ½ ″.
FIG. 1A is an exploded view of the attachable post panels 10 , 20 , 30 , 40 for the invention each with rounded hook ends 12 , 22 , 32 , 42 each having open slit sides and opposite ends 16 , 26 , 36 , 46 having sideways bent protruding portions that can slidably attach and detach with one another.
Referring to FIG. 1A , a sideway bent protruding portion with an enlarged head of one panel can slide into the respective rounded hook end with open slit of an adjacent panel, and vice versa. For example, panels 20 and 40 can be arranged in upright vertical positions substantially parallel to one another and spaced apart the approximate width of one of the panels 10 - 40 . Next, the sideway bent protruding portion 16 and rounded hook end 12 with open slit of panel 10 can be in a raised position and slid downward in the direction of arrows S into respective rounded hook end 22 with open slit of panel 20 and about the sideway bent protruding portion 46 of panel 40 . Next the rounded hook end 32 with open slit, and sideway bent protruding portion 36 of panel 30 can be in a raised position and then slid downward in the direction of arrow S about respective sideway bent protruding portion 26 of panel 20 , as well as into rounded hook end 42 with open slit of panel 40 .
FIG. 1B is another view of the attachable panels 10 , 20 , 30 , 40 , each being able to snap onto ends of an adjacent panel. FIG. 1C shows another view of the panels of FIG. 1 B with hook portion 42 of last panel 40 snapably attaching to sideways bent protruding portion 36 of adjacent panel 30 . FIG. 1D shows multiple panels of the preceding FIG. 1A or 1B and 1C , assembled and attached together.
Referring to FIGS. 1B-1D , panels 10 , 20 , 30 , and 40 can also be snapped together. For example, sideway bent protruding portion 46 of panel 40 can be inserted into the interior facing slit of round hook end 12 of adjacent panel 10 , and is able to snap into place.
FIG. 3 shows a top view of panel 10 having sideway bent protruding portion 16 with a generally rounded head, and an opposite end having a rounded hook end 12 with open slit. Each of the panels 10 - 40 can have a generally rectangular or circular main body configuration with a hook end 12 , 22 , 32 , 42 along one side edge, and a sideway bent protruding portions 26 , 26 , 36 , 46 along an opposite side edge, with adjacent panels being assembled together by sliding the side edge with the sideway bent protruding portion into the rounded hook end with slit in the side edge of the adjacent panel.
Referring to FIGS. 1B, 1C, 1D and 3-4 , the sideway bent protruding portion 46 of panel 40 can be pushed in the direction of arrow P by the installer to slightly spread apart the slit of the rounded hook end 12 of adjacent panel 10 , so that the protruding portion 46 with an enlarged head is inserted through the slit into the interior opening in the hook 12 , which can then snap about the generally rounded head of sideway bent protruding portion 46 of panel 40 . Each of the adjacent panels 10 , 20 , 30 and 40 can be similarly attached to one another in a similar push and snap assembly.
FIG. 2A shows the panels 10 , 20 and 30 of FIG. 1 ready to assemble to a lower end of a mailbox post 100 . FIG. 2B the panels 10 , 20 , 30 and 40 of FIG. 2A almost assembled about a lower end of a mailbox post 100 .
Referring to FIGS. 1A, 1B, 2A, 2B, 3-4 , three of the panels 10 , 20 , 30 can be attached to one another by having ends slid into adjacent hook ends or vice versa, or the sideway bent protruding portions snapped into slits of rounded hook ends of adjacent panels, as described above. Once three panels 10 , 20 , 30 are assembled together, they can be moved in the direction of arrow M about a lower portion of post 100 . Next, the last panel 40 can be slid downward or snapped in place with adjacent panels 10 , 30 .
FIG. 2C shows another embodiment 200 of extended length panels 210 , 220 , 230 , 240 , almost assembled about the entire mailbox post 100 . Here, larger height panels 210 , 220 , 230 and 240 can be slid into place or snapped into place in a manner similar to the embodiments described above. This larger size version of panels 210 , 220 , 230 and 250 can be used for protecting and covering the post from lawn maintenance equipment, weathering and discoloration.
FIG. 3 is a top view of one of the panels 10 of the preceding figures. FIG. 4 is a front view of the panel 10 of FIG. 3 which also shows optional vertical ribs 14 , which can be used for causing better gripping action between the inside of each panel and the side surfaces of the post 100 . While the ribs 14 are shown vertical, the ribs 14 can be arranged in horizontal parallel rows, or other configurations such as crossed, and different combinations, and the like. The ribs 14 can be raised molded on portions of the plastic panels
Alternatively, components 14 can be moisture barrier strips which can protect the sides of the posts 100 from mold and mildew.
FIG. 5 is a top view of another embodiment of another panel 310 for the invention. FIG. 6 is a front view of the panel 310 of FIG. 5 . Referring to FIGS. 5-6 , panel 310 can include a rounded hook end 312 with open slit on one end, and an opposite end having a sideways bent protruding portion 316 , which can have a different shaped head than the previous embodiment panels. Here, portion 316 can have a blunt tipped head that does not have a larger diameter than the thickness of the enlarged heads of sideway bent protrusions of the previously described panels. Component 314 can parallel molded on ribs and/or moisture strips similar to those previously described.
FIG. 7 is a top cross-sectional view along arrows 7 Y of FIG. 2B showing the assembled panels 10 - 40 attached about a post 100 . As shown, the inside walls of panels 10 , 20 , 30 , 40 can rest close to touch against the sides of posts 100 .
While the panels 10 , 20 , 30 , 40 , 210 , 220 , 230 , 240 , 310 are shown as generally planar panels, the invention can be used with the panels having slightly concave bent mid portions which allow at least the interior bending portions to be able to touch and/or grip against side exterior surfaces of the underlying posts.
The novel post protectors described above can be used to protect and cover posts from nicks, cuts and scrapes from lawn maintenance equipment and improves the appearance of the property.
The novel post protectors can be made of a durable material, such as but not limited to plastic, and the like, to protect and decorate the mailbox, deck, pergola, fence, garden, and utility and recreation posts. The panels can be formed from molded plastic, extruded plastic, and the like.
Although the preferred embodiment has the posts being wooden, the novel post protectors can also be used on the plastic post. The shields will protect the plastic post from scuffs and damage and can be replaced without having to replace the more expensive plastic post.
The novel panels have hook portions that also form hinged corners to allow movement to better-fit cracked, warped or misshapen posts.
The corners on each of the panels, can be rounded and enhanced to reduce ware and damage to the lawn maintenance equipment.
The sides of the panels can be made smooth with a non-abrasive surface to reduce ware and damage to the lawn maintenance equipment.
The novel panels are interchangeable with panels having different colors, different designs, and the like.
Although the embodiments show multiple panels being assembled to one another by sliding protruding portions along one side of a panel into hook portions along an adjacent panel, the post protectors can use as little as three panels attached to one another. Additionally, the panels can be assembled to have five or more panels interconnected with one another.
The panels can each be of the same size. Alternatively different sized panels can be attached to one another to fit about different diameter posts. Although only the bases of the posts are shown protected, the panels can be arranged to run up part of or substantially up most of the sides of the posts as needed.
The panels can be formed from different indicia, such as different colors, and the like. For example, a college team colors can be combined on one panel or the panels can have different colors thereon. Additionally, other types of designs, indicia, and the like, can be painted on the panels, Also, the colors, designs, indicia and the like, can be screen printed on the panels. Additionally, other information, such as but not limited to street addresses, and the like, can be painted on the panel surfaces, or screen printed thereon, or applied by other techniques, such as but not limited to applying tape with the numbers and address information to the surfaces of the panels.
Although the hook edges are shown being longitudinal generally across the entire side edge, the hook edges can be spaced apart from one another.
While the posts being protected are generally shown having rectangular or circular cross-sections, other types of posts having cylindrical cross-sections, and other shapes can be protected.
While the panels are shown having generally flat planar surfaces, the panels can have non planar surfaces, such as but not limited to rounded surfaces for fitting about other shaped posts, such as cylindrical posts, and other non-rectangular or circular cross-section posts, and the like.
Although the panels are shown as rectangular or circular, other geometrical shapes can be used, such as but not limited to hexagon, triangular, and the like, and other shapes.
While the invention has been described, disclosed, illustrated and shown in various terms of certain embodiments or modifications which it has presumed in practice, the scope of the invention is not intended to be, nor should it be deemed to be, limited thereby and such other modifications or embodiments as may be suggested by the teachings herein are particularly reserved especially as they fall within the breadth and scope of the claims here appended.
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Devices, apparatus, kits, systems and methods for protecting sides of wood or plastic posts from damage from lawn equipment with easily attachable plastic panels, and for providing marking surfaces, such as addresses for the posts, as well as a surface for applying desirable colors and indicia designs thereon. The panels can have hook end along one side edge, and a raised protrusion edge along an opposite side edge, that slide or snap with one another. One or multiple panels can be attached about a base of a post such as a rectangular or circular cross-section mailbox post or fence post, and the like.
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CROSS REFERENCE TO RELATED APPLICATIONS
This application is a continuation-in-part and claims the benefit of U.S. application Ser. No. 13/008,970, filed on Jan. 19, 2011 now abandoned, entitled, “Nestable Hangar With Articulating Integrated Hook”, which is a continuation-in-part and claims the benefit of U.S. application Ser. No. 12/182,351, filed on Jul. 30, 2008 now U.S. Pat. No. 7,938,300, entitled Nestable Hangar With Integrated Cascade Hook, both of which are incorporated in their entirety herein by reference.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention generally relates to the field of clothing hangers and in particular to the field of nestable hangers having hanger supporting means for supporting additional hangers therefrom. Specifically, the present invention pertains to a clothing hanger that includes an articulating hook for attaching an additional hanger thereto. By having such functionality, a clothing hanger can both add additional hangers and be stored in a nested fashion thereby using a minimal amount of storage.
2. Description of the Related Art
Hangers having nestable configurations are disclosed in the prior art, as are hangers having hanger supporting means for supporting additional hangers therefrom.
One example of a hanger having hanger supporting means for supporting additional hangers therefrom may be found, for instance, in U.S. Pat. No. 4,653,678 to Blanchard et al., which discloses a “ganging hook” via which additional hangers may be supported. The “ganging hook” disclosed in Blanchard et al. extends downwardly from the hanger body. The “ganging hook” of Blanchard et al. does not provide any nesting functionality to the hanger.
Another example of a hanger having supporting means for supporting additional hangers therefrom is U.S. Pat. No. 4,871,098 to Bredeweg et al. The hanger disclosed in Bredeweg et al. discloses a “hook socket for ganging hangers”. As with Blanchard et al., the “hook socket” of the hanger disclosed in Bredeweg et al. extends downwardly from hanger body and does not provide any nesting functionality.
U.S. Pat. No. 5,074,445 to Chen discloses a garment hanger with a “ganging hook” extending from the hanger body. The position of the “ganging hook” of Chen impedes nesting of hangers.
Similarly, U.S. Pat. No. 5,803,321 to Willinger et al. discloses a hanger having “ganging element” extending downwardly from the hanger body. As with the previously cited prior art, the “ganging element” of the hanger disclosed in Willinger et al. does not promote nesting of hangers. Like hangers may also be found in U.S. Pat. No. 6,070,772 to Bond; U.S. Pat. No. 6,105,834 to Cohen; U.S. Pat. No. 6,308,872 to Duerr et al.; and U.S. Pat. No. 6,467,658 to Oik et al.
None of the foregoing prior art discloses hangers with hanger supporting means for supporting additional hangers therefrom configured in such a manner so as to allow for nesting of hangers. It is therefore desirable to have a hanger which not only includes hanger supporting means for supporting additional hangers therefrom, but further readily provides for nesting of hangers. There is therefore a great need in the art for a hanger providing such characteristics.
Accordingly, there is now provided with this invention an improved clothing hanger that effectively overcomes the aforementioned difficulties and longstanding problems discussed above. These problems have been solved in a simple, convenient, and highly effective way by which to form a clothing hanger.
SUMMARY OF THE INVENTION
According to one aspect of the invention, a new and useful hanger having a hanger supporting means in the form of a cascade hook for supporting additional hangers therefrom, wherein the cascade hook facilitates the nesting of one hanger with another similar hanger is disclosed.
One embodiment of the present invention includes a garment hanger comprising a hanger frame comprising a hanger body, the hanger body having a front surface and a rear surface, a top and a bottom; a hook member extending from the top of the hanger body, the body having a hole formed therethrough, the hole having a front aperture formed in the front surface and a rear aperture formed in the rear surface; the body having a cascade hook member extending from the front surface and disposed in front of the front aperture. In these embodiments, the hole is adapted to receive through the rear aperture a cascade hook member from a first identical garment hanger and the cascade hook member is adapted to be inserted into a rear aperture of a hole in a second identical garment hanger.
In certain embodiments, the cascade hook member has an inclined portion having a first end disposed at the bottom of the hole and a second end disposed opposite from the first end, and a second portion extending upwardly from the second end of the inclined portion embodiments, the cascade hook member has an inclined portion having a first end disposed at the bottom of the hole and a second end disposed opposite from the first end, and a second portion extending upwardly from the second end of the inclined portion.
In any of the foregoing embodiments, the cascade hook member may comprise a rear surface substantially facing the front surface of the body; a front surface substantially facing away from the front surface of the body. A projection of the cascade hook member onto a plane containing the front surface of the body may be shaped substantially the same as the front aperture, and the projection may have an area less than the area of the front aperture. The rear aperture may have an area greater than the area of the front aperture. There may also be a concavity formed in the rear surface of the cascade hook member.
Furthermore, in any of the foregoing embodiments, the cascade hook member may be adapted to be inserted through the hole of the second identical garment hanger and extend out of a front aperture of the hole of the second identical garment hanger. Upon being inserted through the hole of the second identical garment hanger, the front surface of the cascade hook member may abut a portion of a rear surface of a cascade hanger member of the second identical garment hanger.
A channel may be formed between a portion of the front surface of the cascade hook member and a portion of the rear surface of the cascade hook member of the second identical hanger. Similarly, a cavity may be formed between a portion of the front surface of the cascade hook member and a concavity formed in the rear surface of the cascade hook member of the second identical hanger. Where both a cavity and a channel are formed, the width of the channel may be smaller than the width of the cavity.
In a further embodiment of the invention, a garment hanger is disclosed comprising a hanger body having a front surface, a rear surface, and a hole therethrough, and a hook attached within the hole to the hanger body, wherein the hook is adapted to articulate between a first position extending beyond the front surface and a second position extending beyond the rear surface.
In another embodiment of the invention, a pair of substantially identical nested first and second garment hangers are disclosed wherein each of the first and second garment hangers comprise a hanger body having a front surface, a rear surface, a hole therethrough, and a hook attached within the hole to the hanger body. The hook is adapted to articulate between a first position extending beyond the front surface and a second position extending beyond the rear surface. When the hook of the first hanger is in the first position, the hook extends into the hole of the second hanger and the front surface of the first hanger abuts a rear surface of the second hanger so that the first and second hangers are nested in a common horizontal plane relative to one another.
In yet another embodiment of the invention, a pair of substantially identical nested first and second garment hangers are disclosed wherein each of the first and second garment hangers comprise a hanger body having a front surface, a rear surface, a hole therein, and a hook attached within the hole to the hanger body. The hook is adapted to articulate between a first position extending beyond the front surface and a second position housed within the body. When the hook of the first hanger is in the second position, the front surface of the first hanger abuts a rear surface of the second hanger so that the first and the second hangers are nested in a common horizontal plane relative to one another.
These and other aspects of the subject invention will become more readily apparent to those having ordinary skill in the art from the following detailed description of the invention taken in conjunction with the drawings described herein. Additional objects of the present invention will become apparent from the following description.
The method and apparatus of the present invention will be better understood by reference to the following detailed discussion of specific embodiments and the attached figures which illustrate and exemplify such embodiments.
DESCRIPTION OF THE DRAWINGS
A specific embodiment of the present invention will be described with reference to the following drawings, wherein:
FIG. 1 is a front plan view of a preferred embodiment of the present invention.
FIG. 2 is a cross-sectional detail of the preferred embodiment depicted in FIG. 1 .
FIG. 3 is a front plan view of two hangers of a preferred embodiment of the present invention shown in a nested configuration.
FIG. 4 is a cross-sectional detail of the hangers depicted in FIG. 3 .
FIG. 5 is an orthogonal view of two hangers of a preferred embodiment of the present invention shown in a nested configuration.
FIG. 6 is an orthogonal view of two hangers of a preferred embodiment of the present invention shown in a cascaded configuration.
FIG. 7 is a substantially rear orthogonal view of a preferred embodiment of the present invention.
FIG. 8 is an orthogonal view of another embodiment of a hanger of the present invention.
FIG. 9 is an enlarged view of a hole in a body of an embodiment of a hanger of the present invention.
FIG. 10 is an orthogonal view of a hook of an embodiment of a hanger of the present invention.
FIG. 11 is an orthogonal view of the hook in the body of FIG. 9 .
FIG. 12 is an orthogonal view of the hook housed within the body of a hanger of the present invention.
FIG. 12A is a sectional view of FIG. 12 .
FIG. 13 is an orthogonal view of the hook extending beyond the rear surface of a hanger of the present invention.
FIG. 13A is a sectional view of FIG. 13 .
FIG. 14 is an orthogonal view of a pair of nested hangers of FIG. 8 .
FIG. 14A is a sectional view of FIG. 14 .
FIG. 15 is an orthogonal view of a pair of hangers of FIG. 8 showing one hanger hanging from another.
FIG. 16 is a front orthogonal view of a hook insert for another embodiment of a hanger of the present invention.
FIG. 17 is a rear orthogonal view of a hook insert for the embodiment of a hanger of FIG. 16 .
FIG. 18 is a sectional view of FIG. 16 .
FIG. 19 is an orthogonal view of the hook insert set in the embodiment of a hanger of FIG. 16 .
DESCRIPTION OF THE PREFERRED EMBODIMENT
The following preferred embodiment as exemplified by the drawings is illustrative of the invention and is not intended to limit the invention as encompassed by the claims of this application. A nestable clothes hanger with an integrated articulating hook is disclosed herein.
Referring generally to the Figures, the hanger generally comprises hanger frame 1 and hook member 2 extending upwardly therefrom. Hanger frame comprises body 4 and arms 5 extending from each side of body 4 . Hook member 2 is connected to frame 1 via vertical portion 3 .
Hanger body 4 includes a generally planar front surface 10 and a rear surface 11 substantially collateral with front surface 10 . Cascade hook 20 , which may also be called a “finger”, extends from front surface 10 .
Cascade hook 20 , shown in FIG. 1 and in cross section in FIG. 2 , has a front surface 21 and a rear surface 22 , a vertical portion 27 substantially collateral with front surface 10 of hanger body 4 and an inclined portion 28 extending upwardly and outwardly from front surface 10 of hanger body 4 . Inclined portion 28 may form an angle of less than 90 degrees from vertical (i.e., less than 90 degrees from the plane of front surface 10 ). Cascade hook 20 may omit a vertical portion, and inclined portion 28 may be arranged perpendicularly to front surface 10 without departing from the invention disclosed herein, provided that cascade hook 20 may function to support additional hangers therefrom and allows for nesting of hangers, as will be described in greater detail below.
Cascade hook 20 may include a concavity 23 , which may be formed at the intersection of the vertical portion 27 and inclined portion 28 . Alternatively, concavity 23 may be omitted.
Body 4 includes a hole 26 . The hole may either be formed completely through the body, or alternatively, may be only a recess in the body. When the hole is through the body, the hole 26 has a rear aperture 24 formed in the rear surface 11 and a front aperture 25 formed in front surface 10 . Rear aperture 24 may include chamfer 30 (depicted more clearly in FIG. 7 ). Each of the front and rear apertures have a certain area, that is, each has a certain measure of the planar extent it defines. Cascade hook 20 is shaped substantially the same as front aperture 25 , that is, if one projects the shape of cascade hook 20 on the same plane as that occupied by aperture 25 (which is the same as the plane of front surface 10 ), the projected shape of cascade hook 20 will be substantially the same as the shape of aperture 25 . One in the art will readily understand that the projection disclosed herein is not a physical structure, but instead an orthographic projection, that is, a representation of the three dimensional cascade hook 20 on a planar surface corresponding to the plane containing aperture 25 .
Front surface 10 may also be curved, in which case apertures 24 and 25 would likewise be curved. In this case, the projection of cascade hook 20 onto a plane would have substantially the same shape as a projection of aperture 25 onto the same plane.
The surface area of front surface 10 which is not occupied by cascade hook 20 may be at least approximately twice that of the surface area occupied by cascade hook 20 .
Referring now to FIGS. 3 and 4 , two hangers of one embodiment of the present invention may be seen in a nested configuration. Hanger 50 is placed in front of hanger 60 , which is nested with hanger 50 . Cascade hook 61 of hanger 60 extends through rear aperture 52 of hanger 50 , through hole 53 , and partially out front aperture 54 of hanger 50 . Front surface 60 of the inclined portion of cascade hook 61 abuts rear surface 55 of cascade hook 51 . Front surface 62 of hanger 60 abuts rear surface 56 of hanger 50 . Cascade hook 61 may be dimensioned to closely conform to the dimensions of front aperture 54 , thereby nesting hanger 60 to hanger 50 . Rear aperture 53 may be dimensioned larger than front aperture 54 to more easily receive cascade hook 61 in hole 53 .
When nested as shown in FIGS. 3 , 4 , and 5 , cascade hooks 51 and 61 form channel 71 therebetween, terminating in cavity 72 , formed in part by concavity 73 and the front face of cascade hook 61 . Concavity 73 may be dimensioned so as to hold a hook member of another hanger therein, while channel 71 may be of smaller dimensions, prohibiting a hook member present in cavity 72 from moving through channel 71 , thereby maintaining the hook member in cavity 72 . Cavity 72 may be dimensioned to closely approximate the diameter of hook member 2 , depicted, for example, in FIGS. 1 and 6 .
Another embodiment of the invention is depicted in FIGS. 8-15 . As shown specifically in FIGS. 8 and 9 , the hook 20 may be attached within the hole 26 of the body. As shown in FIGS. 9 and 10 , one manner of attaching the hook within the hole may be by providing a pin hole 80 for receiving a projection 82 of the hook. In this embodiment, the hook may have arms 84 extending from each of the projections adapted for resting upon and being supported by the lower portion 86 of the hole. The arms 84 of the hook are joined to each other by an arch 88 completing the hook of this embodiment.
FIG. 11 depicts an enlarged orthogonal view of the hook extending beyond the front surface of the hanger for another hanger to hang therefrom.
As further illustrated in FIGS. 12 and 12A , the hook may articulate between a first position extending beyond the front surface of the hanger for another hanger to hang therefrom ( FIG. 11 ) to a second position in which the hook is completely housed within the body of the hanger. The articulation is accomplished by the pivoting of the projections within the pinholes. When the hook is in the position thus depicted, multiple hangers may be stored in a nested fashion for minimizing the storage space they occupy.
As more specifically shown in FIG. 12A , the hanger may be formed by joining two portions along a joint 90 . Alternatively, the hanger may be made monolithically with a hole therethrough, as shown in FIG. 13 A.
FIG. 13 shows a further embodiment of the present invention in which the hook may articulate between a first position extending beyond the front surface of the hanger for another hanger to hang therefrom ( FIG. 11 ) to a second position in which the hook extends beyond the rear surface of the hanger. The articulation is accomplished by the pivoting of the projections within the pinholes. Another hanger may be hung from the hook when it extends beyond the rear surface of the hanger. In this embodiment, an intermediate position is provided in which the hook may be housed within the body for storing multiple hangers in a nested fashion thereby minimizing the storage space they occupy.
FIGS. 14 and 14A illustrate an alternative way to nesting the hangers from that of positioning the hooks within the body. In this embodiment, the hangers may be nested with the hook in a position extending beyond the front surface of the hanger. As shown therein, the hook extending beyond the front surface of a first hanger extends into the hole of a second hanger positioned in front of the front surface of the first hanger. The front surface of the first hanger abuts a rear surface of the second hanger so that the first and the second hangers are nested in a common horizontal plane relative to one another.
Still another embodiment of the present invention is depicted in FIGS. 16-19 . FIG. 16 is a front orthogonal view of a hook insert 90 for another embodiment of a hanger of the present invention. The hook insert 90 may be made of any material, for example, either metal or plastic.
The hook insert is configured to be inserted into a hole 92 in the hanger. The shape of the hole may be of any shape, be it polygonal, elliptical, or circular. In the particular embodiment depicted, the hole 92 in the hanger is circular thereby matching the circular configuration of the hook insert 90 . The hook insert 90 has a flange 94 on one side. The flange 94 is circumferential in shape, matching the shape of the hook insert itself. The circumferential flange 94 is configured to fit snugly within a corresponding recess 96 in the hanger which is slightly larger than the hole itself.
FIG. 17 is a rear orthogonal view of the hook insert and more particularly illustrates the flange 94 and its corresponding recess 96 in the hanger.
FIG. 18 is a sectional view of FIG. 16 showing the hook insert set in the hanger. In this view, the form fitting hole of the hanger is shown as well as the setting of the flange in the recess. On the side of the hook insert opposite that of the flange is a hook 98 that has a similar profile to the hooks previously described in the present application. As shown, the hook 98 is attached at its base to the hook insert and curves upwardly and outwardly therefrom by an inclined portion 100 . The hook may form an angle of less than 90 degrees from vertical (i.e., less than 90 degrees from the plane of the front of the hanger) and typically has an arcuate top portion.
The hook 98 may include a vertical portion 102 and a concavity 104 , which may be formed at the intersection of the vertical portion 102 and the inclined portion 100 . Alternatively, the concavity 104 may be omitted.
Further shown in both FIGS. 17 and 18 is insert cavity 106 . Insert cavity 106 may be dimensioned to closely approximate the size of the hook 98 . In this manner, one hanger having an insert therein may be nested with another hanger having an insert therein.
FIG. 19 is an orthogonal front view of the hook insert set in the embodiment of a hanger of FIG. 16 .
Although the particular embodiments shown and described above will prove to be useful in many applications in the clothing storage art to which the present invention pertains, further modifications of the present invention will occur to persons skilled in the art. All such modifications are deemed to be within the scope and spirit of the present invention as defined by the appended claims.
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A garment hanger is disclosed having a hook insert therein wherein the hook may be inserted into the body of its hanger to facilitate the nesting of one hanger with the other like hanger.
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PRIOR ART STATEMENT
Although considerable improvements have been made in sealing materials, the basic design of the slush pump or mud pump for oil field operations has generally remained constant during the past thirty-five years.
Traditional mud pumps have employed a one-piece molded rubber compound having a rigid or semi-rigid backing as an integral part of the molded rubber ("piston rubber"). The backing used in the piston rubber has included a woven fabric, a metal and a plastic-like material such as nylon.
The most common deficiency of slush pump pistons has been their wearing of the cylinder liner thereby leaving a gap between the rigid backing and the metal flange adjacent the backing and the liner wall. The resulting gap causes a portion of the rubber seal to extrude into the gap on the pressure stroke which, during the power stroke as well as on the return stroke of the piston, causes the extruded portion of the rubber seal to be nibbled away. As the material is nibbled from the seal, the piston continues to shift within the liner which in turn accelerates the wear on one side of the seal and the portion of the piston body contacting the liner wall. The one sided wear pattern causes continued extrusion of the seal into the gap, a wearing and degeneration of the rigid or semi-rigid backing of the seal and produces or accelerates the metal to metal contact between the metal flange and the liner. The metal removed from the liner wall by this metal to metal contact is deposited on the seal which causes the metal particles to be worked against the liner wall as an abrasive. Metal to metal contact between the piston body and the liner is so commonly and accepted in the current technology that manufacturers often locate a circumferential wear groove within the outer circumference of the piston body which, as the piston body is worn away, indicates the degree of wear on the piston body as well as the need to replace it. It is unclear whether the seal first moves thereby causing a shift of the flange or whether the flange itself is worn from metal to metal contact thereby causing the seal to shift and to extrude into the extrusion gap. The result, however, is a rapid deterioration of the liner wall, the rubber seal, the metal piston body and the effectiveness of the slush pump.
Rubber seals have historically been relatively large radially and axially in order to provide a bulk material which is worn and nibbled during the pumping cycle. The large seals expand from frictional heat, design preload and pressure exerted during the pumping stroke. The combined expansion exerts a tremendous force on the liner wall thereby increasing both friction and wear on the liner and the piston seal.
Applicant is aware of existing methods which tend to reduce the temperatures within the liner during pumping operations. For example, a water source is connected to the piston body which is ejected radially onto the liner wall during the backstroke. Applicant is further aware of existing pistons manufactured by Mission Manufacturing Company, utilizing a cotton dunk backing with a snap ring and piston endplate engagement as shown in the Composite Catalog, '54-'55 Ed, pg. 3314 and 157 Ed Vol. 2, pgs. 3472-3473, pages 4-5 of the Mission Fluid and Pump Parts Catalog of October 1975, by Reed Tool Company as shown on pages 4250 et seq. of the Composite Catalog, utilizing a nylon backing, Wooley Tool & Manufacturing Division of Cromalloy American Corporation utilizing a fabric backing, B.A.L. Ltd. "polypac" design as disclosed in "World Oil", January, 1961 issue page 58 utilizing nylon inserts for anti-extrusion and wear resistance, Stabylia Becap as disclosed in a trade magazine utilizing a homogeneous packing technique with varying hardness characteristics, the IADC Manual, Section 3, pages 1-2, Fluid King of United States Steel disclosed in the pamphlet ADOWD 8-75 utilizing a fabric backing, Harrisburg, Inc., disclosed in a company advertisement page 2597 also utilizing a fabric backing with lubrication fittings, National as shown in the company trade literature further utilizing a fabric reinforcement, Seal-Tite Manufacturing Company utilizing an elastomeric seal having a harder material bonded thereto which in turn is further backed by a fabric, Southwest utilizing a nonreplaceable sealing element, and pages 291 et seq. of a paper presented at the 1978 Drilling Technology Conference, by M. L. Rizzone of OILWELL, a Division of U.S. Steel. All of these designs incur a fraying or melting of the backing, a shifting of the piston within the liner and an extruding of the rubber seal into the extrusion gap thereby accelerating liner wear.
Applicant additionally wishes to cite to the examiner U.S. Pat. Nos. 2,819,131 to Lankford, 2,977,165 to Olson, 2,991,806 to Rocheville et al, 2,987,354 to Olson, 3,720,140 to Lee, all of which generally relate to the prior art herein described.
Copies of the above mentioned prior art, wherever available is included herewith in accordance with 37 CFR 1.97 and 1.98.
SUMMARY OF THE INVENTION
The present invention relates to a high pressure piston and piston seal suitable for use, by example and not by way of limitation, in a mud pump. The present invention also relates to the lower pressure slurry pumps utilized in moving abrasive slurries in mining and ore processing installations and the like. The piston includes a piston body which can be subdivided into a forward main body and a rear support threadedly engaged to the main body. A first annular recess in the piston body contains an annular seal and a gap filler having water channels therethrough. A second annular recess receives a rear wearband. The seal is formed of an elastomeric material which extends radially somewhat more than the piston body. Preferrably acting on at least a portion of the seal is an expander or energizer which uniformly urges at least a portion of the seal into sealing engagement with the liner during piston operation. The expander means can be an integral part of the seal ring or a separate, specifically designed element such as an elastomeric spring, a metal spring, a pressure energized expander or even an enlarged aspect or lip on the seal ring which is compressed radially upon insertion of the piston into the liner. Immediately behind and abutting the seal is a gap filler which is substantially creep resistent axially but which has controlled radial creep. The gap filler controllably creeps radially in order to maintain constant intimate contact with the liner wall, thereby filling the extrusion gap between the smaller radius of the piston body and the larger radius of the liner. Within the gap filler is a plurality of water channels communicating a source of fluid from a passageway within the piston body to the cylinder liner. A wearband is disposed into an annular recess located at the rear support of the piston and extends radially outwardly substantially the same as the gap filler.
The wearband assists to align the piston within the liner and prevent metal to metal contact between the piston body and the liner. The wearband has a plurality of flowpaths traversing its axial width which are angled relative to the piston axis. The flowpaths permit abrasive particles to pass therethrough without being trapped between the outermost wearband surfaces contacting the liner which abrasively act upon the liner. The flowpaths are angled sufficiently that an abrasive particle which escapes from a flowpath has a short axial distance to travel during the piston stroke in order to enter a neighboring flowpath or to pass entirely from the wearband. The angled grooves further provide a 360° bearing effect against the liner contrary to axially aligned grooves found in conventional designs which produce hot spots in which only a portion of the wearband contacts the liner throughout the piston's stroke.
A water source under pressure is communicated through the piston body and through a plurality of angled water channels in the rear of the annular gap filler to produce a vortex washing effect on the liner to remove abrasive particles from the liner and to minimize the temperature of the liner, the seal, the gap filler and the wearband.
The use of a thin seal and gap filler permits their rear removal from the piston body, comprising a main body and removable rear support, by disengaging the rear support from the main body and exchanging the elements through the inner surface of the rear support. Thus, the elements can be easily replaced while the piston remains in the liner.
It is therefore an object of the present invention is to provide an annular gap filler abutting the rear of the seal, the gap filler having controlled radial creep characteristics whereby the outer cylindrical surface of the gap filler remains in intimate contact with the liner thereby closing the extrusion gap between the piston and the liner and minimizing the degradation of the seal ring.
Another object of the present invention is to provide a piston which has one or more radially expanding elements therearound which substantially remain in sliding contact with the liner of a pump thereby substantially reducing or eliminating metal to metal contact between the piston body and the liner.
Another object of the present invention is to provide a piston within a liner which piston is axially aligned with the liner and without metal to metal contact.
Yet a further object of the present invention is to provide a two-part piston body whereby as the two parts are disengaged from each other, the thin seal and gap filler can be removed from the rear of the piston through the rod orifice in the rear support and onto the piston rod for inspection and replacement.
An even further object of the present invention is to provide an axially compressed seal to minimize axial movement of the seal on the piston backstroke.
Another object of the present invention is to provide a wearband and a gap filler which have a useful life at least that of the liner.
Yet another object of the present invention is to provide a gap filler having a plurality of water channels communicating the inner surface to the outer surface suitable for communicating a liquid from the piston to the cylinder liner.
Another object of the present invention provides for the radial creep of the wearband thereby facilitating contact by the wearband with the liner.
Still another object of the present invention is to provide a piston in a cylinder wall having a wearband with angularly aligned flowpaths therein whereby the sliding contact of the wearband on the liner creates a series of flowpaths through the grooves which in turn allows a liquid under pressure to pass through the flowpaths and to create a vortex washing action on the liner wall.
An even further object of the present invention is the use of a thin wearband, seal and gap filler thereby reducing the heat retained within seal elements, the axial load on said elements and the rear support, and reducing the jetting of abrasive particles between the elements and the piston body.
These and other objects of the present invention will become apparent when read in light of the appended drawings, description of the preferred embodiment and the claims herein.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side view in partial section of a conventional slush pump piston and seal within the cylinder liner.
FIG. 1A is a partial side view in section of another embodiment of the prior art showing a seal, a rear metal flange and a means for forward removal of the seal.
FIG. 2 is an enlarged sectional side view of an embodiment of a portion of the invention showing an upper front portion of the piston, an annular seal and a radially creeping gap filler.
FIG. 3 is a side sectional view similar to FIG. 2 but disclosing a modified seal having an expander therein, and a modified, radially creeping gap filler.
FIG. 4 is a view similar to FIGS. 2 and 3 but showing a modified seal, and a modified, radially creeping gas filler.
FIG. 5 is an enlarged radial view of the wearband showing a plurality of spaced apart flowpaths within the outer cylindrical surface of the wearband, a particle in first position on the outermost cylindrical surface, the same particle in a second position within one of the flowpaths and an arrow depicting the freedom path taken by the particle in moving from the first position to the second position.
FIG. 6 is a rear axial view of the gap filler of the invention showing the water channels aligned obliquely from a radius and communicating through the gap filler to the outer surface of the ring.
FIG. 7 is a partial diagrammatical side view in section of a preferred embodiment showing the first and second annular recesses in the piston body, the grooved, energized wearband, an energized seal, the gap filler, the water channels in the gap filler ring and the passageway through the piston communicating with a source of liquid under pressure.
FIG. 8 is a diagrammatical side view of the upper portion of the piston disposed within the cylinder liner showing the radial compression of a seal lip, the radial creep of the gas filler and the alignment of the piston within the liner which is facilitated by means of the wearband.
FIG. 9 is a side view and partial section diagrammatically showing a frontally removable portion of the piston body threadedly engaged to the remainder of the piston.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to the drawings, FIG. 1 shows a typical conventional single-stroke reciprocating slush pump piston 6 and seal 10 as the piston operates within the slush pump cylinder liner 11. A piston body 6 has a radially extending flange 12, the combination of which is secured to a piston rod 8, for example, by means of a nut 16 threadedly engaging a threaded portion 18 of the piston rod 8. A snap ring 14 abuts the forward surface of the seal 10 so that the seal is generally retained between the snap ring 14 and the flange 12. As the piston operates within the liner, an extrusion gap 4 develops as the flange 12 or backing wears. The extrusion gap occurs in a conventional piston in the vicinity of the seal ring, more particularly between the liner and a conventional backing or flange which results from a wearing away of the backing which fails to remain in intimate sliding contact with the liner. During the forward stroke, pressure bears against the exposed part of the seal 10 thereby causing the seal to compress axially and a portion of the seal to be extruded into an extrusion gap 4 located between the flange 12 and the adjacent liner surface 11. The extrusion gap is present because the metal piston body must be smaller in diameter than the liner for the piston to slide within the liner. On the powerstroke (and on the return stroke with supercharged pumps), the extruded portion of the seal 10 is frictionally trapped within the extrusion gap such that chunks of the seal 10 are broken off or nibbled away. As the seal 10 deteriorates, the metal flange 12 is allowed to contact the liner 11 producing a metal to metal contact which in turn accelerates the deterioration of the liner 11 and the seal 10.
As shown in FIG. 1A, the seal 10a can be structured so that radial compression of the seal is necessary in order to insert the seal and, hence, the piston into the liner. Nevertheless, the extrusion gap between the backing or flange 12 continues to permit the growth of an extrusion gap between the backing or flange 12 and the cylinder liner 11.
The present invention calls for an annular elastomeric seal which is abutted from the rear by an annular gap filler which has controlled radial creep characteristics which urge the gap filler ring into continuous contact with the liner such that an extrusion gap does not occur between the piston body and the liner is reduced.
FIG. 2 shows one format of the seal and gap filler combination of the present invention having the piston body 20 secured to a piston rod 22, an elastomeric seal ring 24 abutting a gap filler ring 26, for purposes discussed hereinafter, channels 36 in the rear of the gap filler communicating with liner 11 and with a fluid passageway 34.
FIG. 3 shows another diagrammatical representation of FIG. 2 having an elastomeric seal ring 38 with a recess 40 which accommodates an expander means 42. The expander means or energizer 42 can be a spring, a resilient material, a pressurized chamber and the like which urges at least a portion of the seal ring 38 into sealing contact with a cylinder liner 11. A gap filler 44, having substantially the same material characteristics as the gap filler 26 of FIG. 2, abuts the rear of the seal 38, hence closing the extrusion gap between the piston body 44 and the liner.
FIG. 4 shows yet another embodiment of FIG. 2 with a seal 46 in sealing contact with the liner 11 and having a gap filler 48 generally abutting the rear portion of the seal 46 such that the extrusion gap between the piston body and the liner is closed. In all three embodiments of FIGS. 2, 3 and 4, axial pressure is applied through the seals 24, 38 and 46 respectively causing the gap fillers to creep radially outwardly toward the liner thereby reducing the extrusion gap between the piston and the liner on the power stroke. In all three embodiments, the rear surface of the gap filler is angled from a radius to the rear of the piston so that forces applied to and transmitted through the seals assist in urging the corresponding gap filler radially outwardly into intimate sliding contact with the liner.
A preferred embodiment of the present invention, diagrammatically showing a piston body, piston rod and various synergistic elements aligning and sealing the piston to the liner 11 is shown in FIGS. 7, 8, and 10. Referring to FIG. 7, a piston rod 50 has a rear radially extending flange 60, a threaded portion 52 onto which a compatible nut 54 can be threadedly engaged. The piston body comprises a main body 56 having a passageway 57 to receive the piston rod 50, and a rear support 58. Those skilled in the art will realize that the rear support 58 and the main body 56 may be secured to each other by any number of techniques, a threaded engagement being merely one satisfactory manner of doing so. Preferably, the main body 56 and the rear support 58 are threadedly engaged, to abut one another at the surfaces 55.
The main body 56 and the rear support 58 generally comprise the piston body. The main body 56 has an outer surface 86 at its forward portion and a threaded surface 61 having a smaller radius than the surface 86 located at the rear portion of the main body 56. The piston body has a first annular recess within the outer cylindrical surface of the piston body generally defined by the surfaces 62, 64 and 66. A second annular recess within the outer cylindrical surface of the piston body is disposed between surfaces of the piston body 68, 70 and 72.
The first annular recess includes a rear surface 66 which diverges radially rearwardly as shown in FIG. 7. The first annular recess contains an internally lubricated annular seal 74, a portion of which abuts the front surface 62. The seal 74 can, for example, receive an energizer 76 therein which urges at least a portion of the seal into intimate contact with the liner 11 as shown in FIG. 8. The gap filler 78 synergistically cooperates with many conventional seals, however, to produce the new result of substantially closing the extrusion gap located adjacent to and rearward of conventional seals.
Located within the first annular recess is the annular gap filler 78 having a front face 81 in intimate abutting contact with the rear face 82 of the seal ring 74 and a rear face 84, the faces 81 and 84 diverging radially outwardly. The gap filler is composed of a material which is creep resistent axially but which has controlled creep characteristics radially. Controlled radial creep with reduced axial creep can be obtained by proper orientation of the internal grain of the material used in the gap filler. The use of a glass-filled nylon material as well as its divergent configuration urges the gap filler into intimate sliding contact with the liner 11 as fluid forces are transmitted through the seal 74 onto the gap filler 78 during the power stroke. The gap filler 78 is preferably a wear resistent material which promotes reduced wear of the liner during the pumping operation. The purpose of the gap filler 78 is to insure that a portion of the extrusion gap located between the liner 11 and the outer cylindrical surface 86 of piston body is minimized in order that the seal ring 74 is not extruded on the power stroke into the extrusion gap and thereby nibbled away on the return stroke of the piston. Those skilled in the art will realize that the seal ring 74 and the gap filler ring 78 can comprise a single unit having progressively increasing creep resistence from the front to the rear of the unit, but for ease of manufacture and replacement, a separate seal ring 74 and gap filler ring 78 are shown.
Located within the annular gap filler 78 is a plurality of water channels 88. The water channels are more clearly shown in FIG. 6 taken along lines 7--7 of FIG. 7. The water channels can be aligned radially or obliquely, but an oblique alignment is preferred in order to create a vortex action on the liner 11 as the fluid is communicated through the passageway 34, the water channels 88 and into the gap 90 shown in FIG. 8.
A wearband 92 is located in the second annular recess of the piston body. Although there are many suitable shapes for the wearband, a preferred embodiment is a wearband which conformingly abuts the surfaces 68 and 72 of the second annular recess. A portion of the wearband 92, shown in FIGS. 5, 7, 8 and 9 by the number 94, includes a plurality of ridges which extend radially outwardly past the rear support 58 substantially equidistantly with the gap filler 78.
The ridges 94 are circumferentially spaced apart from one another by a corresponding plurality of flowpaths 96. The ridges 94 and flowpaths 96 are preferably disposed at an angle to the axis of the piston so that when a fluid is passed through the plurality of flowpaths, a vortex is created so that the entire circumference of the liner wall 11 is washed during the operation of the piston. For example, a fluid such as water is forcefully communicated through the passageway 34 of the piston, through the plurality of water channels 88 disposed within the annular gap filler 78, thence into the annular gap 90 and finally through the flowpaths 96 of the wearband 92. Preferably, the direction of the vortex induced by the flowpaths 96 of the wearband 92 is the same direction as the vortex induced by the flow of the fluid through the water channels 88 in the gap filler 78. Hence, an effective washing vortex action is induced by the water channels 88 and reinforced by the flowpaths 94 so that the circumference of the liner 11 is effectively washed and cooled.
Preferably, the angle of alignment of the ridges 94 and flowpaths 96 is sufficient to produce a circumferential bearing effect; that is, during the reciprocal axial motion of the piston, the complete circumference of the liner wall 11 which receives and contacts the wearband 92 is contacted by at least a portion of one or more of the ridges 94. The unusual cooperation of the ridges 94, therefore, eliminates the "hot spots" of the prior art. The "hot spots" arise when the ridges are axially aligned such that the ridges reciprocate axially upon a particular section of the liner while the adjacent flowpaths wash and cool their respective areas of the liner. Those areas of the liner in contact with the axially aligned ridges wear more quickly and experience locally higher temperatures than those areas of the liner cooled by the flowpaths. In the present invention, however, the washing and cooling action generated by the vortex is substantially uniform. Moreover, the circumferential bearing effect of the angularly aligned ridges 94 produce a bearing effect which tends to distribute more evenly the wear of the wearband 92 on the liner 11.
The angular alignment of the ridges 94 further reduces the effects of wear on the liner 11 which occurs when abrasive particles become disposed between the outer circumference of a ridge and the liner wall. With conventional elements, when a particle is lodged between the outer surface of an element and the liner, it is worked fore and aft against the liner as the piston reciprocates within the liner. Hence, wear on the liner is accelerated by the abrasive effects of the particles on the wall.
In the present invention, however, the abrasive effects caused by particles which have migrated between the outer circumference of the ridges 94 and the liner wall 11 are minimized. Referring to FIG. 5, a particle 98 is shown on the outer circumference of a ridge 94. On the return and power stroke of the piston, however, the angular alignment of the ridges 94 and flowpaths 96 is such that as the particle 98 traverses axially towards the rear of the wearband 92, it is again received by another flowpath 96 and effective exhausted to the rear of the wearband by the vortex washing action of the fluid within the flowpath. Consequently, although the migration of a particle into an area between the outer circumference of the ridges and the liner is perhaps unavoidable, the deleterious abrasive effect of the migratory particles is greatly reduced.
As shown in FIGS. 7-9, the seal 74 can be energized by applying the seal in tension around the piston body. Hence, heat imparted to the seal ring 74 by the fluid pressure and friction tends to cause the seal ring to relax thereby reducing the tendency present in conventional seal rings to expand radially outwardly, thus increasing the friction between the seal and the liner. The seal 74 preferably abuts the front surface 62 in order to minimize axial movement of the seal on the piston body during the return stroke.
Because the annular seal 74 and the annular gap filler 78 are thin and thus easily manipulated, these elements can be removed toward the rear of the assembly, unlike conventional slush pump pistons. Rear removal requires the rear support 58 to be threadedly disengaged from the main body 56, at which time the elements can be removed from the piston body through the inner diameter in the rear support defined by the threaded surface 59. The employment of a two-piece piston body and a relatively thin seal 74 and gap filler 78 makes rear removal of those elements possible on some presently existing piston rods and flanges. For instance, utilizing American Petroleum Institute terminology, an SA2 rod having a two inch outer diameter and one inch thread is adaptable to a rear removed three and one-half inch outer diameter piston. Similarly, an SA4 rod having a three and one-quarter inch outer diameter with a one and one-half inch thread and a one and one-half inch main rod diameter is compatible with four and one-half inch piston body thereby permitting rear removal. Similarly, a non-API rod having a three and seven-eighths diameter with a one and one-half inch thread and a one and five-eighths main rod diameter is compatible with a five and one-half inch piston body to permit rear removal.
As shown in FIGS. 7 and 8, the rear support 58 can be removed rearwardly from the main body 56. As shown in FIG. 9, the front element 100 can be removed forwardly from the remainder of the piston body. Those skilled in the art will realize that combination of FIGS. 7-9 can be utilized so that both front and rear removal is possible.
Those skilled in the art will further realize that the gap filler 78 and the wearband 92, urged radially outwardly by their diverging surfaces, can furthermore be urged radially outwardly in any suitable means including mechanical springs, pressure chambers, pressurized lubricant reservoirs and the like.
As shown in FIGS. 7-9, in order to urge more fully the wearband 92 radially outwardly into contact with the liner 11, a bias means such as, for example, a pressure source, a spring or a resilient O-ring 108, can be disposed radially inwardly of the wearband. Preferably, the wearband 92 has a pair of arms 110 projecting radially inwardly from the remainder of the wearband which abut a pair of shoulders 114 formed as a part of the rear support 58. An annular recess 112 spaces apart the pair of shoulders 114 so that when the arms 110 abut or are in proximity to the shoulders 114, a chamber 116 is defined within which is disposed the bias means 108. The abutment of the arms 110 against the shoulders 114 insures that the wearband 92 will not be compressed radially inwardly to the point that sufficient contact by the wearband 92 with the liner 11 is sacrificed, thereby encouraging the proper alignment of the piston within the liner.
Because the flowpaths 96 in the wearband 92 are more restrictive to flow than the water channels 88 or the passageway 34, the annular gap 90 is substantially filled with fluid at all times of operation. Accordingly, the fluid in the annular gap 90 acts as a hydrostatic liquid seal which tends to prevent air in the system from passing between the piston and the liner to the pressure side on the backstroke.
Hence, the present invention as shown and described herein clearly fulfills and meets all the objectives as noted heretofor. For purposes of the present application, applicant has shown and described a preferred embodiment. It is well understood that numerous equivalent structures, combinations of structures, combination of elements and materials are covered within the specification, drawings and appended claims and, therefore, fall both within the scope and the spirit of the present invention.
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In a pump having a cylinder liner, there is a piston therein, a seal around the piston and rear wearband around the piston body to align the piston within the liner. An elastomeric seal ring is in sealing and sliding contact with the liner. A gap filler, with minimal axial creep and controlled radial creep, abuts the rear surface of the seal and maintains continuous contact with the liner thereby continuously closing the extrusion gap between the gap filler and the liner as the liner wears. The wearband has a plurality of angled grooves longitudinally traversing it. Abrasive particles are directed within and through the grooves in the wearband while a source of liquid is communicated into the piston body, through water channels in the gap filler and through the flowpaths in the wearband to create a vortex action which washes the liner wall. The wearband insures no metal to metal contact between the piston and liner and provides a constant piston gap between the metal piston and liner. A thin seal ring improves the temperature gradient within the ring, controls the creep of the ring, reduce the axial load on the ring and allows rear removal of the ring without removing the piston from the liner.
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This is a division of application Ser. No. 296,429 filed on Aug. 26, 1981, now U.S. Pat. No. 4,521,372.
This invention relates generally to the storage of material and in particular to the monitoring of storage containers to detect leakage of material from the storage containers and to detect the migration of fluids into the storage containers. The stored material may be immediately retrieved from storage when the leakage of material from the storage containers is detected or when the migration of fluid into the storage containers is detected. The invention is particularly suited for monitoring the storage of hazardous material such as radioactive waste material.
BACKGROUND OF THE INVENTION
Numerous industrial processes generate waste material. Some types of waste material are hazardous to the environment by virtue of their dangerous chemical or physical properties. Such hazardous waste materials include radioactive wastes, carcinogens, chemical insecticides and pesticides, acids, corrosives, active metal compounds, nerve gases and materials contaminated by such substances. In order to prevent such waste materials from damaging and contaminating the environment, it is necessary either to render the materials harmless or to isolate the materials from the environment in a waste storage facility.
High level radioactive waste materials generated by the operation of nuclear reactors in nuclear power plants are especially dangerous due to the high levels of radioactivity which remain present in the radioactive waste materials for many, many years. Some of the radioactive isotopes in the spent fuel elements of a nuclear reactor or in other high level radioactive waste materials have very long half lives. The leakage of such radioactive waste material could cause long-term radioactive contamination of the environment. An additional problem that arises in the storage of high level radioactive waste materials is the problem of disposing of the heat from the decay of the radioactive isotopes in the stored high level radioactive waste materials.
A similar problem arises with respect to low level radioactive waste materials including numerous radioactive isotopes used in medicine and scientific research. Although such low level radioactive waste materials may exhibit a lower level of radioactivity and heat production than high level radioactive waste materials, such low level radioactive waste materials still pose the threat of long-term contamination of the environment. In addition, when large quantities of such low level radioactive waste materials are stored in the aggregate, the cumulative levels of radioactivity and heat production are not insignificant.
Although the apparatus and method of the present invention may be used to monitor the storage of all types of hazardous and non-hazardous materials, it finds one of its most useful applications in connection with the monitoring of the storage of radioactive waste materials. The continued operation of nuclear reactors will generate an ever increasing amount of high level radioactive wastes in the form of spent fuel elements. Presently, such high level radioactive wastes are being stored in various underground sites such as caves. The possible dangers of environmental contamination inherent in unmonitored underground storage can be avoided if the radioactive waste materials are stored and monitored using the apparatus and method of the present invention.
SUMMARY OF THE INVENTION
The apparatus of the present invention generally comprises a series of nested containers and means for circulating fluids between the containers. The innermost container in the series of nested containers holds the material to be stored and monitored. The spaces between the nested containers are filled with circulating fluids. Said circulating fluids are designed to monitor the environment in the immediate area of the nested containers. Said circulating fluids may also be circulated through heat exchangers to cool said monitoring fluids thereby removing heat from the stored materials.
The nested containers of the present invention are provided with a plurality of conduits for carrying circulating fluids to and from the nested containers when the containers have been lowered into a storage cell. In the present embodiment of the invention, said storage cell comprises a cylindrical metal casing vertically disposed and cemented within an excavation in the earth. In the preferred embodiment of the invention, said casing possesses a length of approximately 100 feet and possesses an inner diameter sufficiently large enough to receive the nested containers. The nested containers and associated conduits for transporting the monitoring fluids may be lowered to the bottom of said storage cell, thereby causing said nested containers to come to rest approximately 100 feet below the surface of the earth. The storage cell may be filled with a fluid such as water to provide additional shielding for the stored materials.
The nested containers are lowered into said storage cell on a support cable. If at any time it is desired to retrieve the stored materials, the nested containers may be raised simply by exerting a lifting force on said support cable with conventional means such as a winch.
The circulating fluids which pass through the conduits connecting the nested containers with the surface convey information concerning the status of the materials contained within said nested containers. For example, a liquid scintillation fluid may be used to detect whether any radioactive material is leaking from the innermost nested container containing radioactive material. By way of further example, it is possible to monitor the scintillation fluid for the presence of water in said fluid to detect increased levels of water in said fluid indicative of the migration of water into the nested containers from outside the containers. Volume monitoring devices are used to detect whether any leakage of the monitoring fluids is occurring. As previously mentioned, it is also possible to use heat exchangers to cool said monitoring fluids, thereby removing heat from said stored material.
A computer based monitoring system continually measures the value of various parameters of the monitoring fluids to determine the existence of any anomalous condition as soon as it occurs. Detection of an anomalous condition causes the computer system to immediately generate an alarm indicating both the anomalous condition detected and the location of the particular storage cell involved. Having been alerted by the alarm, the operator of the storage facility may immediately take whatever action is appropriate to respond to the particular anomalous condition. Alternatively, the computer system may be programmed to immediately take action itself to correct the anomalous condition.
The apparatus and method of the invention provides a means for safely and retrievably storing materials. With respect to the storage of hazardous materials, it is noted that the retrievability feature of the apparatus and method of the invention provides means for recovering the stored hazardous materials for later use. For example, future developments in technology may make it possible to reprocess radioactive materials such as spent fuel elements from nuclear reactors to recover valuable radioactive materials. Such a development would turn what is now "waste" into a valuable natural resource. Methods currently in use for non-retrievably storing such radioactive "waste" material would not permit the easy and rapid retrieval of such material from storage.
The apparatus and method of the invention are not designed to provide a means for the permanent disposal of nuclear waste materials. It is seen, however, that nuclear waste materials can be safely and retrievably stored in the apparatus of the invention for an indefinite period of time. In this manner hazardous nuclear waste materials can be safely contained until permanent disposal techniques are perfected.
The apparatus and method of the invention also provide a significant degree of protection for the environment. Because any leakage of stored material or similar malfunction can be immediately detected and corrected, there is very little risk that the environment will be harmed. Further, use of the apparatus and method of the invention will enhance the safety of individuals engaged in the work of handling and storing hazardous materials.
OBJECTS OF THE INVENTION
It is an object of the apparatus and method of the invention to provide a means for the safe and retrievable storage of materials.
Another object of the apparatus and method of the invention is to provide means for continually monitoring the seal integrity against leakage of the containers containing the stored materials in order to immediately detect any leakage of said stored materials.
Still another object of the apparatus and method of the invention is to provide means for continually monitoring the seal integrity against leakage of the containers containing the stored materials in order to detect the migration of fluids into said stored materials.
A further object of the apparatus and method of the invention is to provide means for removing heat from stored materials that generate heat such as radioactive waste materials.
Yet another object of the apparatus and method of the invention is to temporarily provide continually monitored and retrievable storage for radioactive waste materials until a safe method of permanently disposing of such materials is found.
These and other objects and features of advantage of the invention will be apparent from the drawings, the detailed description, and the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
In the drawings in which is shown a preferred embodiment the invention may assume, and in which like numerals indicate like parts,
FIG. 1 is a schematic view of a storage cell constructed in accordance with the invention and illustrating a set of nested containers together with means for raising and lowering said containers;
FIG. 2 is a vertical sectional side view of a first container within a second container showing the nesting of the containers and showing the connection for conduits for transporting fluids to and from a cavity between said containers;
FIG. 3 is a top view of the top end cap of a first container showing the placement of metal ribs for directing the flow of fluid around said first container;
FIG. 4 is an end view of the first container showing four cylindrically shaped compartments for containing material to be stored;
FIG. 5 is a bottom view of the bottom end cap of the first container showing the placement of metal ribs for directing the flow of fluid around said first container;
FIG. 6 is a perspective view showing an assembled first container;
FIG. 7 is a top view of the top end cap of a second container for containing the first container showing the location of the entry port and exit port of the conduits leading to and from said first container;
FIG. 8 is a bottom view of the top end cap of the second container for containing the first container showing grooves within the bottom of said top end cap for receiving metal ribs for directing the flow of fluid around said first container and showing the location of the entry port and exit port of the conduits leading to and from said first container;
FIG. 9 is an end view of the second container for containing the first container;
FIG. 10 is a top view of the bottom end cap of the second container for containing the first container showing grooves within the top of said bottom end cap for receiving metal ribs for directing the flow of fluid around said first container;
FIG. 11 is a partial sectional side view of a first container within a second container showing the location of metal ribs for directing the flow of fluid around said first container when said first container is within said second container and showing the direction of fluid flow around said first container; and
FIG. 12 is a top view of the top end cap of a third container for containing the second container showing the location of the entry port and exit port of the conduits leading to and from said third container and showing the entry port and exit port for conduits leading to and from said second container;
FIG. 13 is a bottom view of the top end cap of the third container for containing the second container showing metal ribs for positioning said second container within said third container and showing the entry port and the exit port for conduits leading to and from said second container;
FIG. 14 is an end view of the third container for containing the second container;
FIG. 15 is a top view of the bottom end cap of the third container for containing the second container showing grooves for receiving metal ribs to position said second container within said third container;
FIG. 16 is a bottom view of the bottom end cap of the third container for containing the second container showing the placement of metal ribs for directing the flow of fluid around said third container;
FIG. 17 is a bottom view of the top end cap of a fourth container for containing the third container showing grooves within the bottom of said top end cap for receiving metal ribs for directing the flow of fluid around said third container and showing the entry port and exit port for conduits leading to and from said third container and for conduits leading to and from said second container within said third container;
FIG. 18 is an end view of the fourth container for containing the third container;
FIG. 19 is a top view of the bottom end cap of the fourth container for containing the third container showing grooves within the top of said bottom end cap for receiving metal ribs for directing the flow of fluid around said third container;
FIG. 20 is a vertical sectional side view of a series of four nested containers showing the nesting of the containers and showing the connection of conduits for transporting fluids to cavities between said nested containers;
FIG. 21 is a schematic perspective view showing conduits for transporting fluid to and from a series of nested containers and showing means for monitoring the fluid circulating between the containers to monitor the storage conditions of material stored within the containers.
FIG. 22 is a vertical sectional view showing one form of a scintillation detector suitable for detecting the presence of leaked radioactive material in a closed loop of fluid flow of a non-scintillation radiation monitoring fluid.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The apparatus and method of the invention may be used to monitor both hazardous and non-hazardous stored material. The description of the preferred embodiment, however, will be directed to a version of the apparatus and method for monitoring stored hazardous waste materials. It will be understood that the numerous safeguards necessary to safely and efficiently monitor hazardous waste materials will not in all cases be necessary when the material to be stored is non-hazardous. For example, a scintillation detector for detecting the leakage of stored radioactive materials is not needed when the stored material is not radioactive.
Because highly radioactive materials are probably the most hazardous materials which the apparatus and method of the invention will be called upon to monitor, the description of the preferred embodiment will be specifically directed to monitoring stored materials of a highly radioactive nature. It will be understood that the apparatus and method of the invention may be equally well adapted to monitor other hazardous materials such as low level radioactive materials and toxic chemicals. For example, if one desires to monitor the storage of a particular toxic chemical then the detecting equipment used in the apparatus of the invention will be designed to detect that particular toxic chemical.
The numeral 20 generally denotes a series of nested containers for containing the material to be stored and monitored. As shown in FIG. 1, the nested containers 20 may be stored within a storage cell 22. In the preferred embodiment of the invention storage cell 22 comprises a cylindrical metal casing 24 vertically disposed and cemented within an excavation in the earth. The cement 26 generally extends over the exterior surface of casing 24 between casing 24 and the surrounding earth. The cement 26 used to cement said casing 24 extends horizontally across the open bottom of said casing 24 thereby forming a base upon which the nested containers 20 may rest when said nested containers 20 are lowered by a support cable 28 to the bottom of casing 24 of storage cell 22. Cement 26 forms a watertight seal closing the open bottom end of casing 24 thereby enabling storage cell 22 to hold water. Storage cell 22 may be filled with water to provide additional shielding material for further isolating the nested containers 20 at the bottom of storage cell 22.
Support cable 28 is connected to conventional means such as a winch 30 for exerting a lifting force on the nested containers 20 to raise the nested containers 20 to the top of storage cell 22 when the retrieval of the materials stored within nested containers 20 is desired. Conduit take-up reels 29 roll up and unroll the conduits, 80 and 82, that conduct fluid to nested containers 20. The hollow axle (not shown) of each conduit take-up reel 29 is constructed having an aperture therein through which its respective conduit, 80 or 82, extends permitting said conduit, 80 or 82, to pass through and exit from said hollow axle as shown in FIG. 1. In this manner a continuous closed loop of fluid flow may be maintained through the conduit, 80 or 82, at all times.
Turning now to a detailed description of the first and innermost container for containing the material to be stored, one sees by referring to FIG. 4 that said first container generally comprises a group of four cylindrically shaped hollow tubes 32 which may be welded or otherwise fixed together. Of course, other geometric designs for the first container could be employed, including that of a single cylinder. In the preferred embodiment of the invention utilizing the four tube design shown in FIG. 4, the tubes 32 are made of copper. The copper facilitates the efficient transmission of heat from the stored material within the tubes 32 to fluid flowing over the external surfaces of the tubes 32.
The inner diameter of each tube 32 is large enough to slidably receive one fuel rod of the type typically used in pressurized water reactors in nuclear power plants. Each tube 32 is long enough to completely contain within it one such fuel rod. The four tubes 32 comprise the body 34 of first container 36 (as shown in FIGS. 2 and 6). Each end of each tube 32 is formed with a groove 35 for receiving an O-ring 37 (as shown in FIG. 2) in the end surface of said tube 32. An O-ring 37 placed within groove 35 of each tube 32 insures that the ends of the tubes 32 may be tightly sealed against leakage.
As shown in FIG. 4 and in FIG. 6, the outermost surface of each tube 32 of first container 36 possesses longitudinal ribs 38 disposed along the entire length of each tube 32. In the preferred embodiment of the invention, each longitudinal rib 38 is constructed of stainless steel and has a substantially rectangular cross-sectional area. As will be described more fully below, the longitudinal ribs 38 serve as partition members for directing the flow of fluid around said first container 36 while said first container 36 is contained within a second container 40 as depicted in FIG. 2.
Once the material to be stored within said first container has been placed within said tubes 32, the ends of said body 34 of said first container are sealed. The bottom end of said body 34 is sealed with a bottom end cap 42 constructed as shown in FIG. 5. Said bottom end cap 42 generally comprises a substantially flat metal plate 44 having a size and shape large enough to seal the four tubes 32 of said body 34 of said first container 36. Bottom end cap 42 also has a plurality of bottom end cap ribs 46 as shown in FIG. 5. The bottom end cap ribs 46 are arranged in a generally circular pattern with the end of each bottom end cap rib 46 aligned with the end of a longitudinal rib 38. As shown in FIG. 5, the outermost end of each bottom end cap rib 46 is located over a portion of metal plate 44 underlying the end of a longitudinal rib 38. As will be more fully described below, this alignment of the ends of the longitudinal ribs 38 and ribs 46 channels the flow of fluid around said first container 36. Bottom end cap ribs 46 extend radially toward the center 48 of said metal plate 44 of bottom end cap 42. As shown in FIG. 5, the bottom end cap ribs 46 do not extend all the way to said center 48. Thus, an open area near the center 48 of said metal plate 44 is formed through which fluid may flow. In the preferred embodiment of the invention metal plate 44 is made of copper and the bottom end cap ribs 46 are made of stainless steel.
The top end of said body 34 of said first container 36 is sealed with a top end cap 50. The design of top end cap 50 is shown in FIG. 3. It may be seen that the construction of top end cap 50 is similar to that of bottom end cap 42 in that top end cap 50 generally comprises a metal plate 52 having a size and shape sufficient to cover the ends of the four tubes 32 of body 34 of first container 36. Top end cap 50 also has a plurality of top end cap ribs 54 radially disposed along the surface of metal plate 52. As in the case of the bottom end cap 42, each top end cap rib 54 has its outermost end aligned with a corresponding longitudinal rib 38. Also as in the case of bottom end cap 42, the metal plate 52 of top end cap 50 is made of copper and the top end cap ribs 54 are made of stainless steel.
Unlike bottom end cap 42, however, top end cap 50 has one top end cap rib 54 which extends all the way across the surface of metal plate 52 through the center 56 of said metal plate 52. This particular top end cap rib 54 will be referred to as the partition rib 55. A perspective view of the assembled first container 36 is shown in FIG. 6.
The point 58 on top end cap 50 shown in FIG. 3 denotes the approximate location with respect to said first container 36 of an entry port 76 (as shown in FIGS. 2 and 8) through second container 40 when said first container 36 is contained within said second container 40 as depicted in FIG. 2. Similarly, the point 60 on top end cap 50 in FIG. 3 denotes the approximate location of an exit port 78 (as shown in FIGS. 2 and 8) through said second container 40 when said first container 36 is contained within said second container 40.
Because entry port 76 and exit port 78 are on opposite sides of partition rib 55, fluid flowing through entry port 76 into the space between first container 36 and second container 40 cannot flow directly toward exit port 78 but must first flow around first container 36. Specifically, the fluid passing through entry port 76 of said second container 40 will flow along the surface of metal plate 52 of top end cap 50 between the radially disposed top end cap ribs 54. The fluid will then flow down the length of the body 34 of said first container 36 between longitudinal ribs 38. Once the fluid reaches the bottom end cap 42 of said first container 36 the fluid will flow along the surface of metal plate 44 of bottom end cap 42 between the radially disposed bottom end cap ribs 46. The fluid will then pass through the central open portion at the center 48 of metal plate 44, through the bottom end cap ribs 46 and around and up the other side of said body 34 of said first container 36. The fluid will flow upwardly between said longitudinal ribs 38 until it reaches the surface of top end cap 50 once again. The fluid will flow between the top end cap ribs 54 of top end cap 50 until the fluid reaches the exit port 78 at the approximate location 60 shown in FIG. 3. Partition rib 55 which extends all the way across the metal plate 52 through the center of metal plate 52 prevents the fluid from crossing the boundary defined by said partition rib 55. The configuration shown and described in the drawings insures that there will be an even distribution of fluid flow around said first container 36.
Turning now to a description of second container 40, one sees with reference to FIGS. 2, 7, 8, 9 and 10 that second container 40 is generally configured for receiving first container 36 within its interior. Specifically, the body 62 of second container 40 as shown in FIG. 9 is constructed having grooves 64 for slidably receiving the longitudinal ribs 38 on the external surface of the body 34 of first container 36. Grooves 64 have a depth that is only one-half that of the corresponding dimensions of the longitudinal ribs 38 so that a cavity 66 (as shown in FIGS. 2 and 11) is formed between the body 34 of first container 36 and the body 62 of second container 40 when first container 36 is contained within second container 40. Fluid flowing around the sides of first container 36 flows through said cavity 66 formed between first container 36 and second container 40.
After first container 36 has been placed within the body 62 of second container 40, the bottom end cap 68 of second container 40 and the top end cap 70 of second container 40 are secured onto the ends of the body 62. As shown in FIG. 10, the top surface of bottom end cap 68 of second container 40 is formed with grooves 72 which receive the bottom end cap ribs 46 of first container 36. Similarly, as shown in FIG. 8, the bottom surface of top end cap 70 of second container 40 is formed with grooves 74 which receive the top end cap ribs 54 and partition rib 55 of first container 36.
Grooves 72 and grooves 74 are formed having a depth that is only one-half that of the corresponding dimension of their respective bottom end cap ribs 46 and top end cap ribs 54 and partition rib 55 of first container 36. The space formed between the two top end caps, 50 and 70, and the space formed between the two bottom end caps, 42 and 68, together with the space between the body 34 of first container 36 and the body 62 of second container 40 will be generally referred to as cavity 66.
As shown in FIG. 2, metal gaskets 75 are provided to seal the juncture between top end cap 70 and body 62 and the juncture between bottom end cap 68 and body 62 of second container 40. As shown in FIG. 2, metal gaskets 75 have apertures to accommodate the alignment pins 73 and bolts 77 (shown in dotted outline) connecting top end cap 70 and body 62 and connecting bottom end cap 68 and body 62.
As shown in FIGS. 7 and 8, top end cap 70 possesses an entry port 76 and an exit port 78. As shown in FIG. 21, fluid is carried to entry port 76 via a first conduit 80 and is carried from exit port 78 via a second conduit 82. As previously described, fluid entering entry port 76 circulates through cavity 66 and exits cavity 66 through exit port 78.
FIG. 11 shows the path the fluid takes in its flow around first container 36 in the cavity 66 between first container 36 and second container 40. FIG. 11 also shows a first coupling 84 for the connection of the first conduit 80 for transporting fluid to the cavity 66 formed between first container 36 and second container 40 when first container 36 is contained within second container 40. First conduit 80 is connected to entry port 76 within second container 40. As described above, the fluid flows around first container 36 through the cavity 66 formed between the exterior surfaces of first container 36 and the interior surfaces of second container 40. Also shown in FIG. 11 is a second coupling 86 for the connection of the second conduit 82 for transporting the fluid out of cavity 66 via exit port 78.
As shown schematically in FIG. 1, said first conduit 80 and said second conduit 82 are connected to pump means 88 for moving said fluid through said first conduit 80, through said cavity 66 between said first container 36 and said second container 40, through said second conduit 82, and through said pump means 88 and back into said first conduit 80 in a continuous closed loop of a fluid flow. Although depicted schematically in FIG. 1 as a block structure, pump means 88 actually comprises a complete pumping system including such elements as compressors, fluid reservoirs and the like necessary for pumping fluid through a closed loop of fluid flow. As long as pump means 88 continues to operate and circulate the fluid through the conduits and containers as described, a continual flow of fluid will exist around the exterior surface of first container 36 containing the stored material.
The monitoring equipment of the invention (omitted from FIG. 1 for clarity) is schematically depicted in FIG. 21. As shown in FIG. 21, means for monitoring said fluid to detect leakage of said material from said first container 36 may be connected within the closed loop comprising said first conduit 80, said cavity 66 between said first container 36 and said second container 40, said second conduit 82 and said pump means 88. If any material stored within first container 36 leaks into the cavity 66 the leaking material will be carried along by the fluid flowing out of cavity 66 and through second conduit 82. A material detector 90 connected within said closed loop of fluid flow can detect the presence of portions of the stored material within the circulating fluid.
Material detector 90 may take the form of any of a number of well known means for identifying chemical substances. Specifically, material detector 90 may be a gas chromtography analyzer, a liquid chromatography analyzer, an infrared analyzer, an ultraviolet analyzer, a nuclear magnetic resonance analyzer, or some other analyzer appropriate for identifying particular chemical substances.
In an alternative form of the invention material detector 90 is not connected within the closed loop of fluid flow. In this form of the invention a sample of the circulating fluid is removed from the closed loop of fluid flow via a valve or similar means. Said sample may then be taken to material detector 90 at an "offline" location for analysis to determine whether any portion of the stored material is present within the circulating fluid. The primary disadvantage of the "offline" method is that the monitoring process is not continuous. Monitoring and detection occurs only when fluid is removed from the closed loop of fluid flow for analysis.
In the preferred embodiment of the invention, the first conduit 80 and second conduit 82 extend from the bottom of storage cell 22 to the surface of the earth within which said storage cell is disposed and cemented. First conduit 80 and second conduit 82 are connected to pump means 88 at the surface. If material detector 90 is connected within said closed loop of fluid flow as described, it is also located at the surface. Generally, all equipment used to monitor the flow of fluid through the conduit system is located at the surface. Thus, the invention provides a means for conveying information to the surface concerning the status of the stored materials at the bottom of storage cell 22.
When the stored materials are radioactive, the material detector 90 may take the form of a radiation detector 92 capable of monitoring a radiation monitoring fluid moving through the closed loop comprising first conduit 80, cavity 66, second conduit 82 and pump means 88. The particular radiation detector 92 used in the preferred embodiment of the invention is a scintillation detector 94 and the particular radiation monitoring fluid used is a scintillation fluid. The scintillation fluid contains materials which will scintillate in the presence of radiation emitted by radioactive material. The scintillation fluid may be any of a number of well known preparations such as a xylene or toluene based fluid containing organic phosphors. The scintillation detectors 94 detects the presence of scintillation flashes of light caused by the presence of radioactive material within the circulating scintillation fluid.
First assume that the stored radioactive materials within first container 36 do not leak into cavity 66. Radiation from said stored materials will pass through the walls of said first container 36 and irradiate the scintillation fluid flowing through cavity 66 thereby causing the scintillating material within said scintillation fluid to give off flashes of scintillation light in the vicinity of first container 36. However, as the scintillation fluid flows toward the top of storage cell 22, the scintillating material is carried away from the radioactive radiation at the bottom of storage cell 22. The flashes of scintillation light induced by the exposure of scintillating material to radioactive radiation from the stored radioactive materials within first container 36 cease before the scintillating material reaches scintillation detector 94 at the top of storage cell 22. Because scintillation detector 94 is constructed to detect the presence of scintillations within the scintillation fluid as it passes through the scintillation detector 94, the scintillations induced by the radioactive material stored within first container 36 will not be detected. In this instance scintillation detector 94 would detect only a relatively small number of scintillation flashs of light caused by background radiation from the environment.
Now assume that radioactive material stored within first container 36 leaks out of said container into cavity 66. Said radioactive material will be carried along with said scintillation fluid to the top of said storage cell 22 where it will pass through said scintillation detector 94. In this instance, however, large numbers of scintillation flashes of light will be detected by scintillation detector 94 because the leaking radioactive materials will be present in the scintillation fluid as the scintillation fluid flows through said scintillation detector 94. In this manner leaking radioactive materials may be detected by scintillation detector 94 immediately upon the occurrence of leakage of radioactive material into the circulating scintillation fluid. If no radioactive material leaks into the scintillation fluid, only "background" scintillations will be detected and the scintillations induced by the radiation normally present in the stored radioactive material will not be detected by scintillation detector 94 because those scintillations cease once the scintillation fluid leaves the immediate area of first container 36 containing said materials.
Scintillation detector 94 may either be connected within the closed loop of fluid flow of the scintillation fluid or may be located "offline" outside the closed loop of fluid flow as previously noted in the description of material detector 90. In the latter case, a sample of scintillation fluid may be taken from the closed loop of fluid flow and transported to the "offline" scintillation detector 94 for analysis.
It will also be appreciated that use of the "offline" method permits the use of an inert, non-scintillation radiation monitoring fluid for carrying the leaked radioactive material through the closed loop of fluid flow. When a sample of inert non-scintilliation radiation monitoring fluid containing leaked radioactive material is taken from the closed loop of fluid flow for "offline" analysis, the leaked radioactive material may be detected by a geiger counter or other means for detecting radioactive radiation. With respect to the use of either a scintillation fluid or a non-scintillation fluid in the methods described above, it is seen that the use of a scintillation fluid is preferred when scintillation detector 94 is connected "online" within the closed loop of fluid flow. This is due to the fact that the scintillations in the fluid caused by the leaked radioactive material may be optically detected "online" as the scintillation fluid flows through scintillation detector 94 without the necessity of impeding the flow of scintillation fluid through the closed loop of fluid flow by removing a portion of the fluid for "offline" analysis.
It is possible, however, to use a scintillation detector 94 that employs a solid scintillator 95 in conjunction with an inert, non-scintillation radiation monitoring fluid to achieve an "online" monitoring for leaked radioactive material. As shown in FIG. 22, scintillation detector 94 comprises a solid scintillator 95 optically coupled through interface 97 to a photomultiplier section 99. The solid scintillator 95 may take the form of a thallium-activated sodium iodide crystal, NaI(Tl), as is well known in the scintillation detector art. The components of the scintillation detector 94 are enclosed within a sealed canister 101.
A portion of the sealed canister 101 containing solid scintillator 95 is placed within the closed loop of fluid flow so that the fluid may pass in close proximity to solid scintillator 95. If any leaked radioactive material is present in the inert, non-scintillation radiation monitoring fluid passing by solid scintillator 95, then the radiation from said radioactive material will pass through sealed canister 101 and will cause scintillation flashes of light 105 to occur in solid scintillator 95. These scintillation flashes of light may be optically detected through interface 97 and amplified in photomultiplier section 99 to generate a signal indicative of the presence of leaked radioactive material in the closed loop of fluid flow. Background radiation from the environment will cause a relatively small number of scintillation flashes of light 105 to always be present in solid scintillator 95. This phenomenon enables anyone monitoring the performance of scintillation detector 94 to determine whether it is functioning at any given time. Because the number of scintillation flashes of light 105 generated by the presence of leaked radioactive material in the closed loop of fluid flow is so much greater than the number of scintillation flashes of light generated by the background radiation, it is possible to detect the presence of radioactive material in the closed loop of fluid flow. This embodiment of scintillation detector 94 permits one to use a relatively inexpensive non-scintillation radiation monitoring fluid to achieve the preferred "online" monitoring for leaked radioactive materials previously attainable only by using the more costly scintillation fluid method.
When the material detector 90 (or radiation detector 92 in the case of radioactive materials) is located within the closed loop of fluid flow, means are provided for immediately determining when material detector 90 (or radiation detector 92) detects the presence of stored material in the fluid flowing through the closed loop comprising first conduit 80, cavity 66, second conduit 82 and pump means 88. Said means generally comprises a computer 96 having at least one input line connected to said material detector 90 (or radiation detector 92) for transmitting a signal to computer 96 when material detector 90 (or radiation detector 92) detects the presence of material in the fluid. Computer 96 frequently monitors material detector 90 (or radiation detector 92) over said input line to detect a signal signifying the presence of stored material in the fluid.
When computer 96 detects the signal indicating the presence of stored material in the fluid, it may sound an alarm to alert the operator of the storage facility that a leakage condition has occurred. In this manner, any leakage of stored material may be detected within an extremely short amount of time. The use of "fault tolerant" computer systems and frequency operational validity tests on the detecting equipment can insure a very high level of reliability in the monitoring process.
In addition, computer 96 may be programmed to provide different levels of notification to the operator of the storage facility concerning the status of the stored materials being monitored. Not all changes in the status of the monitoring system would require an alarm to be sounded. For example, detection of a decrease in the rate of fluid flow would not necessarily require that an alarm be sounded. Computer 96 could bring the matter to the attention of the operator of the storage facility via well known display means such as a printer or cathode ray tube display. Computer 96 could also be programmed to take immediate corrective action itself such as automatically switching on a back-up pumping system in the event that a pumping system failure was detected.
Although the preferred embodiment of the invention utilizes a computer 96, it is seen that a non-programmable "hard-wired" electronic circuit could be devised to perform the functions of the computer 96 in the monitoring system. The use of computer 96 is preferable because it gives the added flexibility of being able to read, store and retrieve data concerning the various parameters in the monitoring system. Computer 96 can also correlate said data and notify the operator of the storage facility when certain long range trends are detected. For example, computer 96 can store temperature data received from a temperature measuring device which determines the temperature of the monitoring fluid and can compare the values of temperature taken over a period of time to detect an otherside unnoticeable gradual increase or decrease in the temperature of the monitoring fluid.
Turning once again to the description of the monitoring system, one notes that it is important to be able to determine whether the fluid circulating between first container 36 and second container 40 is leaking out of the closed loop of fluid flow. For example, assume that first conduit 80 developed a leak which permitted the fluid to leak out of first conduit 80 into the storage cell 22. After the fluid level had decreased sufficiently, it would become impossible for material detector 90 (or radiation detector 92) to operate correctly. Such a fluid leak would make it impossible to determine whether the material stored within first container 36 was leaking.
The problem may be resolved by providing a volume measuring unit 98 (as shown in FIG. 21) within the closed loop comprising first conduit 80, cavity 66 between first container 36 and second container 40, second conduit 82 and pump means 88 for measuring the changes in the volume of the fluid flowing through said closed loop. Computer 96 may be connected to said volume measuring unit 98 via at least one input line connected to said volume measuring unit 98 for transmitting a signal to said computer 96 when said volume measuring unit 98 detects a change in the volume of said fluid. As in the case of material detector 90 (or radiation detector 92), computer 96 frequency monitors said input line to detect a signal indicative of volume measuring unit 98 having detected a change in the vollume of said fluid. Computer 96 correlates the receipt of said signal with other information it possesses in the manner previously described and determines the appropriate response to be made. If necessary, computer 96 can sound an alarm immediately notifying the operator of the storage facility of the detected change in the volume of the fluid.
One other problem that may arise in the maintenance of a continual fluid flow around the stored material within first container 36 is that of detecting changes in the rate of fluid flow. Assume that pump means 88 malfunctioned in such a manner that the rate of fluid flow through the closed loop was either greatly diminished or stopped entirely. Because a storage facility utilizing the method and apparatus of the present invention would likely comprise several storage cells, the operator of such a facility might not notice when a particular pump means 88 malfunctioned. Although no leakage of fluid would occur from the closed loop of fluid flow, the detection system would no longer operate correctly if the rate of fluid flow were significantly diminished or stopped. Accordingly, the apparatus of said invention is provided with means for detecting a change in the rate of flow of the fluid flowing through the closed loop. Said means comprise a flowmeter 100 (as shown in FIG. 21) connected within the closed loop for measuring the rate of flow of fluid flowing through the closed loop together with means for determining when flowmeter 100 detects a change in the rate of flow of said fluid flowing through the closed loop.
Computer 96 may once again be used to provide the means for determining when flowmeter 100 detects a change in the rate of fluid flow. Specifically, computer 96 may be connected to flowmeter 100 with at least one input line for transmitting a signal to computer 96 indicative of the detection by flowmeter 100 of a change in the rate of flow of the fluid flowing through the closed loop. As before computer 96 may be used to determine the appropriate response including the sounding of an alarm alerting the operator of the storage facility when computer 96 determines that flowmeter 100 has detected a change in the rate of fluid flow.
Certain stored materials give off a considerable amount of heat. This is especially true in the case of radioactive materials. When radioactive materials or other heat generating materials are stored, it may become necessary to cool the fluid which flows through the closed loop. Accordingly, the apparatus of the present invention may be provided with means connected within first conduit 80, cavity 66 between first container 36 and second container 40, second container 82 and pump means 88 for cooling the fluid as the fluid flows through said closed loop. Said means may comprise any of a number of conventional means including a heat exchanger 102 as depicted in FIG. 21.
A temperature measuring device 103 (FIG. 21) may be placed into thermal contact with the fluid flowing through the closed loop in order to monitor the fluid's temperature and thereby indirectly gain knowledge of the temperature of the stored materials. As before, computer 96 may be connected to temperature measuring device 103 with at least one input line for transmitting a signal to computer 96 indicative of the temperature of the fluid being measured by temperature measuring device 103. Computer 96 can then compare said signal on said input line with other signals previously stored in computer 96 which are indicative of a predetermined range of temperatures to determine whether the temperature of the fluid is within said predetermined range of temperatures. Computer 96 may then be used to determine the appropriate response including the sounding of an alarm alerting the operator of the storage facility when computer 96 determines that the temperature of the fluid is outside the predetermined range of temperatures. In order to obtain an accurate temperature measurement, temperature measuring device 103 should be placed within the closed loop between the set of nested containers 20 and heat exchanger 102 as shown in FIG. 21 so that the fluid is not cooled before the temperature measurement is taken. Of course, it is also possible to place an additional temperature measuring device after heat exchanger 102 in the closed loop of fluid flow in order to verify that heat exchanger 102 is operating properly.
The apparatus of the present invention may also be used to detect the migration of fluids into the stored materials within first container 36 from outside of second container 40. When materials are stored underground, it is very common for water to migrate into the stored materials thereby dissolving and carrying away soluble portions of the stored materials. This is very undesirable if the stored materials are hazardous materials. For example, stored water-soluble toxic chemicals may be carried away by the migration of ground water and eventually find their way into the fresh water supply of communities. The apparatus of the present invention provides a means for detecting the migration of an external fluid into the fluid flowing between first container 36 and second container 40. The fluid flowing between first container 36 and second container 40 will be referred to as the first fluid. The external fluid outside of second container 40 (usually water) will be referred to as the second fluid.
The general structure of the apparatus of the invention is as has been previously described. However, in this application, the chemical composition of the first fluid differs from that of the second fluid. In a specific example, assume that the second fluid to be detected is water. The first fluid is a scintillation fluid containing a known small amount of water in it. If water external to second container 40 manages to permeate or leak through said second container 40 and enter cavity 66, it will mix with the scintillation fluid flowing through the closed loop of fluid flow thereby causing the amount of water in the scintillation fluid to increase with respect to the previously known level of water in the scintillation fluid.
The scintillation fluid carrying the extra amount of invading water will travel up to the detecting equipment on the surface via second conduit 82 where it will pass through a second fluid detector 104 for detecting the presence of a second fluid (here water) in the first fluid (here scintillation fluid) flowing through said closed loop of fluid flow. In this embodiment of the invention, second fluid detector 104 would replace and be used in lieu of material detector 90 within the closed loop of fluid flow. As previously described, computer 96 monitors an input line connected to said second fluid detector 104 and can notify the storage facility operator when said second fluid detector 104 detects the presence of water in the scintillation fluid in amounts that are greater than normally expected. Of course, when the invading second fluid to be detected is not water but is some other fluid, an appropriate second fluid detector 104 is chosen for detecting the specific second fluid involved.
The elements of the apparatus previously described including specifically the volume measuring unit 98, the flowmeter 100, the heat exchanger 102 and the temperature measuring device 103 may all be used in conjunction with the second fluid detector 104. It should be noted that second fluid detector 104 may also be used in an "offline" manner as previously described in connection with other types of detectors. Of course, the "online" method utilizing computer 96 for continuous monitoring is preferable when the immediate detection of the invasion of the second fluid is desired. The "offline" method would provide information concerning the presence of the second fluid only when the manually conducted "offline" tests were performed.
The apparatus of the present invention thus provides a means for immediately notifying the operator of a storage facility when a second fluid such as water has invaded or migrated into the cavity 66 between first container 36 and second container 40. Of course, the occurrence of any leakage or migration of said second fluid into said cavity 66 may be immediately remedied by raising the containers 36 and 40 from the bottom of storage cell 22 and effecting immediate repairs.
In addition to detecting leakage or migration of a second fluid into cavity 66, the first fluid may also simultaneously be used to detect the leakage of the stored material from first container 36 into cavity 66 as previously described. In this embodiment of the invention, second fluid detector 104 would be placed in series with and used in addition to material detector 90 within the closed loop of fluid flow. The continual flow of first fluid through the closed loop comprising first conduit 80, cavity 66, second conduit 82 and pump means 88 would carry any stored material that has leaked into cavity 66 from first container 36 to material detector 90 and would simultaneously carry to second fluid detector 104 any second fluid which is leaked into the closed loop of fluid flow.
It is possible to use a non-water-based scintillation fluid such as xylene or toluene as the first fluid in such an arrangement. Examples of commercially available preparations of such scintillation fluids include Insta-Gel, Insta-Fluor and Filter Count (the foregoing names are all registered trademarks of United Technologies Corporation). Such scintillation fluids, in addition to serving in the capacity of a scintillation fluid as previously described, can simultaneously serve as a first fluid for transporting to a second fluid detector 104 any second fluid that leaked or migrated into the closed loop of fluid flow.
Although it is possible to detect leakage of stored material from first container 36 and to detect leakage of a second fluid into the closed loop of fluid flow using only a single fluid circulating throughout said closed loop of fluid flow, for reasons to be described more fully below the preferred method involves the separation of the two detection processes. Accordingly, the preferred embodiment of the apparatus comprises a third container 106 for containing second container 40 and a fourth container 108 for containing third container 106 as depicted in FIG. 20. Third container 106 and fourth container 108 are constructed in a manner similar to that previously described for first container 36 and second container 40. As shown in FIG. 20, a cavity 110 is formed between third container 106 and fourth container 108 when third container 106 is contained within fourth container 108. When second container 40 is contained within third container 106, a dead air space 112 is formed.
In this embodiment of the apparatus utilizing four containers, a second closed loop of fluid flow exists as depicted in FIG. 21 comprising third conduit 114, cavity 110 (FIG. 20), fourth conduit 116 and pump means 118. The detection of leakage or migration of an external third fluid into the nested container 20 will be monitored by a second fluid circulating between third container 106 and fourth container 108 in said second closed loop of fluid flow. The previously described first closed loop of fluid flow of first fluid between first container 36 and second container 40 now serves solely to detect leakage of stored material from first container 36.
A primary reason for using two closed loops of fluid flow each with its own circulating fluid is to increase the detection efficiency of the monitoring system. Specifically, it has been determined that the task of carrying material performed by the first fluid in the innermost closed loop of fluid flow requires a fluid having different rheological or flow properties than the second fluid flowing in the outermost closed loop of fluid flow. One desires that the first fluid have a great capacity for carrying solid material. Accordingly, one desires that said fluid have thixotropic qualities. A thixotropic fluid is one that will tend to thicken or "gel" if it ceases to flow and is left to stand. The optimal choide of a first fluid would be an aliphatic fluid such as kerosene or diesel containing a thixotropic agent such as a bentone.
Conversely, because the task to be performed by the second fluid flowing in the outermost closed loop of fluid flow is to dissolve and disperse an external fluid (usually water) it should have no thixotropic agent in it. A suitable second fluid for use in the apparatus of the invention would be an aliphatic fluid such as kerosene or diesel containing no thixotropic agent. Thus, it may be seen that the utilization of two closed loops of fluid flow contributes to the efficiency of the detection process in providing fluids specifically chosen for the tasks which they must perform. Additionally, the use of four containers instead of two containers adds to and improves the security and integrity of the stored materials within the innermost nested container.
Turning now to a description of third container 106, one sees with reference to FIGS. 12, 13, 14, 15, 16 and 20 that third container 106 is generally configured for receiving second container 40 within its interior. Specifically, the body 120 of third container 106 as shown in FIG. 14 is constructed having grooves 122 for slidably receiving longitudinal ribs 124 on the external surface of second container 40 as shown in FIGS. 7, 8, 9 and 10. Grooves 122 have a depth that is only one-half that of the corresponding dimension of the longitudinal ribs 124 so that a dead air space 112 (FIG. 20) is formed between the body 120 of third container 106 and the body 62 of second container 40 when second container 40 is contained within third container 106.
After second container 40 has been placed within the body 120 of third container 106, the bottom end cap 126 of third container 106 and the top end cap 128 of third container 106 is secured onto the ends of the body 120. As shown in FIG. 20, metal gaskets 129 are provided to seal the juncture between top end cap 128 and body 120 and the juncture between bottom end cap 126 and body 120 of third container 106. As in the case of metal gaskets 75, metal gaskets 129 have apertures to accommodate alignment pins 73 (FIG. 20) and bolts (not shown) connecting top end cap 128 and body 120 and connecting bottom end cap 126 and body 120.
As shown in FIGS. 15 and 16, bottom end cap 126 has a plurality of bottom end cap ribs 130 on its bottom side and a plurality of grooves 131 on its top side. The bottom end cap ribs 130 are arranged in a generally circular pattern with the end of each bottom end cap rib 130 aligned with the end of a rib 132 of body 120 of third container 106 as shown in FIG. 14. In a manner similar to that described in the case of first container 36 and second container 40, this alignment of the ends of ribs 130 and ribs 132 channels the flow of fluid around third container 106. Also in a manner similar to that described in the case of first container 36 and second container 40, bottom end cap ribs 130 extend radially toward the center of bottom end cap 126. As shown in FIG. 16, the bottom end cap ribs 130 do not extend all the way to the center of bottom end cap 126 in order that an open area may be formed through which fluid may flow around third container 106. The grooves 131 in the top of bottom end cap 126 receive correspondingly positioned ribs of second container 40 to correctly position second container 40 within third container 106.
The top end of body 120 of third container 106 is sealed with a top end cap 128. The design of top end cap 128 is shown in FIGS. 12 and 13. Top end cap 128 has a plurality of top end cap ribs 134 radially disposed and aligned with a corresponding longitudinal rib 132 of body 120 as previously described. Also in a manner similar to the design previously described for first container 36 and second container 40, top end cap 128 has a particular top end cap rib 134 which extends all the way across said top end cap 128 to function as a partition rib 136. Top end cap 128 has apertures for entry port 76 and exit port 78 as shown in FIGS. 12 and 13.
The point 140 on top end cap 128 shown in FIG. 12 denotes the approximate location with respect to third container 106 of an entry port 144 through fourth container 108 when third container 106 is contained within fourth container 108. Similarly, the point 142 on top end cap 128 in FIG. 12 denotes the approximate location of an exit port 146 through fourth container 108 when third container 106 is contained within fourth container 108.
Because entry port 144 and exit port 146 are on opposite sides of partition rib 136, fluid flowing through entry port 144 into the space between third container 106 and fourth container 108 cannot flow directly toward exit port 146 but must first flow around third container 106. Specifically, the fluid passing through entry port 144 of fourth container 108 will flow along the surface of top end cap 128 between the radially disposed top end cap ribs 134. The fluid will then flow down the length of the body 120 of third container 106 between longitudinal ribs 132. Once the fluid reaches the bottom end cap 126 of third container 106 the fluid will flow along the surface of bottom end cap 126 between the radially disposed bottom end cap ribs 130. The fluid will then pass through the central open portion at the center of bottom end cap 126 and around and up the other side of said body 120 of third container 106. The fluid will flow upwardly between longitudinal ribs 132 until it reaches the surface of top end cap 128 once again. The fluid will flow between the top end cap ribs 134 of top end cap 128 until the fluid reaches the exit port 146 at the approximate location 142 shown in FIG. 12. Partition rib 136 which extends all the way across and through the center of top end cap 128 (except for entry port 76 and exit port 78) prevents the fluid from crossing the boundary defined by said partition rib 136. The configuration shown and described in the drawings insures that there will be an even distribution of fluid flow around said third container 106.
Turning now to a description of the fourth container 108, one sees with reference to FIGS. 17, 18, 19 and 20 that fourth container 108 is generally configured for receiving third container 106 within its interior. Specifically, the body 148 of fourth container 108 as shown in FIG. 18 is constructed having grooves 150 for slidably receiving the longitudinal ribs 132 on the external surface of the body 120 of third container 106. Grooves 150 have a depth that is only one-half that of the corresponding dimension of the longitudinal ribs 132 so that a cavity 110 (as shown in FIG. 20) is formed between the body 120 of third container 106 and the body 148 of fourth container 108 when said third container 106 is contained within fourth container 108. Fluid flowing around the sides of third container 106 flows through said cavity 110 formed between third container 106 and fourth container 108.
After third container 106 has been placed within the body 148 of fourth container 108, the bottom end cap 152 of fourth container 108 and the top end cap 154 of fourth container 108 are secured onto the ends of the body 148. As shown in FIG. 20, metal gaskets 155 are provided to seal the juncture between top end cap 154 and body 148 and the juncture between bottom end cap 152 and body 148 of fourth container 108. As before, metal gaskets 155 have apertures to accommodate alignment pins 73 (FIG. 20) and bolts (not shown) connecting top end cap 154 and body 148 and connecting bottom end cap 152 and body 148. As shown in FIG. 19, the top surface of bottom end cap 152 of fourth container 108 is formed with grooves 156 which receive the bottom end cap ribs 130 of third container 106. Similarly, as shown in FIG. 17, the bottom surface of top end cap 154 of fourth container 108 is formed with grooves 158 which receive the top end cap ribs 134 and partition rib 136 of third container 106.
Grooves 156 and grooves 158 are formed having a depth that is only one-half that of the corresponding dimensions of their respective bottom end cap ribs 130 and top end cap ribs 134 and partition rib 136 of third container 106. The space formed between the two top end caps, 128 and 154, and the space formed between the two bottom end caps, 126 and 152, together with the space between the body 120 of third container 106 and the body 148 of fourth container 108 will be generally referred to as cavity 110 (FIG. 20).
As shown in FIG. 17, top end cap 154 has an entry port 144 and an exit port 146 in addition to an entry port 76 and an exit port 78. As shown in FIG. 21, fluid is carried to entry port 144 via a third conduit 114 and is carried from exit port 146 via a fourth conduit 116. As previously described, fluid entering entry port 144 circulates through cavity 110 and exits cavity 110 through exit port 146.
Turning now to the previously mentioned dead air space 112 shown in FIG. 20, one sees that under normal circumstances there is no fluid in dead air space 112. Fluid will generally be present in dead air space 112 only when said fluid leaks into dead air space 112 from cavity 66 or from cavity 110. Thus, in addition to providing additional insulation of the stored material from the environment, dead air space 112 provides a "pocket" into which fluid leaking from either cavity 66 or cavity 110 may flow so that any such leak may be immediately detected due to the significant decrease in volume of fluid in the closed loop of fluid flow in which the leak into dead air space 112 occurred.
In this connection, it should be noted that it is possible to contain a gas under pressure within dead air space 112 via a conduit (not shown) connecting said dead air space 112 to a source of pressurized gas. The preferred location for said source of pressurized gas and associated gas pressure monitoring equipment would be outside of storage cell 22 next to the other monitoring equipment such as material detector 90 shown in FIG. 21. If the gas pressure within dead air space 112 was ever seen to fall from the expected level of gas pressure, the presence of a leak within dead air space 112 (or its associated conduit) could be detected. The arrangement described above permits the early detection of very small leaks within the inner surface of cavity 110 or within the outer surface of cavity 66.
Although in ordinary circumstances the monitoring fluids used to practice the invention will be liquids, it is possible to use a gas under pressure for each of the previously described monitoring fluids in the closed loops of fluid flow. Because both gases and liquids are fluids as contemplated in the definition of the term "fluid" it is clear that the apparatus and method of the invention may utilize either gases or liquids in performing the task of monitoring stored material.
Other types of storage cells 22 for storing the nested containers 20 may be devised. For example, if one desires to store and monitor more than one set of nested containers, storage cell 22 may take the form of a reinforced concrete trench (not shown) for containing a plurality of sets of nested containers immersed in a volume of water. In such an embodiment each set of nested containers could be disposed within said trench and located at various positions along the length of said trench. Further, each set of nested containers could be located at any desired distance from each of the two neighboring sets of nested containers. The opposite walls of said trench would be strengthened and braced with steel beams transversely disposed to and anchored within the surfaces of said walls. The water used to fill said trench would provide a heat sink having a greater capacity than that provided by the water filling a storage cell for a single set of nested containers.
Although a specific preferred embodiment of the invention has been described it is to be understood that modifications may be made in the disclosed preferred embodiment without departing from the true spirit and scope of the invention.
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An apparatus and method for monitoring stored material is disclosed. Material to be stored and monitored is placed within the innermost container of a series of nested containers and monitoring fluids are circulated in a closed loop of fluid flow through the spaces between the nested containers. Monitoring devices are used to analyze said monitoring fluids to detect leakage of the stored material from the innermost nested container and to detect the migration of external fluids into the series of nested containers. A computer based monitoring system continually checks the values of various parameters of the monitoring fluids to immediately detect and report the presence of stored material or external fluid in the monitoring fluids. The stored material may then be immediately retrieved from storage to repair leaks in the series of nested containers. The invention is particularly suited for monitoring the storage of hazardous material such as radioactive waste material.
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BACKGROUND OF THE INVENTION
1. The Field of the Invention
The present invention relates to a glass ceramic plate providing a cooking surface of a cook top or cooking apparatus, which is composed of a glass ceramic material which is transparent to visible light as well as IR radiation and which is provided with a coating on an underside thereof in the form of a noble metal film. The invention also relates to a coating on an underside of the glass ceramic plate. The present invention relates to a process for coating the underside of the glass ceramic panel.
2. Related Art
Glass ceramic plates, which are used in cooking devices to provide cooking surfaces, so-called glass ceramic cooking surfaces, are typically darkly colored in the melt for the European market, so that they appear black when viewed from the top and prevent viewing of components in the interior of the cooking devices. Generally under intense illumination from above, especially in the modern kitchens, e.g. under conventional halogen lighting, cables or other components in the interior of the cooking devices may still be visible from above. In order to provide an outstandingly opaque cooking surface, an opaque silicone coating is applied to the typically knobbed underside of the glass ceramic plate. The opaque silicone coating must be generally omitted in the display area and in the vicinity of the light of the residual-heat signaling device, so that the light indicator signals are visible to the user. Generally the knobbed structure on the underside of the glass ceramic plate in the vicinity of the light indicator devices (display area and residual heat indicator) is dressed with a smooth colorless silicone coating, so that the observable signals are not distorted.
Currently colorless glass ceramic plates, i.e. glass ceramic plates that are not colored in the melt, which are transparent for visible light and smooth on both sides, are widely used to provide cooking surfaces, especially in Japan. These glass ceramic plates are coated on their undersides in a special way, so that the cooking apparatus interior cannot be viewed from above through them. The cooking surfaces on the colorless smooth glass ceramic plates have the advantage that changing the coatings on the undersides of the glass ceramic plates can change their color in a simple manner. Thus the same colorless glass ceramic plate can be made to appear silver, yellow, green, or any other color besides black by means of the underside coating. Because this glass ceramic plate has no knobs on its underside illuminated cooking zone indicators, displays, or residual heat indicators can be directly mounted on the cooking surface underside and are sufficiently visible, in as much as the opaque coating is omitted in these areas.
Noble metal films used as underside coatings are described in Japanese Disclosure Document H7-17409. Furthermore EP 1,267,593 B1 describes an underside coating based on a glass flux and an inorganic pigment, which can be provided with an additional coating based on organic compounds (silicones, polyamides, among others). DE 100 14 373 C2 mentions sol-gel coatings besides noble metal coatings. Sputtered coatings are mentioned in WO 03/098115 A1.
These coatings have several disadvantages as underside coatings for glass ceramic plates that provide cooking surfaces, as shown by the following results described hereinbelow.
The noble films described in JP H7-17409 are not resistant to burned food because of their content of transition metals, e.g. silver. However the resistance of the underside coating to food is necessary for underside coatings in cooking devices with gas burners, since the food can reach the underside of the glass ceramic plate providing the cooking surface through the openings in the glass ceramic plate for the gas burners, which are necessary for operation of the gas burners. The known solutions are not suitable for a gas cooking apparatus.
Since the noble metal films described in JP H7-17409 are lustrous metal films and reflect light, defects or faults in the glass ceramic (e.g. small bubbles, scratches, or crystalline inclusions or stones) are reflected, i.e. doubled, by these noble metal layers and they are thus especially clearly visible. However small defects in the glass ceramic, such as scratches or bubbles, cannot be completely avoided during production of colorless glass ceramic plates that provide cooking surfaces, so that the exclusive coating of colorless glass ceramic plates with a noble metal preparation leads to a high rejection rate and thus to an uneconomical process.
Porous underside coatings made of glass flux and inorganic pigments according to EP 1,267,593 B1 or based on sol-gel methods described in DE 100 14 373 C2 have similarly proven to be unsuitable for use in gas cooking appliances, because food reaching the undersurface of the glass ceramic plate already forms clearly visible flecks without temperature treatment. Likewise no permanent protection could be obtained by using the sealing silicone coating, as proposed in the above-mentioned document, since the silicone coating cannot withstand the higher temperature in the vicinity of the gas burners (about 450 to 550° C.). Also the destruction of the silicone layer leads to a definite color change (a brightening) of the underside coating.
Sputtered coatings according to the WO reference—even when they were sufficient for the chemical resistance and temperature resistance requirements—have the disadvantage that an expensive marking engineering, e.g. according to JP(A) 2004 342 609, is required for forming display windows or other openings for light signals.
SUMMARY OF THE INVENTION
The object of the present invention is to provide a glass ceramic plate, which provides a cooking surface of a cooking apparatus and which has an underside coating formed so that it has the following properties:
a) chemically resistant to food materials and the usual cleaning agents;
b) opaque under the usual lighting conditions in the kitchen;
c) simple to produce the coated areas;
d) resistant to temperatures up to 550° C.; and
e) observable defects in the glass ceramic not perceived as troublesome.
This object and others, which will be made more apparent hereinafter, is attained in a glass ceramic plate forming a cooking surface of a cooking device, which is composed of a glass ceramic material, which is transparent to visible light as well as IR radiation and which has an underside coating in the form of a noble metal film.
According to the invention
the noble metal film is composed of an alloy of gold and/or platinum and/or palladium, which imparts a reflective property to it, the content of the silver, copper, silicon, bismuth and other metals that are not noble metals in the alloy amounts to a maximum of 5% by weight, i.e. 0 to 5% by weight, in relation to the total metal content, and the spectral transmission of the coated glass ceramic plate amounts to less than 12%, i.e. 0 to 12%, in the infrared region of the spectrum.
The coating of the glass ceramic plate that provides the cooking surface with a noble metal coating or film, which has no or only small amounts (5% by weight or less in relation to the total metal content of the film) of silver, copper, silicon, tin, lead, bismuth, iron, cobalt, nickel, or other metals (for example all non-noble metals, also metals with negative standard potential) that are easily oxidizable by combustion of food materials (cooking oil, Soya, etc.) provides special advantages in the gas cooking range area. This sort of coating containing from 90 to <100% by weight, preferably 95 to <100% by weight, gold, platinum and/or palladium, in relation to the total amount of film material in the noble metal film, above all, has an extremely high chemical resistance, so that no discoloration is observable from the topside of the glass ceramic due to burned-on food materials or conventional cleaning materials.
Especially opaque coatings are obtained, when the noble metal preparation has a total noble metal content of from 5 to 50% by weight, especially from 10 to 20% by weight, in relation to the total amount of pigment paste comprising e.g. organometallic compounds, solvent, and resin prior to burning the pigment paste into the glass ceramic and when the coating thickness prior to burning in amounts to from 1 to 10μ, especially from 2 to 5μ. The noble metal preparation can be adjusted with the aid of a solvent and resin for screen printing, above all so that it is thixotropic, so that the structuring of the coating, e.g. with openings for display windows or a peripheral uncoated edge is possible in a technically simple manner. After burning in the paste the coating thickness of the noble metal coating of less than 1μ, preferably from 0.05 to 0.5μ, and especially from 0.1 to 0.2μ, is preferred. The noble metal preparation is burned in at temperatures over 600° C., usually at 780 to 850° C. and especially at a temperature of 830±10° C.
Because of the features according to the invention the spectral transmission of the underside coated glass ceramic plate amounts to from 0 to 4%, preferably from 0 to 1.7%, in the visible range, which correspond to a very high opacity.
The invention also concerns a method for providing the coating on the underside of the glass ceramic plate, which comprises the steps of:
a) preparing at least one noble metal preparation comprising the alloy of gold and/or platinum and/or palladium, which contains from 0 to 5% by weight of the silver, copper, silicon, bismuth, and the other metals that are not noble metals, in relation to a total metal content of the noble metal film;
b) applying the at least one noble metal preparation in at least one layer to a working undersurface of the glass ceramic plate in a layer thickness of from 1 to 10μ, preferably 2 to 5μ; and
c) burning the at least one noble metal preparation applied in step b) into the working undersurface at a burn-in temperature greater than 600° C., preferably from 780 to 850° C.
The noble metal film is permanently thermally stable to temperatures of over 550° C., because of the chemical inertness of the noble metal, the film stabilizers contained in it (e.g. rhodium oxide) and the high melting point of the noble metal (gold, platinum, and palladium melt over 1000° C.).
Glass ceramic materials, which are suitable for the glass ceramic plates of the present invention, for example the colorless glass ceramic plates of the Li 2 O—Al 2 O 3 —SiO 2 type, which are marketed for example by Schott AG and have a thermal expansion coefficient of −10×10 −7 K −1 to +30×10 −7 K −1 in a temperature range of 30 to 500° C., have a chemical composition expressed in terms of % by weight of elemental oxides in the following table I.
TABLE I
SUITABLE GLASS CERAMIC COMPOSITIONS
Elemental Oxide
Oxide Proportions, % by wt
SiO 2
66-70
50-80
Al 2 O 3
>19.8-23
12-30
Li 2 O
3-4
1-6
MgO
0-1.5
0-5
ZnO
1-2.2
0-5
BaO
0-2.5
0-8
Na 2 O
0-1
0-5
K 2 O
0-0.6
0-0.6
TiO 2
2-3
0-8
ZrO 2
0.5-2
0-7
P 2 O 5
0-1
0-7
Sb 2 O 3
Usual amounts
0-4
As 2 O 3
Usual amounts
0-2
CaO
0-0.5
0
SrO
0-1.
0
Source
EP 1 170 264 B,
JP(A) 2004-193050.
Claims 14-15
Since the noble metal coating applied to the underside of the glass ceramic plate reflects each defect, which is located on or in the glass ceramic plate, because of its high reflectivity for visible light, these defects would be clearly distinguishable. Then the smallest defects (e.g. bubbles with less than 0.5 mm diameter) are reproduced by reflection at the reflecting underside coating and because of that are observable by an observer as a defect in the product, which interferes with its uniformity.
The reduction of the conspicuousness of the small glass ceramic faults (with a size under 1 mm), such as bubbles, scratches, fused inclusions, or also pits (small depressions in the glass ceramic) succeeds by covering the top surface of the glass ceramic with a conventional decoration comprising a decorative paint in a special grid. Enamel paints are conventional decorative paint, such as described in EP 0 771 765 B1 or DE 197 21 737 C1. Since enamel paints do not sufficiently cover a colorless glass ceramic plate, but still permit observation of the cooking unit interior, it is not possible to completely cover the glass defects by a decoration on the topside of the glass ceramic. Furthermore the eye of the observer must be diverted sufficiently from the faults or defects by the grid, on which the topside decoration would be applied.
BRIEF DESCRIPTION OF THE DRAWING
The objects, features and advantages of the invention will now be illustrated in more detail with the aid of the following description of the preferred embodiments, with reference to the accompanying figures in which:
FIG. 1 is a diagrammatic top view of a glass ceramic plate with a decoration on its top surface comprising an unsymmetrical grid, which is effective in concealing defects in the glass ceramic plate;
FIG. 2 is a diagrammatic top view of a glass ceramic plate with a decoration on its top surface comprising a symmetrical grid, which is effective in concealing defects in the glass ceramic plate;
FIGS. 3A and 3B are respective diagrammatic top views of glass ceramic plates with corresponding decorations on their top surfaces comprising different symmetrical grids or patterns, which are not effective in concealing defects; and
FIG. 4 is a graphical illustration of the spectral transmission of an example of the glass ceramic plate according to the invention with the at least one noble metal coating on the underside of the glass ceramic plate.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The typically unsymmetrical grid according to FIG. 1 comprises irregularly oriented dashes or lines with dash lengths from 2.0 to 2.5 mm and dash widths of 0.5 mm, and the grid provides a coverage of 17%. This grid imparts a very non-uniform appearance to the cooking surface and is thus suitable for concealing the defects. Thus the occurring defects in the glass ceramic, or also on the underside noble metal layer, are no longer conspicuous, i.e. they do not “jump out” of the surface.
Surprisingly the required irregular appearance for concealing the occurring defects or faults in the colorless glass ceramic with the reflecting underside coating can be imparted also by a regular, i.e. symmetric grid with a comparatively small surface coverage according to FIG. 2 . The noble metal film on the bottom side of the glass ceramic plate reflects the structural elements of the topside decoration, when the topside decoration has a regular grid whose structural elements are separated from each other by at least 2 mm and at most 4 mm, so that they have coverage of 2 to 12%. Because of that grid structure the entire cooking surface has a non-uniform appearance and the defects or faults in the glass ceramic plate are very satisfactorily concealed. The structural elements of the grid can typically be point-shaped or dash-shaped, i.e. points or dashes. The particular grid shown in FIG. 2 comprises points with a point diameter of 0.5 mm with a smallest point spacing of 2.5 mm. The coverage it provides amounts to 3.4%.
The concealing effectiveness of the decoration decreases when the optimum spacing of the structural elements varies from 2.5 mm (for a 4 mm glass ceramic cooking surface) and an optimum surface coverage varies from 3 to 5%, because
a) with larger spacing of the structural elements, i.e. with reduced surface coverage, image and mirror image form an observable unit, so that the desired irregular appearance, which distracts or diverts attention from the defects present, is lost. An observer can clearly and directly view the occurring defects through the open grid, i.e. its structural elements and their mirror images, in a manner similar to the situation with a cooking surface that has a top surface that is not coated or does not have a decoration; and
b) with increasingly smaller spacing of the structural elements of the grid, i.e. with increased surface coverage, the mirror images of the structural elements more ever closer together, with the result that the irregular appearance of the cooking surface is lost and the defects, which should be concealed, are observable through the decoration applied to the top side of the cooking surface.
FIGS. 3A and 3B show two decorations with grids that do not sufficiently conceal the defects of the glass ceramic.
In the case of the glass ceramic plate shown in FIG. 3A the spacing of the structural elements is less than 2 mm and the defects are insufficiently concealed as a result. In the case of the glass ceramic of FIG. 3A the grid has a point diameter of 0.4 mm, the smallest point spacing is 0.82 mm, and the coverage degree is 20%.
In the case of the glass ceramic plate shown in FIG. 3B the coverage is over 12% respectively and the defects are insufficiently concealed. In the case of the glass ceramic of FIG. 3B the grid has a point diameter of 0.5 mm, the smallest point spacing is 1.2 mm, and the coverage degree is 13%.
The topside decoration reduces the reflective action of the lower side coating, which is desirable for aesthetic reasons, besides the concealment of the occurring defects.
Furthermore the color impression of the entire cooking surface can be changed by variation of the color of the topside decoration (e.g. white, grey, brown). Since the decorative paints applied to the top side are not concealing, but are transparent or translucent, the interesting effect that the color change of the cooking surface observed by the observer is associated with the metallic lustrous lower side coating and not with the topside decoration. For example, the cooking surfaces, which are provided with one and the same lustrous silver lower side coating, appear bright silver with white top surface decorations, dark silver with grey top surface decorations and bronze with brown top surface decorations.
The brightness of the bottom side coating can be changed by variation of the coating thickness of the noble metal film. The coatings are darker, when the coating thickness is increased. Thus a first layer, with which the cooking surface is completely covered, can be applied by screen printing when a screen printable noble metal preparation is employed. Then a second layer comprising a firm logo, among other things, can be printed, which is emphasized by the silver first layer so that it appears darker after burn-in.
The above-described noble metal coatings are surprisingly suitable for induction heated cooking plates despite their high electrical conductivity besides the cook top application for gas ranges. The bake-in time amounts to from 9 to 12 min depending on the type of cook top and its water content. Thus it is within the usual time frame. It is comparable with the bake-in times, which are obtained for radiantly heated cook tops made from conventional black glass ceramic, e.g. CERAN HIGHTRANS®.
The underside coating could be scratched by components within the cooking range, which are applied to or mounted from below on the cooking plate, e.g. the mica plate on the induction coil or the metal plate in the vicinity of an electrically heated warming zone, in induction applications in which noble metal preparations are used as underside coatings in cooking ranges. A coating based on silicones, polyamides, or polyimides can be applied to the noble metal film as an effective scratch preventative layer, which does not impair the application properties of the noble metal film.
The above-described opaque noble metal coatings according to the invention are not suitable for the heated area of a radiantly heated cooking surface, since the infrared radiation from the heating element is too strongly reflected from the coating, so that a satisfactory cooking time is not achievable. The spectral transmission of the above-described noble metal film in the infrared (800 nm to 6000 nm) and in the visible wavelength range (350-800 nm) is under 12%, better from 0 to 4%. The above-described noble metal film thus differs from that described in the above-cited JP H7-17409 and has a transmission of 12 to 87% in the infrared range. Generally if the coating according to the invention is omitted from the cooking zone or replaced by another opaque coating, the glass ceramic plate can be also used from a radiantly heated cooking surface. The coating according to the invention can also be omitted from the display regions or in the region of the light indicator device or in the region of other operating elements, such as the touch control unit of the cooking surface in addition to the heated areas.
The following examples illustrate the above-described invention in more detail, but the details in these examples should not be considered as limiting the claims appended hereinbelow.
EXAMPLES
Example 1
Silvery Underside Coating
A colorless glass ceramic plate with a composition according to EP 1,170,264 B1 (Table I, left column) was coated on its topside with a white decorative paint according to DE 197 21 737 C1 and coated and ceramicized to form a regular concealing grid according to FIG. 2 . Subsequently a commercially obtained silver-free noble metal preparation GPP 4510 (HERAEUS, Hanau) was applied to the underside of the ceramicized glass ceramic plate by means of screen printing (sieve width 140-31) and dried for about 3 hours at 20° C. Then the coated glass ceramic was heated at 1 K/min to 830° C. and the coating was burned in for 1 hour at 830° C. After the burn-in the underside of the glass ceramic plate had a silvery coating (see also experiment 1 in Table II).
The noble metal fraction of the paint amounts to 11% by weight (89% by weight burn-in loss). The noble metal film is composed (in % by weight) from 60 to 90% gold, 16 to 24% platinum, 0.5 to 2% rhodium, and 0 to 1% bismuth and chromium.
The finished glass ceramic plate was built into a cook range for gas cooking applications in order to provide a cooking surface.
Soya and oil were applied to the underside coating and burned-in by operation of the cooking range in order to test the resistance to food. Black flecks resulting from the burn-in of oil and Soya sauce arise on the side, which faces away from, and thus is inaccessible to, the operator. However these flecks were not observable from the topside of the glass ceramic cooking surface. The coating was also not damaged, e.g. loosened, among other damaging events. i.e. the coating was sufficiently resistant to food materials.
The opacity was tested, when the built-in cook top was observed both with daylight (D65 L 18 Watt/72-965, 6500 K) and with light of a halogen radiator of a cooking area (Bosch-Siemans Household Appliance, B/S/H). Since the interior structure of the cooking unit could not be observed in both cases, the underside coating is sufficiently opaque. The spectral transmission of the glass ceramic plate with the coating on its underside but without the decoration on the topside is less than 1.5% in the visible wavelength range according to the transmission curve shown in FIG. 4 .
The temperature resistance was tested, when the glass ceramic plate was heated in an oven for 24 hours at 550° C. No color difference was found when the color shade was subsequently compared with a reference. Also the adherence of the coating was sufficient after tempering. It was tested with a “TESA test”, in which a strip of transparent adhesive film was pasted on the underside coating and then torn off of it (TESAFILM® Type 104, Beiersdorf AG). Since no particles of coating could be found on the adhesive strip under normal visual observation without magnification, the coating was judged to be sufficiently thermally stable.
The concealing action of the grid, with which the glass ceramic plate was decorated on its topside, was judged, when defects in the glass ceramic plate were observed in the glass ceramic substrate or in the coating on its underside. The observed defects were not discovered or found to be not troublesome when the glass ceramic substrate was observed from 50 cm distance.
Example 2
Shiny Golden Underside Coating
Another similarly silver-free noble metal preparation (GGP 070505, HERAEUS, Hanau) was used in a manner similar to example 1 to provide a glass ceramic substrate with a shiny or lustrous golden underside coating. The resistance to food materials, the opacity, the temperature resistance (including adherence), and the concealing action of the topside decoration were found to be satisfactory according to the above-described tests.
Example 3
Variation of Underside Color Shades
The silver color shade of the noble metal preparation GPP 4510 described in example 1 could be changed by application of a white paint layer, without impairing the application properties of the underside coating. Moreover the ceramicized glass ceramic plate was first coated with GPP 4510 by means of screen printing (Sieve width 140-31). An additional paint layer of GPP 4510 was printed over the first paint layer and dried after that. After burn-in at 830° C. the color parameters were measured with a spectrophometer (Mercury 2000, Datacolor GmbH). Comparison of the color parameters of the one layer system with the associated two-layer system showed that the color parameters changed slightly. The color parameters are tabulated in Table II.
TABLE II
COLOR PARAMETERS L*, a*, b* FOR DIFFERENT
NOBLE METAL LAYER SYSTEMS
Color difference
Test
Body tested
L*
a*
b*
ΔE
1
Single silver layer
71.0
2.4
11.2
0.7
2
Twofold silver layer
70.4
2.7
11.4
3
Single gold layer
73.9
8.6
33.7
1.6
4
Twofold gold layer
73.9
8.9
35.3
5
1. Silver layer
71.1
7.5
21.7
—
2. Gold layer
6
Colorless substrate
88.9
−1.0
6.2
—
according to Table I,
left column without
coating, with
underlying white layer
White layer alone
96.3
−0.4
2.5
—
The color parameters were measured through the above-described substrate, i.e. from the standpoint of the observer Color measuring apparatus:
Mercury 2000, Datacolor GmbH. Noble metal preparations:
“Silver”: GGP 4510, Heraeus and “Gold”: GGP 070505, Hereus.
Other noble metal preparations can also be selected as the second paint layer. For example a shiny silver noble metal preparation, a shiny platinum preparation, a noble metal preparation that produces a shiny gold layer after burn-in, or a lustrous gold preparation can be applied. A bronze color shade (Table II, experiment 5) can be produced by a combination of both noble metal preparations, e.g. GPP 4510 and GGP 070505.
Coating thickness variations produce color nuance differences in the color shade of the underside coating. A multi-colored underside coating may be produced using different noble metal preparations.
Comparative Example 4
Chemically Not-Resistant Gold Preparation
A commercially obtained silver-containing shiny gold preparation GGP 1213-10% (Heraeus, Hanau) similar to example 1 was printed on the underside of a glass ceramic plate that provides a cooking surface and was burned in the undersurface. This comparative example is for comparison to the chemically resistant shiny gold preparation GGP 070505 (Example 2), which is resistant to food materials.
The noble metal fraction of the paint amounts to 10% by weight (90% by weight burn-in loss). The noble metal coating is composed of 11 to 17% by weight silver, 66 to 88% by weight gold, 0.5 to 2% by weight rhodium and bismuth each, and 0 to 1% by weight silicon.
The finished glass ceramic plate was built into a cook top for gas cooking applications in order to provide a cooking surface.
Soya and oil were applied to the underside coating and burned-in by operation of the cooking range in order to test the resistance to food. Black flecks resulting from the burn-in of oil and Soya sauce arise on the side, which faces away from, and thus is inaccessible to, the operator. These flecks were observable from the side of the glass ceramic cooking surface that faces the user as brownish colored regions. In other words the coating that was not according to the present invention was not sufficiently resistant to food materials.
Example 5
Silicone Paint for Increased Abrasion Resistance
The entire surface on the underside of a glass ceramic plate, which was prepared in the same manner as the plate in example 1, was additionally coated with heat-resistant black silicone paint (GSX, Daishin Paint) by screen-printing (Screen cloth 54-64). The paint was dried for 5 min at 180° C. and subsequently burned in for 30 min at 400° C. The finished glass ceramic plate was built into a cook top (Bosch-Siemans Household Appliance, B/S/H) with induction heating means to provide a cooking surface. The resistance of the underside coating to abrasively acting components (mica plates over induction coils, metal plates of the warming zone) was tested by repeatedly turning on and off all heating areas and the warming zone at maximum power for ten times. An observer subsequently viewing the cooking surface from the topside of the cooking surface could observe no scratches or tears. The underside coating thus was sufficiently abrasion resistant. The properties measured in example 1 were not impaired by the presence of the silicone paint. Furthermore the resistance to damage by food materials was increased still further by the additional silicone layer, since the silicone paint prevents a direct contact of the food material with the noble metal layer and thus acts as a “sacrificial” layer.
The examples of the present invention primarily concern a colorless glass ceramic, i.e. a glass ceramic that is not colored in the melt. However the glass ceramic could also be slightly colored (e.g. brown, rod, or even blue). Thus the underside coating according to the invention provides an opaque colored glass ceramic or an opaque ceramicized glass ceramic, through which one can no longer see.
The disclosure in German Patent Application 10 2005 046 570.6-45 of Oct. 1, 2005 is incorporated here by reference. This German Patent Application describes the invention described hereinabove and claimed in the claims appended hereinbelow and provides the basis for a claim of priority for the instant invention under 35 U.S.C. 119.
While the invention has been illustrated and described as embodied in a glass ceramic plate providing a cooking surface for a cooking apparatus and having a coating on an underside thereof and coating process for making same, it is not intended to be limited to the details shown, since various modifications and changes may be made without departing in any way from the spirit of the present invention.
Without further analysis, the foregoing will so fully reveal the gist of the present invention that others can, by applying current knowledge, readily adapt it for various applications without omitting features that, from the standpoint of prior art, fairly constitute essential characteristics of the generic or specific aspects of this invention.
What is claimed is new and is set forth in the following appended claims.
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The glass ceramic plate for a cooking apparatus is transparent to visible light and IR radiation and has a noble metal film on its underside. The noble metal film is composed of an alloy of gold, platinum and/or palladium, which imparts a reflective property to it. It contains from 0 to 5 percent by weight, in relation to a total metal content, of silver, copper, silicon, bismuth and other metals that are not noble metals. The glass ceramic plate coated with the noble metal film has a spectral transmission of 0 to 12% in the infrared region of the spectrum. When a decoration consisting of a grid of unsymmetrically distributed elements is provided on the topside of the glass ceramic plate, defects in the glass ceramic material can be concealed. The invention also includes a method of coating.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims priority to U.S. Provisional Patent Application Ser. No. 60/889,032, filed Feb. 9, 2007, the details of which are incorporated by reference.
TECHNICAL FIELD
This application relates generally to warewasher systems which are used in commercial applications such as cafeterias and restaurants and, more particularly, to such a warewash system with associated door construction.
BACKGROUND
Commercial warewashers commonly include a housing area which defines the washing and rinsing area for dishes, pots pans and other wares. Liquid is typically pumped from a tank through a pump intake and delivered to lower and/or upper wash arms that direct the liquid onto the wares. In some embodiments, the warewashers may include access doors for gaining access to components of the warewasher. For example, it may be desirable to gain access to the housing area to remove the wash arms from the warewasher to clean them.
SUMMARY
In an aspect, a warewasher for washing wares including a housing defining an internal space with at least one spray zone for washing wares. The housing includes an opening defined in part by a lower shelf. A liquid delivery system provides a spray of liquid within the spray zone. An access door has a vertically hinged connection to the housing to provide an open configuration that allows user access to the spray zone and a closed configuration that inhibits user access to the spray zone. The access door includes a threshold seal member at the bottom of the access door. The threshold seal member includes a lower sealing portion that mates with an upper surface of the shelf to provide a lower seal extending laterally along a width of the access door, and an inner sealing portion that cooperates with an inner edge the shelf to provide an inner seal extending laterally along the width of the access door. The inner seal located nearer the spray zone than the lower seal.
In another aspect, a warewasher for washing wares includes a housing defining an internal space with at least one spray zone for washing wares. The housing includes an opening defined in part by a lower shelf having a groove therein. A liquid delivery system provides a spray of liquid within the spray zone. An access door has a vertically hinged connection to the housing to provide an open configuration that allows user access to the spray zone and a closed configuration that inhibits user access to the spray zone. The vertically hinged connection permits some vertical movement of the access door along its hinge axis. The access door includes a threshold seal member at the bottom of the access door. The threshold seal member includes a downwardly extending rib that locates within the groove to provide a lower seal extending laterally along a width of the access door. During opening of the access door, the rib rides upward along the shelf and out of the groove causing the door to move vertically upward.
In another aspect, a warewasher for washing wares includes a housing defining an internal space with at least one spray zone for washing wares. The housing includes an opening defined in part by a lower shelf having a groove therein. A liquid delivery system provides a spray of liquid within the spray zone. A tank is located beneath the spray zone, the tank including the lower shelf. An access door has a vertically hinged connection to the housing to provide an open configuration that allows user access to the spray zone and a closed configuration that inhibits user access to the spray zone. The vertically hinged connection permits some vertical movement of the access door along its hinge axis. A labyrinth seal assembly extends vertically along a vertically oriented edge of the access door. The labyrinth seal assembly including a channel extending along a height of the access door. The channel is in communication with the spray zone so that liquid entering the channel along a leak path formed between the access door and the labyrinth seal assembly with the access door in its closed configuration drains down into the tank.
The details of one or more embodiments are set forth in the accompanying drawings and the description below. Other features, objects, and advantages will be apparent from the description and drawings, and from the claims.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a diagrammatic side, section view of an embodiment of a warewash system;
FIG. 2 is a partial, perspective view of an embodiment of a warewash section for use with the warewash system of FIG. 1 ;
FIG. 3 is a section, detail view of the warewash section of FIG. 2 with a door in its closed configuration;
FIG. 4 is a partial, front view of the warewash section of FIG. 2 highlighting locations of pivot pins;
FIG. 5 is a section, detail view of the warewash section of FIG. 2 with the door in its open configuration;
FIG. 6 is a detail, section view of the warewash section along line 6 - 6 of FIG. 2 with the door in its closed configuration;
FIG. 7 is a detail, section view of the warewash section along line 6 - 6 of FIG. 2 with the door being opened;
FIG. 8 illustrates the warewash section of FIG. 2 with the door being openable in a reverse direction;
FIG. 8A is a side, detail view of an embodiment of a hinge pin connection arrangement;
FIGS. 9-12 are various views of another embodiment of a warewash section including a double door configuration; and
FIG. 13 is a section, detail view of another threshold seal member embodiment with a door in its closed configuration.
DETAILED DESCRIPTION
Referring to FIG. 1 , an exemplary conveyor-type warewash system, generally designated 10 , is shown. Warewash system 10 can receive racks 12 of soiled wares 14 from an operator side 16 which are moved through tunnel-like chambers from the operator side toward a dryer unit 18 at an opposite end of the warewash system by a suitable conveyor mechanism 20 . Either continuously or intermittently moving conveyor mechanisms or combinations thereof may be used, depending, for example, on the style, model and size of the warewash system 10 . The racks 12 of soiled wares 14 enter the warewash system 10 through a flexible curtain 22 into a pre-wash chamber 24 where sprays of liquid from upper and lower pre-wash manifolds 26 and 28 above and below the racks, respectively, function to flush heavier soil from the wares. The liquid for this purpose comes from a tank 30 via a pump 32 and supply conduit 34 .
The racks proceed next to a curtain 38 into the main wash chamber 40 , where the wares are subject to sprays of cleansing liquid from upper and lower wash manifolds 42 and 44 , respectively, these sprays being supplied through a supply conduit 46 by a pump 48 , which draws from a main tank 50 . A heater 58 , such as an electrical immersion heater provided with suitable thermostatic controls (not shown), maintains the temperature of the cleansing liquid in the tank 50 at a suitable level. Not shown, but which may be included, is a device for adding a cleansing detergent to the liquid in tank 50 . During normal operation, pumps 32 and 48 are continuously driven, usually by separate motors, once the warewash system 10 is started for a period of time.
The warewash system 10 may optionally include a power rinse chamber (not shown) that is substantially identical to main wash chamber 40 . In such an instance, racks of wares proceed from the wash chamber 40 into the power rinse chamber, within which heated rinse water is sprayed onto the wares from upper and lower manifolds.
The racks 12 of wares 14 exit the main wash chamber 40 through a curtain 52 into the final rinse chamber 54 . The final rinse chamber 54 is provided with upper and lower spray heads or arms 56 , 58 that are supplied with a flow of fresh hot water via pipe 60 under the control of solenoid valve 62 . A rack detector 64 is actuated when rack 12 of wares 14 is positioned in the final rinse chamber 54 and through suitable electrical controls, the detector causes actuation of the solenoid valve 62 to open and admit the hot rinse water to the spray heads 56 , 58 . The water then drains from the wares into tank 50 . The rinsed rack 12 of wares 14 then exit the final rinse chamber 54 through curtain 66 , moving into dryer unit 18 . Although not shown in FIG. 1 , any of the various sections of the warewash system 10 may include a side access door that provides access to the respective chamber. The access door can provide for user access to various components within the chamber and will be described in greater detail below.
Referring now to FIG. 2 , warewash system 10 includes warewash section 70 which may, for example, be associated with any of the pre-wash chamber 24 , main wash chamber 40 , final rinse chamber 54 , etc. The warewash section 70 includes a frame 72 and a side access door 74 . Hinge pins 76 and 78 pivotally connect the door 74 to the frame 72 , providing a pivot axis P so that the door is openable relative to the frame between closed (as shown) and opened configurations. A handle 80 is provided on the door 74 that can be grasped and pulled by an operator to open the door.
Referring to FIG. 3 , the door 74 and frame 72 are shown in end view in the closed configuration. Door 74 includes a threshold seal member 82 (e.g., formed of hard rubber, plastic, etc.) that is connected to a bottom 84 of the door. Threshold seal member 82 includes an embossment 85 (e.g., a downward extended rib) that is sized and arranged to mate with a groove or recess 86 that is formed by tank shelf 87 to form an embossment seal and an edge seal member 88 that is sized and arranged to mate with an upper edge 90 of tank shelf 87 to form a tank edge seal. As can be appreciated, the embossment seal forms an outer seal that is spaced furthest away from the tank 92 and the edge seal forms an inner seal that is closest to the tank. The seals inhibit water and steam from escaping the chamber during use. Additionally, the mating between the groove 86 and the embossment 85 acts as a latch that inhibits unintended opening of the door 74 .
Because threshold member 82 mates with the tank shelf 87 , vertical movement of the door 74 in the direction of arrow 96 is desired in order to open the door. Referring to FIG. 4 , hinge pins 76 and 78 and pin receiving openings in the door 74 are sized and positioned to allow for vertical movement of the door so that the embossment seal and tank edge seal can disengage. Referring to FIG. 5 , the embossment 85 and edge seal member 88 rest against surface 98 with the door 74 in the open configuration. When the door 74 is placed back in the closed configuration as shown by FIG. 3 , the door moves down once the embossment 85 is aligned with the groove 86 and the edge seal member 88 is aligned with the upper edge 90 of the tank shelf 87 , forming the inner and outer seals.
Referring now to FIG. 6 , warewash section 70 further includes a labyrinth seal assembly 100 located along the left and right sides of the door. Labyrinth seal assembly 100 includes an elongated channel 102 that is formed by an exterior wall 104 , interior walls 106 and 108 and a lip or flange 107 extending inwardly of the door 74 when the door is in the closed orientation. The channel 102 extends along the height H ( FIG. 2 ) of the door 74 , is in communication with the chamber of the warewash section 70 and includes an opening 110 between the interior wall 108 and the door 74 . In some embodiments, the walls 104 , 106 , 108 are formed using stainless steel, however other materials may be used. A similar labyrinth arrangement could be located at the top of the door.
Arrows 112 illustrate a tortuous steam and water leak path during use. Steam entering the channel 102 along the path condenses therein and drains down into the chamber of the warewash section 70 . Labyrinth seal assembly 100 inhibits the escape of steam and water from the warewash section 70 , which can allow for elimination of temporary rubber/plastic seals that may eventually break down and need replacement. In some embodiments, rubber and/or plastic seals may also be used with the labyrinth seal assembly 100 . Referring to FIG. 7 , the labyrinth seal assembly 100 is sized and arranged so that it does not interfere with opening of the door 74 .
Referring back to FIG. 2 , in some embodiments, pivot axis P may be moved from the configuration illustrated to the configuration illustrated in FIG. 8 . In other words, the configuration of the door 74 may be changed so that it can be opened in a reverse direction. In order to accomplish this, hinge pins 76 and 78 are removable from their locations in FIG. 2 to the locations in FIG. 8 . Door 74 includes a second set of pin receiving openings 112 that are located at an opposite edge of the door from pin receiving openings 114 . Handle 80 may also be made removable so that it can be repositioned at door edge 116 that is furthest from the pivot axis P. Alternatively, the hinge pins may be moved and the orientation of the door changed by simply rotating the door 180 degrees to place the handle at the opposite side, in which case the threshold member could also be moved.
Referring to FIG. 8A , the pin receiving openings 112 , 114 are formed through the door 74 and the frame 72 . A frame opening 89 can be hex-shaped (or another shape) to match the shape of a nut 91 that is fit with in the frame opening. The hex-shape of the frame opening 89 prevents the nut 91 from turning when tightening the hinge pin 76 . This allows for hinge pin adjustment from outside the chamber.
Referring to FIG. 9 , an alternative warewash section 120 includes two doors 74 a and 74 b (shown in their open configurations). Each door 74 a and 74 b may include one, all or any combination of the features described above including the threshold member 82 that mates with the tank shelf 87 , a hinged connection (e.g., using hinge pins 76 and 78 ) that allow for vertical movement of the door and the labyrinth seal 100 .
FIG. 10 illustrates a threshold member arrangement where the threshold members 82 a and 82 b overlap each other when the doors 74 a and 74 b are placed in their closed positions. The threshold members 82 a , 82 b include overlap portions 121 a and 121 b that overlap each other in a side-by-side arrangement, which creates a somewhat tortuous leak path for liquid to pass therebetween.
Referring now to FIG. 11 , in some embodiments, the warewash section 120 includes a steam deflector 122 that inhibits passage of steam and liquid from the warewash section during use and with the doors 74 closed. The steam deflector 122 is arranged and configured to abut the inside surface of the doors 74 with the doors in their closed positions.
Referring also to FIG. 12 , the steam deflector 122 is an L-shaped member (e.g., formed of stainless steel or other suitable material) including a vertical component 124 and a horizontal component 126 . The horizontal component 126 is the part of the steam deflector 122 that abuts the doors when they are closed.
Because the doors 74 include the threshold members 82 with embossment 85 (e.g., a downward extended rib) that is sized and arranged to mate with the groove or recess 86 that is formed by tank shelf 87 and the edge seal member 88 that is sized and arranged to mate with the upper edge 90 of tank shelf 87 ( FIG. 3 ), the steam deflector 122 is made adjustable in order to accommodate the sealing engagements between the threshold members 82 of the doors 74 . In the illustrated embodiment, the steam deflector 122 includes an array of slots 128 that are sized and arranged to receive fasteners for fastening the steam deflector in the position shown. The slots 128 are elongated to allow for forward and rearward adjustment of the threshold member 122 in the direction of arrow 130 ( FIG. 12 ) to ensure that the steam deflector engages the doors 74 with the threshold members 82 properly mated with the tank shelf 87 .
Referring back to FIG. 11 , the steam deflector 122 is illustrated as a single, continuous member. However, as represented by the dotted lines, the steam deflector 122 may include two separate members 122 a and 122 b , where member 122 a is associated with door 74 a and member 122 b is associated with door 74 b . Providing two separate members 122 a and 122 b allows for independent adjustment of the members based on the closed position of the respective doors. Use of the steam deflector 122 can be used to replace a rubber or plastic upper seal, which can wear over time.
It is to be clearly understood that the above description is intended by way of illustration and example only and is not intended to be taken by way of limitation, and that changes and modifications are possible. For example, the above-described door construction may be used in non-conveyor type warewash machines such as box-type machines. Referring to FIG. 13 , an alternative arrangement is shown where threshold seal member 140 includes a groove or recess 142 that is sized and arranged to mate with an embossment 144 (e.g., a rib) that is formed by tank shelf 87 to form an embossment seal. Accordingly, other embodiments are contemplated and modifications and changes could be made without departing from the scope of this application.
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A warewasher for washing wares including a housing defining an internal space with at least one spray zone for washing wares. The housing includes an opening defined in part by a lower shelf. A liquid delivery system provides a spray of liquid within the spray zone. An access door has a vertically hinged connection to the housing to provide an open configuration that allows user access to the spray zone and a closed configuration that inhibits user access to the spray zone. The access door includes a threshold seal member at the bottom of the access door. The threshold seal member includes a lower sealing portion that mates with an upper surface of the shelf to provide a lower seal extending laterally along a width of the access door, and an inner sealing portion that cooperates with an inner edge the shelf to provide an inner seal extending laterally along the width of the access door. The inner seal located nearer the spray zone than the lower seal.
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RELATED APPLICATIONS
[0001] This application is a continuation-in-part of, and claims priority to U.S. application Ser. No. 10/147,445, filed on May 16, 2002. It claims priority to both U.S. application Ser. No. 10/147,445 and U.S. Provisional Application No. 60/368,892, filed on Mar. 29, 2002. The contents of these two applications are incorporated herein by reference.
BACKGROUND
[0002] Angiogenesis, formation of new blood vessels, occurs in the healthy body for healing wounds and restoring blood flow to tissues after injury. The angiogenic process is tightly controlled by various positive and negative regulatory factors. In many disease states, the body loses control over angiogenesis.
[0003] Excessive blood vessel growth may be triggered by certain pathological conditions such as cancer, age-related macular degeneration, rheumatoid arthritis, and psoriasis. As a result of excessive angiogenesis, new blood vessels feed diseased tissues and destroy normal tissues. In cancer, the new vessels allow tumor cells to escape into the circulation and lodge in other organs.
[0004] Angiogenesis occurs via a series of sequential steps, including division and migration of endothelial cells that form the walls of blood vessels. About 15 proteins are known to activate endothelial cell growth and movement. Therefore, angiogenesis can be suppressed by inhibitors of these activating proteins, e.g., angiogenin, epidermal growth factor, estrogen, fibroblast growth factor, interleukin 8, prostaglandins E1 and E2, tumor necrosis factor, vascular endothelial growth factor, or granulocyte colony-stimulating factor.
[0005] Excessive angiogenesis-related disorders include cancer (both solid and hematologic tumors), cardiovascular diseases (e.g., atherosclerosis), chronic inflammation (e.g., rheutatoid arthritis or Crohn's disease), diabetes (e.g., diabetic retinopathy), psoriasis, endometriosis, and adiposity. See, e.g., Pharmacological Reviews 52: 237-268, 2001. Compounds that effectively inhibit angiogenesis are drug candidates for treating or preventing these disorders.
SUMMARY
[0006] This invention is based on a surprising discovery that a number of fused pyrazolyl compounds possess anti-angiogenic effect and inhibit the growth of certain cancer cell lines.
[0007] Thus, this invention features a method for treating cancer including administrating to a subject in need thereof an effective amount of a compound of the formula:
In which A is H or
each of Ar 1 , Ar 2 , and Ar 3 , independently, is phenyl, thienyl, furyl, pyrrolyl, pyridinyl, or pyrimidinyl; each of R 1 , R 2 , R 3 , R 4 , R 5 , and R 6 , independently, is R, nitro, halogen, C(O)OR, C(O)SR, C(O)NRR′, (CH 2 ) m OR, (CH 2 ) m SR, (CH 2 ) m NRR′, (CH 2 ) m CN, (CH 2 ) m C(O)OR, (CH 2 ) m CHO, (CH 2 ) m CH═NOR, (CH 2 ) m C(O)N(OR)R′, N(OR)R′, or R 1 and R 2 together, R 3 and R 4 together, or R 5 and R 6 together are O(CH 2 ) m O, in which each of R and R′, independently, is H or C 1 ˜C 6 alkyl, and m is 0, 1, 2, 3, 4, 5, or 6; and n is 0, 1, 2, or 3. (CH 2 ) m can be branched or linear. Note that the left atom shown in any substituted group described above is closest to the fused pyrazolyl ring. Also note that when there are one or more R or (CH 2 ) m moieties in a fused pyrazolyl compound, the R or the (CH 2 ) m moieties can be the same or different.
[0008] A subset of the above-described compounds are those in which A is
each of R 1 , R 2 , R 3 , R 4 , R 5 , and R 6 , independently, is R, nitro, halogen, C(O)OR, C(O)SR, C(O)NRR′, (CH 2 ) m OR, (CH 2 ) m SR, (CH 2 ) m NRR′, (CH 2 ) m CN, (CH 2 ) m C(O)OR, (CH 2 ) m CHO, (CH 2 ) m CH═NOR, or R 1 and R 2 together, R 3 and R 4 together, or R 5 and R 6 together are O(CH 2 ) m O. In some embodiments, each of Ar 1 , Ar 2 , and Ar 3 is phenyl or furyl and each of R 1 , R 2 , R 5 , and R 6 is H, halo, or C 1 ˜C 6 alkyl, and n is 1.
[0009] Another subset of the above-described compounds are those in which A is
each of R 1 , R 2 , R 3 , R 5 , and R 6 , independently, is R, nitro, halogen, C(O)OR, C(O)SR, C(O)NRR′, (CH 2 ) m OR, (CH 2 ) m SR, (CH 2 ) m NRR′, (CH 2 ) m CN, (O)OR, (CH 2 ) m CHO, (CH 2 ) m CH═NOR, or R 1 and R 2 together, or R 5 and R 6 together are O(CH 2 ) m O; and R 4 is (CH 2 ) m C(O)N(OR)R′ or N(OR)R′. In some embodiments, each of Ar 1 , Ar 2 , and Ar 3 is phenyl or furyl; and each of R 1 , R 2 , R 5 , and R 6 is H, halo, or C 1 ˜C 6 alkyl; and n is 1.
[0010] Still another subset of the above-described compounds are those in which A is H. In some embodiments, each of Ar 1 and Ar 2 is phenyl or furyl; and each of R 1 , R 2 , and R 3 is H, and R 4 is CH 2 (OH) or CO 2 CH 3 .
[0011] Examples of cancer that can be treated by the method described above include leukemia, colorectal cancer, prostate cancer, lung cancer, breast cancer, and renal cancer.
[0012] Shown below are exemplary compounds used in this invention:
[0013] The term “Ar,” as used herein, refers to both aryl and heteroaryl groups. Aryl, e.g., phenyl, is a hydrocarbon ring system having at least one aromatic ring. Heteroaryl is a hydrocarbon ring system having at least one aromatic ring which contains at least one heteroatom such as O, N, or S. Examples of heteroaryl include, but are not limited to, thienyl, furyl, pyrrolyl, pyridinyl, and pyrimidinyl. An “Ar” may contain one, two, three, or more substituents on its ring. In addition to those assigned to R 1 , R 2 , R 3 , R 4 , R 5 , and R 6 (see above), the substituents can also be nitro, C 2 ˜C 6 alkenyl, C 2 ˜C 6 alkynyl, aryl, heteroaryl, cyclyl, or heterocyclyl. Alkyl, alkenyl, alkynyl, alkoxy, aryl, heteroaryl, cyclyl, and heterocyclyl, as used herein, are optionally substituted with C 1 ˜C 6 alkyl, halogen, amino, hydroxyl, mercapto, cyano, or nitro. Note that the term “alkyl” refers to both linear alkyl and branched alkyl.
[0014] The fused pyrazolyl compounds described above include the compounds themselves, as well as their salts and their prodrugs, if applicable. Such salts, for example, can be formed by interaction between a negatively charged substituent (e.g., carboxylate) on a fused pyrazolyl compound and a cation. Suitable cations include, but are not limited to, sodium ion, potassium ion, magnesium ion, calcium ion, and an ammonium cation such as teteramethylammonium ion. Likewise, a positively charged substituent (e.g., amino) can form a salt with a negatively charged counterion. Suitable counterions include, but are not limited to, chloride, bromide, iodide, sulfate, nitrate, phosphate, or acetate. Examples of prodrugs include esters and other pharmaceutically acceptable derivatives, which, upon administration to a subject, are capable of providing the fused pyrazolyl compounds described above.
[0015] Also within the scope of this invention are a composition containing one or more of the fused pyrazolyl compounds described above for use in treating cancer, and the use of such a composition for the manufacture of a medicament for cancer.
[0016] Other features, objects, and advantages of the invention will be apparent from the description and from the claims.
DETAILED DESCRIPTION
[0017] A fused pyrazolyl compound used to practice the method of this invention can be prepared by procedures well known to a skilled person in the art (see, e.g., U.S. Pat. No. 5,574,168). They include the following synthetic route: An aryl aryl ketone is first prepared by coupling an arylcarbonyl chloride with another aryl compound. Either aryl compound is optionally mono- or multi-substituted. The ketone then reacts with an arylalkylhydrazine, the aryl group of which is also optionally mono- or multi-substituted, to form a hydrazone containing three aryl groups. The hydrazone group is transformed into a fused pyrazolyl core via an alkylene linker, another aryl group is fused at 4-C and 5-C of the pyrazolyl core, and the third aryl group is directly connected to 3-C of the pyrazolyl core. Derivatives of the fused pyrazolyl compound may be obtained by modifying the substituents on the aryl groups via known transformations. For example, a methoxylcarbonyl group (—CO 2 Me) is transformed into a hydroxymethyl group (—CH 2 OH) by a suitable reducing agent. As another example, a methoxycarbonyl group is hydrolyzed to a carboxylic acid (—COOH), which is subsequently converted to a more reactive group, acyl halide (—C(O)X). The acyl halide can be reacted with ammonium or hydroxylamine to form an amide group (—C(O)NH 2 ) or a hydroxamic acid group (—C(O)NHOH).
[0018] The chemicals used in the above-described synthetic route may include, for example, solvents, reagents, catalysts, protecting group and deprotecting group reagents. The methods described above may also additionally include steps, either before or after the steps described specifically herein, to add or remove suitable protecting groups in order to ultimately allow synthesis of the fused pyrazolyl compound. In addition, various synthetic steps may be performed in an alternate sequence or order to give the desired compounds. Synthetic chemistry transformations and protecting group methodologies (protection and deprotection) useful in synthesizing applicable fused pyrazolyl compounds are known in the art and include, for example, those described in R. Larock, Comprehensive Organic Transformations , VCH Publishers (1989); T. W. Greene and P. G. M. Wuts, Protective Groups in Organic Synthesis, 2d. Ed., John Wiley and Sons (1991); L. Fieser and M. Fieser, Fieser and Fieser's Reagents for Organic Synthesis , John Wiley and Sons (1994); and L. Paquette, ed., Encyclopedia of Reagents for Organic Synthesis , John Wiley and Sons (1995) and subsequent editions thereof.
[0019] A fused pyrazolyl compound thus synthesized can be further purified by a method such as column chromatography, high pressure liquid chromatography, or recrystallization.
[0020] This invention features a method for treating cancer including administering to a subject in need thereof an effective amount of one or more fused pyrazolyl compounds and a pharmaceutically acceptable carrier. The term “treating” is referred to as application or administration of a composition including one or more fused pyrazolyl compounds to a subject, who has cancer, a symptom of cancer, or a predisposition toward cancer, with the purpose to cure, heal, alleviate, relieve, alter, remedy, ameliorate, improve, or affect the cancer, the symptoms of the cancer, or the predisposition toward the cancer. “An effective amount” is referred to as the amount of a fused pyrazolyl compound which, upon administration to a subject in need thereof, is required to confer therapeutic effect on the subject. Effective amounts may vary, as recognized by those skilled in the art, depending on route of administration, excipient usage, and the possibility of co-usage with other agents.
[0021] As used herein, “cancer” is referred to cellular tumor. Cancer cells having the capacity for autonomous growth, i.e., an abnormal state or condition characterized by rapidly proliferating cell growth. The term is meant to include all types of cancerous growths or oncogenic processes, metastatic tissues or malignantly transformed cells, tissues, or organs, irrespective of histopathologic type, or stage of invasiveness. Examples of cancers include, but are not limited to, carcinoma and sarcoma such as leukemia, sarcomas, osteosarcoma, lymphomas, melanoma, ovarian cancer, skin cancer, testicular cancer, gastric cancer, pancreatic cancer, renal cancer, breast cancer, prostate cancer, colorectal cancer, cancer of head and neck, brain cancer, esophageal cancer, bladder cancer, adrenal cortical cancer, lung cancer, bronchus cancer, endometrial cancer, nasopharyngeal cancer, cervical or hepatic cancer, or cancer of unknown primary site.
[0022] To practice the method of the present invention, a fused pyrazolyl compound can be administered orally, parenterally, by inhalation spray, or via an implanted reservoir. The term “parenteral” as used herein includes subcutaneous, intracutaneous, intravenous, intramuscular, intraarticular, intraarterial, intrasynovial, intrasternal, intrathecal, intralesional and intracranial injection or infusion techniques.
[0023] A composition for oral administration can be any orally acceptable dosage form including, but not limited to, tablets, capsules, emulsions and aqueous suspensions, dispersions and solutions. Commonly used carriers for tablets include lactose and corn starch. Lubricating agents, such as magnesium stearate, are also typically added to tablets. For oral administration in a capsule form, useful diluents include lactose and dried corn starch. When aqueous suspensions or emulsions are administered orally, the active ingredient can be suspended or dissolved in an oily phase combined with emulsifying or suspending agents. If desired, certain sweetening, flavoring, or coloring agents can be added.
[0024] A sterile injectable composition (e.g., aqueous or oleaginous suspension) can be formulated according to techniques known in the art using suitable dispersing or wetting agents (such as, for example, Tween 80 ) and suspending agents. The sterile injectable preparation can also be a sterile injectable solution or suspension in a non-toxic parenterally acceptable diluent or solvent, for example, as a solution in 1,3-butanediol. Among the acceptable vehicles and solvents that can be employed are mannitol, water, Ringer's solution and isotonic sodium chloride solution. In addition, sterile, fixed oils are conventionally employed as a solvent or suspending medium (e.g., synthetic mono- or diglycerides). Fatty acids, such as oleic acid and its glyceride derivatives are useful in the preparation of injectables, as are natural pharmaceutically-acceptable oils, such as olive oil or castor oil, especially in their polyoxyethylated versions. These oil solutions or suspensions can also contain a long-chain alcohol diluent or dispersant, or carboxymethyl cellulose or similar dispersing agents.
[0025] An inhalation composition can be prepared according to techniques well-known in the art of pharmaceutical formulation and can be prepared as solutions in saline, employing benzyl alcohol or other suitable preservatives, absorption promoters to enhance bioavailability, fluorocarbons, and/or other solubilizing or dispersing agents known in the art.
[0026] A carrier in a pharmaceutical composition must be “acceptable” in the sense of being compatible with the active ingredient of the formulation (and preferably, capable of stabilizing it) and not deleterious to the subject to be treated. For example, solubilizing agents, such as cyclodextrins (which form specific, more soluble complexes with fused pyrazolyl compounds), can be utilized as pharmaceutical excipients for delivery of fused pyrazolyl compounds. Examples of other carriers include colloidal silicon dioxide, magnesium stearate, cellulose, sodium lauryl sulfate, and D&C Yellow # 10.
[0027] A suitable in vitro assay can be used to preliminarily evaluate the efficacy of a fused pyrazolyl compound in inhibiting the activities of fibroblast growth factor (FGF) or vascular endothelial growth factor (VEGF). In vivo assays can also be performed by following procedures well known in the art to screen for efficacious fused pyrazolyl compounds. See the specific examples below.
[0028] Similarly, an suitable in vitro assay can be used to preliminarily evaluate the efficacy of a fused pyrazolyl compound in inhibiting the growth of cancer cells. The fused pyrazolyl compound can further be examined for its efficacy in treating cancer by in vivo assays. For example, the compound can be applied to an animal (e.g., a mouse model) having cancer and its therapeutic effects are then accessed. Based on the results, an appropriate dosage range and administration route of the pyrazolyl compound can also be determined.
[0029] Without further elaboration, it is believed that the above description has adequately enabled the present invention. The following specific embodiments are, therefore, to be construed as merely illustrative, and not limitative of the remainder of the disclosure in any way whatsoever. All of the publications, including patents, cited herein are hereby incorporated by reference in their entirety.
Synthesis of 1-benzyl-3-(5′-hydroxymethyl-2′-furyl)indazole (Compound 1)
[0030] Calcium borohydride was first prepared by stirring anhydrous calcium chloride (88.8 mg, 0.8 mmole) with sodium borohydride (60 mg, 1.6 mmole) in anhydrous THF (20 mL) for 4 hrs. Then a 30 mL THF solution containing 88.0 mg 1-benzyl-3-(5′-methoxycarbonyl-2′-furyl)indazole (0.27 mmole) was added dropwise to the calcium borohydride solution at 30±2° C. The mixture was heated under reflux for 6 hrs, cooled, quenched into crushed ice, placed at a reduced pressure to remove THF, and filtered to obtain a solid product. The solid was extracted with dichloromethane. The extract was concentrated to 50 mL and a solid precipitated after petroleum ether was added. The precipitate was collected and purified by column chromatography (silica gel-benzene) to obtain 70.0 mg 1-benzyl-3-(5′-hydroxymethyl-2′-furyl)indazole at a yield of 87%.
[0031] mp: 108-109° C.
[0032] MS (%), m/z: 304 (M + ).
[0033] IR (KBr) v max : 3350 cm −1 (—OH).
[0034] 1 H-NMR (DMSO-d 6 , 200 MHz) δ: 4.51 (2H, d, J=5.5 Hz, —CH 2 O—), 5.31 (1H, t, J=5.5 Hz, —OH), 5.70 (2H, s, ═NCH 2 —), 6.48 (1H, d, J=3.4 Hz, H-4′), 6.97 (1H, d, J=3.4 Hz, H-3′), 7.21-7.31 (6H, m, H-5, phenyl), 7.45 (1H, t, J=8.2 Hz, H-6), 7.75 (1H, dd, J=8.2, 1.8 Hz, H-7), 8.12 (1H. dd, J=8.2, 1.0 Hz, C4-H).
[0000] Inhibition of DNA synthesis
[0035] Human umbilical vein endothelial cells (HUVECs) were incubated in the absence of Compound 1 (basal and control) or presence of Compound 1 (with a concentration of 0.1 μM, 0.03 μM, 0.1 μM, 0.3 μM, or 1 μM). Vascular endothelial growth factor (VEGF) or basic fibroblast growth factor (bFGF) was added (except for basal) to induce DNA synthesis, which was detected based on [ 3 H]thymidine incorporation. The results show that Compound 1 inhibited VEGF- and bFGF-induced cell proliferation of HUVECs in a concentration-dependent manner. Unexpectedly, Compound 1 had IC 50 values of 9.0×10 −8 M and 1.4×10 −7 M, for VEGF and bFGF, respectively.
[0036] Additional 23 fused pyrazolyl compounds were also tested. All of them inhibited VEGF-induced cell proliferation of HUVECs, some as potent as Compound 1.
[0000] Inhibition of Tube Formation
[0037] HUVECs were cultured onto chamberslide, which was pre-coated with Matrigel (10 mg/mL). Cells were treated without Compound 1 (control) or with Compound 1 (10 μM). VEGF (10 ng/mL) or bFGF (10 ng/mL) was added to induce tube formation. All photos were taken at 100× magnification. The results show that Compound 1 inhibited VEGF- and bFGF-induced formation of networks of elongated endothelial cells.
[0000] Inhibition of Angiogenic Effect
[0038] Nude mice were subcutaneously injected with a Matrigel plug containing 150 ng/mL VEGF or bFGF. Vehicle or Compound 1 was administrated to the mice orally (1 mg/kg/day, 3 mg/kg/day, 10 mg/kg/day, 30 mg/kg/day, or 100 mg/kg/day) for seven days. The angiogenic response was monitored visually through the transparent skin. Matrigel itself did not elicit an angiogenic response. After seven days the mice were sacrificed and the Matrigel plugs were observed in situ to quantify the ingrowth of blood vessels. The plugs were removed, fixed in 4% formaldehyde, embedded in paraffin, sectioned at 5-μm thick for histological analysis, and blood vessel growth quantitated by hematoxylin-eosin staining. All photos were taken at 40× magnification. The results show that oral administration of Compound 1 for seven days effectively inhibited VEGF or bFGF-induced angiogenic effect in a dose-dependent manner.
[0039] In a quantitative analysis of angiogenic effect, nude mice were treated as described above, and the plugs were removed and dissolved. Hemoglobin concentrations were measured using a hemoglobin detection kit (Sigrna Chem. Co.) as indices of angiogenesis. The results illustrates that Compound 1 effectively inhibited VEGF or bFGF-induced angiogenic effect.
[0000] Inhibitory Effect on Cancer Growth
[0040] BALB/c-nu mice were subcutaneously injected with A549 lung tumor cells (10 7 cell/mouse). After inoculation for 29 days, each tumor was grown to a size of 30 to 50 mm 3 . The mice were divided into two groups. A number of pyrrazolyl compounds were each dissolved in 0.5% carboxymethyl cellulose to provide sample solutions (1 mg/ml). The solutions were each orally administered to the mice every day (for pyrrazolyl compounds 10 mg/kg/day) from the 29 th day, and the tumor sizes were measured every 3 to 4 days. The mice were euthanatized with intraperitoneal administration of pentobarbital at the 53 rd day. The tumors were removed and weighed.
[0041] The results show that the mice treated with Compounds 1, 12, and 14 had unexpectedly smaller tumors than that treated with the vehicle.
[0042] A number of pyrrazolyl compounds were also tested, following procedures similar to that described above, for their inhibitory effect on the growth of other cancer cells, i.e., NCI-H226 (lung cancer cells), A 498 (renal cancer cells), ACHN (renal cancer cells), UO-31 (renal cancer cells), HA22T (hepatoma cells), HT-29 (colorectal cancer cells), HCT-116 (colorectal cancer cells), PC-3 (prostate cancer cells), MDA-MB-468 (breast cancer cells), and CCRF-CEM (leukemia cells).
[0043] The results show that Compounds 1, 10, 11, 15, and 16 effectively inhibited the growth of NCI-H226 cells, Compounds 1, 3, 5-7, 11, and 13-16 effectively inhibited the growth of A 498 cells, Compound 2 effectively inhibited the growth of ACHN cells, Compounds 1, 2, 4, and 6 effectively inhibited the growth of UO-31 cells, Compound 7 effectively inhibited the growth of HT-29 cells, Compounds 1, 2, and 5 effectively inhibited the growth of HCT-116 cells, and Compounds 1, 4, and 6-8 effectively inhibited the growth of PC-3 cells, Compound 1 effectively inhibited the growth of MDA-MB-468 cells, and Compounds 1, 3, 4, 6, 8, and 9 effectively inhibited the growth of CCRF-CEM cells. Unexpectedly, Compound 1 inhibited growth of A498 cells, NCI-H226 cells, and MCF-7 cells more effectively than HA22T cells.
OTHER EMBODIMENTS
[0044] All of the features disclosed in this specification may be combined in any combination. Each feature disclosed in this specification may be replaced by an alternative feature serving the same, equivalent, or similar purpose. Thus, unless expressly stated otherwise, each feature disclosed is only an example of a generic series of equivalent or similar features.
[0045] From the above description, one skilled in the art can easily ascertain the essential characteristics of the present invention, and without departing from the spirit and scope thereof, can make various changes and modifications of the invention to adapt it to various usages and conditions. For example, a compound structurally analogous to a fused pyrazolyl compound can also be used to practice the present invention. Thus, other embodiments are also within the claims.
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This invention relates to a method for treating cancer including administrating to a subject in need thereof an effective amount of a compound of the formula:
wherein, A is H or
each of Ar 1 , Ar 2 , and Ar 3 , independently, is phenyl, thienyl, furyl, pyrrolyl, pyridinyl, or pyrimidinyl; each of R 1 , R 2 , R 3 , R 4 , R 5 , and R 6 , independently, is R, nitro, halogen, C(O)OR, C(O)SR, C(O)NRR′, (CH 2 ) m OR, (CH 2 ) m SR, (CH 2 ) m NRR′, (CH 2 ) m CN, (CH 2 ) m C(O)OR, (CH 2 ) m CHO, (CH 2 ) m CH═NOR, (CH 2 ) m C(O)N(OR)R′, N(OR)R′, or R 1 and R 2 together, R 3 and R 4 together, or R 5 and R 6 together are O(CH 2 ) m O, in which each of R and R′, independently, is H or C 1 ˜C 6 alkyl; and m is 0, 1, 2, 3, 4, 5, or 6, and n is 0, 1, 2, or 3.
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[0001] The present disclosure is directed to medical instruments and, more specifically, to an applier that may be used to apply a left atrial appendage occlusion clip.
[0002] It is a first aspect of the present invention to provide a medical instrument comprising: (a) a first joint comprising a first member and a second member, the first member configured to be repositionable with respect to the second member in a first degree of freedom; (b) a second joint operatively coupled to the first joint, the second joint comprising a third member and a fourth member, the third member configured to be repositionable with respect to the fourth member in a second degree of freedom; (c) a pair of repositionable jaws operatively coupled to the first joint and the second joint; (d) an occlusion clip detachably mounted to the pair of repositionable jaws; and, (e) a controller operatively coupled to the first joint, the second joint, and the pair of repositionable jaws, the controller including a first control configured to direct repositioning of at least one of the first member and the second member, and a second control configured to direct repositioning of at least one of the third member and the fourth member, and a third control configured to direct repositioning of the pair of repositionable jaws.
[0003] In a more detailed embodiment of the first aspect, the first control comprises a first active control configured to be repositionable among an infinite number of positions, where each of the infinite number of positions orients the first member with respect to the second member within the first degree of freedom, and the second control comprises a second active control configured to be repositionable among an infinite number of positions, where each of the infinite number of positions orients the third member with respect to the fourth member within the second degree of freedom. In yet another more detailed embodiment, the first active control includes a first wheel around which is partially wound a first wire operatively coupled to at least one of the first member and the second member so that rotation of the first wheel translates into movement of at least one of the first member and the second member, and the second active control includes a second wheel around which is partially wound a second wire operatively coupled to at least one of the third member and the fourth member so that rotation of the second wheel translates into movement of at least one of the third member and the fourth member. In a further detailed embodiment, the medical instrument further includes a repositionable lock in selective communication with at least one of the first control and the second control to retard movement in at least one of the first degree of freedom and the second degree of freedom. In still a further detailed embodiment, the repositionable lock is in selective communication with both the first control and the second control to retard movement of the first joint in the first degree of freedom and the second joint in the second degree of freedom. In a more detailed embodiment, the first control includes a plurality of first teeth, the second control includes a plurality of second teeth, and the repositionable lock includes a catch that concurrently engages at least one of the plurality of first teeth and at least one of the plurality of second teeth. In a more detailed embodiment, the controller is operatively coupled to a hand-held housing, and the repositionable lock is repositionably mounted to the hand-held housing. In another more detailed embodiment, the first control is operatively coupled to a hand-held housing and includes at least one of a pivoting, a sliding, and a rotating first projection extending from the hand-held housing, the second control is operatively coupled to the hand-held housing and includes at least one of a pivoting, a sliding, and a rotating second projection extending from the hand-held housing, and the repositionable lock is operatively coupled to the hand-held housing and includes at least one of a pivoting, a sliding, and a rotating third projection extending from the hand-held housing. In yet another more detailed embodiment, the first control includes a rotating first projection that comprises a first wheel, the second control includes a rotating second projection that comprises a second wheel, the repositionable lock includes a sliding third projection. In still another more detailed embodiment, the medical instrument further includes a longitudinal conduit extending between the controller and the first joint.
[0004] In yet another more detailed embodiment of the first aspect, the first member comprises a clevis, and the second member comprises a universal. In yet another more detailed embodiment, the universal includes at least one of a first cavity and a first projection, as well as at least one of a second cavity and a second projection, the clevis includes the other of at least one of the first cavity and the first projection, as well as the other of the second cavity and the second projection, the first projection is configured to be repositionable within the first cavity, and the second projection is configured to be repositionable within the second cavity, in order to allow repositioning of the clevis with respect to the universal within the first degree of freedom. In a further detailed embodiment, the third member comprises the universal, and the fourth member comprises a linkage housing. In still a further detailed embodiment, the universal includes at least one of a third cavity and a third projection, as well as at least one of a fourth cavity and a fourth projection, the linkage housing includes the other of at least one of the first cavity and the first projection, as well as the other of the second cavity and the second projection, the third projection is configured to be repositionable within the second cavity, and the fourth projection is configured to be repositionable within the third cavity, in order to allow repositioning of the universal with respect to the linkage housing within the second degree of freedom. In a more detailed embodiment, the medical instrument further includes a first connection extending along the longitudinal conduit connecting the first control to at least one of the first member and the second member, and a second connection extending along the longitudinal conduit connecting the second control to at least one of the third member and the fourth member. In a more detailed embodiment, the medical instrument further includes a third connection extending along the longitudinal conduit connecting the first control to at least one of the first member and the second member, and a fourth connection extending along the longitudinal conduit connecting the second control to at least one of the third member and the fourth member. In another more detailed embodiment, the first connection, the second connection, the third connection, and the fourth connection each comprise a wire. In yet another more detailed embodiment, the controller further includes a fourth control configured to detachably mount the occlusion clip to the pair of repositionable jaws. In still another more detailed embodiment, the fourth control includes a wire concurrently mounted to the occlusion clip and the pair of repositionable jaws.
[0005] In a more detailed embodiment of the first aspect, the wire comprises at least a first wire and a second wire, the first wire is concurrently mounted to the occlusion clip and a first of the pair of repositionable jaws, the second wire is concurrently mounted to the occlusion clip and a second of the pair of repositionable jaws, the fourth control is repositionable to selectively dismount the first wire from at least one of the occlusion clip and the first of the pair of repositionable jaws, and is repositionable to selectively dismount the second from at least one of the occlusion clip and the second of the pair of repositionable jaws. In yet another more detailed embodiment, the fourth control includes a tab mounted to the first wire and the second wire, and the tab is selectively detachable from a hand-held housing. In a further detailed embodiment, the tab is rotationally repositionable with respect to the hand-held housing. In still a further detailed embodiment, the medical instrument further includes a first connection extending along the longitudinal conduit and operatively coupling the third control to the pair of repositionable jaws. In a more detailed embodiment, the medical instrument further includes a folding support that is concurrently mounted to the pair of repositionable jaws and the fourth member of the second joint, the folding support repositionable between a folded position and an unfolded position, where the folded position has the pair of repositionable jaws in closer proximity to one another than in the unfolded position. In a more detailed embodiment, the folding support is operatively coupled to a pulley and the first link. In another more detailed embodiment, the folding support includes: (a) a first link concurrently repositionably and operatively coupled to a first of the pair of repositionable jaws; (b) a second link concurrently repositionably and operatively coupled to a second of the pair of repositionable jaws; (c) a third link concurrently repositionably and operatively coupled to the first of the pair of repositionable jaws and the second link; and, (d) a fourth link concurrently repositionably and operatively coupled to the second of the pair of repositionable jaws and the first link, where the third link is repositionably and operatively coupled to the fourth link.
[0006] In a more detailed embodiment of the first aspect, the folding support includes a fifth link concurrently repositionably and operatively coupled to a sixth link and to the first link, wherein the sixth link is concurrently repositionably and operatively coupled to the fifth link and to the second link. In yet another more detailed embodiment, the fifth and sixth links are both mounted to and repositionable with respect to a pulley. In a further detailed embodiment, the second joint includes a first camming surface to facilitate repositioning of the fifth link, and the second joint includes a second camming surface to facilitate repositioning of the sixth link. In still a further detailed embodiment, the first connection is operatively coupled to the fifth and sixth links In a more detailed embodiment, the first connection includes a pulley operatively coupled to the fifth and sixth links. In a more detailed embodiment, the third control comprises a repositionable handle operatively coupled to a hand-held housing of the controller. In another more detailed embodiment, the third control includes a slide arm concurrently mounted to the repositionable handle and the first connection. In yet another more detailed embodiment, the third control includes a spring to bias at least one of the slide arm and the handle, and the third control includes a trigger to selectively unlock the orientation of the handle with respect to the slide arm. In still another more detailed embodiment, the first wire comprises a first pair of wires partially wound around the first wheel, where the first pair of wires is mounted to the second member, and the second wire comprises a second pair of wires partially wound around the second wheel, where the second pair of wires is mounted to the third member.
[0007] In yet another more detailed embodiment of the first aspect, the first wheel around which the first pair of wires are partially wound around has a first diameter, the second wheel around which the second pair of wires are partially wound around has a second diameter, where the first diameter is larger than the second diameter. In yet another more detailed embodiment, the folding support comprises a folding pantograph support.
[0008] It is a second aspect of the present invention to provide a method of controlling an end effector of a medical instrument, the medical instrument including a hand-held device operatively coupled to the end effector, comprising: (a) providing a first control of the hand-held device configured to direct repositioning of at least one of a first member and a second member of a first joint of the end effector, the first member and second member being repositionable with respect to one another in a first degree of freedom; (b) providing a second control of the hand-held device configured to direct repositioning of at least one of a third member and a fourth member of a second joint of the end effector, the third member and fourth member being repositionable with respect to one another in a second degree of freedom different from the first degree of freedom; and, (c) providing a third control of the hand-held device configured to direct repositioning of a folding support between a compact position and an expanded position, the folding support connecting the first and second joints.
[0009] In a more detailed embodiment of the second aspect, the method further includes providing a fourth control of the hand-held device configured to selectively disengage an occlusion clip operatively coupled to the folding support. In yet another more detailed embodiment, the first control includes a first wheel having a first wire partially wound therearound, where the first wire is also operatively coupled to at least one of the first member and the second member of the first joint of the end effector, and the second control includes a second wheel having a second wire partially wound therearound, where the second wire is also operatively coupled to at least one of the third member and the fourth member of the second joint of the end effector. In a further detailed embodiment, the third control includes a repositionable handle operatively coupled to the hand-held device, the repositionable handle operatively coupled to a wire that is operatively coupled to the folding support to allow repositioning of the folding support between the compact position and the expanded position.
[0010] It is a third aspect of the present invention to provide a medical instrument end effector comprising: (a) a first joint comprising a first member and a second member, the first member configured to be repositionable with respect to the second member in a first degree of freedom; (b) a second joint operatively coupled to the first joint, the second joint comprising a third member and a fourth member, the third member configured to be repositionable with respect to the fourth member in a second degree of freedom; and, (c) a pair of repositionable jaws operatively coupled to the first joint and the second joint by a folding support.
[0011] In a more detailed embodiment of the third aspect, the end effector further includes an occlusion clip detachably mounted to the pair of repositionable jaws. In yet another more detailed embodiment, the end effector further includes a controller including a first control configured to direct repositioning of the first joint, a second control configured to direct repositioning of the second joint, and a third control configured to direct repositioning of the pair of repositionable jaws, and a longitudinal conduit extending between the controller and the first joint. In a further detailed embodiment, the first member comprises a clevis, and the second member comprises a universal. In still a further detailed embodiment, the universal includes at least one of a first cavity and a first projection, as well as at least one of a second cavity and a second projection, the clevis includes the other of at least one of the first cavity and the first projection, as well as the other of the second cavity and the second projection, and the first projection is configured to be repositionable within the first cavity, and the second projection is configured to be repositionable within the second cavity, in order to allow repositioning of the clevis with respect to the universal within the first degree of freedom. In a more detailed embodiment, the third member comprises the universal, and the fourth member comprises a linkage housing. In a more detailed embodiment, the universal includes at least one of a third cavity and a third projection, as well as at least one of a fourth cavity and a fourth projection, the linkage housing includes the other of at least one of the first cavity and the first projection, as well as the other of the second cavity and the second projection, the third projection is configured to be repositionable within the second cavity, and the fourth projection is configured to be repositionable within the fourth cavity, in order to allow repositioning of the universal with respect to the linkage housing within the second degree of freedom. In another more detailed embodiment, a wire concurrently mounts the occlusion clip to the pair of repositionable jaws. In yet another more detailed embodiment, the folding support is concurrently mounted to the pair of repositionable jaws and the fourth member of the second joint, the folding support repositionable between a folded position and an unfolded position, where the folded position has the pair of repositionable jaws in closer proximity to one another than in the unfolded position. In still another more detailed embodiment, the folding support is operatively coupled to a pulley and the first link.
[0012] In yet another more detailed embodiment of the third aspect, the folding support includes: (a) a first link concurrently repositionably and operatively coupled to a first of the pair of repositionable jaws; (b) a second link concurrently repositionably and operatively coupled to a second of the pair of repositionable jaws; (c) a third link concurrently repositionably and operatively coupled to the first of the pair of repositionable jaws and the second link; and, (d) a fourth link concurrently repositionably and operatively coupled to the second of the pair of repositionable jaws and the first link, where the third link is repositionably and operatively coupled to the fourth link. In yet another more detailed embodiment, the folding support includes a fifth link concurrently repositionably and operatively coupled to a sixth link and to the first link, wherein the sixth link is concurrently repositionably and operatively coupled to the fifth link and to the second link. In a further detailed embodiment, the fifth and sixth links are both mounted to and repositionable with respect to a pulley. In still a further detailed embodiment, the second joint includes a first camming surface to facilitate repositioning of the fifth link, and the second joint includes a second camming surface to facilitate repositioning of the sixth link. In a more detailed embodiment, a first connection is operatively coupled to the fifth and sixth links. In a more detailed embodiment, the first connection includes a pulley operatively coupled to the fifth and sixth links. In another more detailed embodiment, the folding support comprises a folding pantograph support.
[0013] It is a fourth aspect of the present invention to provide a method of deploying an occlusion clip comprising: (a) inserting an occlusion clip removably mounted to an end effector deployment device having repositionable jaws through at least one of an incision and a trocar, the occlusion clip and the end effector deployment device mounted to one another when inserted into and through at least one of the incision and the trocar; (b) repositioning the end effector deployment device to reposition the occlusion clip so the occlusion clip is interposed by a portion of a left atrial appendage interposing a base and a tip of the left atrial appendage by passing the tip of the left atrial appendage between opposing clamping surfaces of the occlusion clip and; (c) clamping the left atrial appendage with the occlusion clip to occlude the left atrial appendage without piercing the left atrial appendage between the occlusion clip; (d) disengaging the occlusion clip from the end effector deployment device; and, (e) withdrawing the end effector deployment device through at least one of the incision and the trocar.
[0014] In a more detailed embodiment of the fourth aspect, the inserting step occurs during at least one of an open sternotomy, a left thoracotomy, a right thoracotomy, a left port procedure, a right port procedure, a subxiphoid approach, and a transdiaphragmatic approach. In yet another more detailed embodiment, the method further includes insufflating a thoracic space prior to the inserting step. In a further detailed embodiment, the method further includes making an incision as part of a procedure comprising at least one of an open sternotomy, a left thoracotomy, a right thoracotomy, a left port procedure, a right port procedure, a subxiphoid approach, and a transdiaphragmatic approach, and introducing a trocar through the incision. In still a further detailed embodiment, the end effector deployment device is mounted to a longitudinal conduit, which is mounted to a hand-held device, and repositioning the end effector deployment device step includes actuating at least one of a first control and a second control associated with the hand-held device to actively reposition the end effector within at least one of an X-Y plane and a Y-Z plane with respect to the hand-held device. In a more detailed embodiment, the end effector deployment device is mounted to a longitudinal conduit, which is mounted to a hand-held device, the method further comprising repositioning the occlusion clip from a compressed position to an expanded position prior to interposing a portion of the left atrial appendage between the opposing clamping surfaces. In a more detailed embodiment, the method further includes actuating a handle associated with the hand-held device to direct repositioning of the occlusion clip between the compressed position and the expanded position. In another more detailed embodiment, actuating the handle causes a pair of jaws associated with the end effector to reposition with respect to one another, and the pair of jaws is mounted to the occlusion clip. In yet another more detailed embodiment, the end effector deployment device is mounted to a longitudinal conduit, which is mounted to a hand-held device, the method further comprising rotationally repositioning the occlusion clip with respect to the left atrial appendage by rotating the hand-held device. In still another more detailed embodiment, the method further includes grasping the left atrial appendage concurrent with repositioning the end effector deployment device to reposition the occlusion clip so the open end of the occlusion clip is interposed by the portion of the left atrial appendage.
[0015] In yet another more detailed embodiment of the fourth aspect, the method further includes repeating the repositioning and clamping steps prior to the disengaging step. In yet another more detailed embodiment, the method further includes confirming a clamping position of the occlusion clip is operative to occlude the left atrial appendage using at least one of visualization and a transesophageal echocardiogram. In a further detailed embodiment, the end effector deployment device is mounted to a longitudinal conduit, which is mounted to a hand-held device, and disengaging the occlusion clip from the end effector deployment device includes actuating a control associated with the hand-held device. In still a further detailed embodiment, the control comprises a repositionable tab operatively coupled to a wire, which is operatively coupled the end effector and the occlusion clip, and removing the repositionable tab from the hand-held device repositions the wire with respect to at least one loop encompassing at least one of the occlusion clip and the end effector deployment device in order to disengage the occlusion clip from the end effector deployment device. In a more detailed embodiment, the inserting step includes inserting the occlusion clip and the end effector deployment device through the trocar, the withdrawing step includes withdrawing the end effector deployment device through the trocar, and the trocar comprises a twelve millimeter or less diameter orifice. In a more detailed embodiment, the end effector deployment device is mounted to a longitudinal conduit, which is mounted to a hand-held device, and the step of repositioning the end effector deployment device to reposition the occlusion clip includes locking a position of the end effect deployment device in at least one of an X-Y plane and a Y-Z plane with respect to the hand-held device.
[0016] It is a fifth aspect of the present invention to provide a method of deploying an occlusion clip comprising: (a) inserting an occlusion clip removably mounted to an end effector deployment device having repositionable jaws through at least one of an incision and a trocar, the occlusion clip and the end effector deployment device mounted to one another when inserted into and through the trocar; (b) repositioning the end effector deployment device to reposition the occlusion clip so the occlusion clip is interposed by a portion of a left atrial appendage interposing a base and a tip of the left atrial appendage by passing the tip of the left atrial appendage between opposing clamping surfaces of the occlusion clip; (c) clamping the left atrial appendage with the occlusion clip in an initial position without piercing the left atrial appendage between the occlusion clip; (d) assessing the operability of the occlusion clip in the initial position to occlude the left atrial appendage; and, (e) repositioning the end effector deployment device to reposition the occlusion clip to a subsequent position, different from the initial position, to clamp the left atrial appendage, where repositioning the occlusion clip from the initial position to the subsequent position is repeatable without affecting the structural integrity of the left atrial appendage.
[0017] It is an sixth aspect of the present invention to provide a method of deploying an occlusion clip comprising: (a) inserting an occlusion clip removably mounted to an end effector deployment device, having repositionable jaws, through at least one of an incision and a trocar, the occlusion clip biased to a clamping position; (b) repositioning the end effector deployment device to counteract a bias of the occlusion clip and reposition the occlusion clip to a tissue insertion position where the full bias of the occlusion clip is not applied to a left atrial appendage tissue; (c) repositioning the end effector deployment device to reposition the occlusion clip in the tissue insertion position so a portion of a left atrial appendage between a base and a tip of the left atrial appendage interposes the occlusion clip by having the tip of the left atrial appendage pass between opposing beams of the occlusion clip; (d) repositioning the occlusion clip to apply the full bias to the left atrial appendage; and, (e) removing the end effector deployment device from around the left atrial appendage without passing the tip of the left atrial appendage between the repositionable jaws.
[0018] In a more detailed embodiment of the sixth aspect, the method further includes disengaging the occlusion clip from the end effector deployment device, and withdrawing the end effector deployment device through at least one of the incision and the trocar. In yet another more detailed embodiment, the inserting step occurs during at least one of an open sternotomy, a left thoracotomy, a right thoracotomy, a left port procedure, a right port procedure, a subxiphoid approach, and a transdiaphragmatic approach. In a further detailed embodiment, the method includes insufflating a thoracic space prior to the inserting step. In still a further detailed embodiment, the method further includes making an incision as part of a procedure comprising at least one of an open sternotomy, a left thoracotomy, a right thoracotomy, a left port procedure, a right port procedure, a subxiphoid approach, and a transdiaphragmatic approach, and introducing a trocar through the incision. In a more detailed embodiment, the end effector deployment device is mounted to a longitudinal conduit, which is mounted to a hand-held device, and repositioning the end effector deployment device step includes actuating at least one of a first control and a second control associated with the hand-held device to actively reposition the end effector within at least one of an X-Y plane and a Y-Z plane with respect to the hand-held device. In a more detailed embodiment, the end effector deployment device is mounted to a longitudinal conduit, which is mounted to a hand-held device, the method further comprising repositioning the occlusion clip from a compressed position to an expanded position prior to interposing a portion of the left atrial appendage between the opposing clamping surfaces. In another more detailed embodiment, the method further includes actuating a handle associated with the hand-held device to direct repositioning of the occlusion clip between the compressed position and the expanded position. In yet another more detailed embodiment, actuating the handle causes a pair of jaws associated with the end effector to reposition with respect to one another, and the pair of jaws is mounted to the occlusion clip. In still another more detailed embodiment, the end effector deployment device is mounted to a longitudinal conduit, which is mounted to a hand-held device, the method further comprising rotationally repositioning the occlusion clip with respect to the left atrial appendage by rotating the hand-held device.
[0019] In yet another more detailed embodiment of the sixth aspect, the method further includes grasping the left atrial appendage concurrent with repositioning the end effector deployment device to reposition the occlusion clip so the open end of the occlusion clip is interposed by the portion of the left atrial appendage. In yet another more detailed embodiment, the method further includes confirming application of the full bias of the occlusion clip is operative to occlude the left atrial appendage using at least one of visualization and a transesophageal echocardiogram. In a further detailed embodiment, the method further includes disengaging the occlusion clip from the end effector deployment device, where the end effector deployment device is mounted to a longitudinal conduit, which is mounted to a hand-held device, and disengaging the occlusion clip from the end effector deployment device includes actuating a control associated with the hand-held device. In still a further detailed embodiment, the control comprises a repositionable tab operatively coupled to a wire, which is operatively coupled to the end effector and the occlusion clip, and removing the repositionable tab from the hand-held device repositions the wire with respect to at least one loop encompassing at least one of the occlusion clip and the end effector deployment device in order to disengage the occlusion clip from the end effector deployment device. In a more detailed embodiment, the inserting step includes inserting the occlusion clip and the end effector deployment device through the trocar, and the trocar comprises a twelve millimeter or less diameter orifice. In a more detailed embodiment, the end effector deployment device is mounted to a longitudinal conduit, which is mounted to a hand-held device, and the step of repositioning the end effector deployment device to reposition the occlusion clip includes locking a position of the end effect deployment device in at least one of an X-Y plane and a Y-Z plane with respect to the hand-held device.
[0020] It is a seventh aspect of the present invention to provide a method of facilitating repositioning of an end effector and an occlusion clip mounted thereto, the method comprising: (a) providing an occlusion clip removably mounted to an end effector; (b) providing a first attachment operatively coupled to the end effector and the occlusion clip, the first attachment operatively coupled to a first user control configured to selectively disengage the end effector from the occlusion clip; (c) providing a first joint as part of the end effector to allow repositioning of a first portion of the end effector with respect to a second portion of the end effector, the first portion mounted to the occlusion clip, while the second portion is operatively coupled to the occlusion clip via the first portion.
[0021] In a more detailed embodiment of the seventh aspect, the first attachment comprises loop and a wire, the loop at least partially circumscribing the occlusion clip and the wire when the occlusion clip is mounted to the end effector and no longer circumscribing the wire when the occlusion clip is removed from the end effector. In yet another more detailed embodiment, the method further includes providing a second joint as part of the end effector to allow repositioning of the second portion of the end effector with respect to a third portion of the end effector, the first joint allowing motion between the first portion and the second portion in a first degree of freedom, the second joint allowing motion between the second portion and the third portion in a second degree of freedom, different from the first degree of freedom. In a further detailed embodiment, the method further includes providing a second user control to direct repositioning of the first portion with respect to the second portion, providing a third user control to direct repositioning of the second portion with respect to the third portion, where the second user control and the third user control comprise a handheld control. In still a further detailed embodiment, the method further includes providing a second user control to direct repositioning of the first portion with respect to the second portion, wherein the first user control and the second user control comprise a handheld control. In a more detailed embodiment, the method further includes providing a second joint as part of the end effector to allow repositioning of the second portion of the end effector with respect to a third portion of the end effector, the first joint allowing motion between the first portion and the second portion in a first degree of freedom, the second joint allowing motion between the second portion and the third portion in a second degree of freedom, different from the first degree of freedom.
[0022] In yet another more detailed embodiment of the seventh aspect, the method further includes providing a third user control to direct repositioning of the second portion with respect to the third portion, wherein the third user control comprises a portion of the handheld control. In yet another more detailed embodiment, the method further includes providing parallel opening jaws that are removably mounted to the occlusion clip and comprise a portion of the end effector. In a further detailed embodiment, the parallel opening jaws comprise a first jaw and a second jaw, the first jaw is pivotally mounted to a first drive link and a first parallel link, the second jaw is pivotally mounted to a second drive link and a second parallel link, and at least two of the first drive link, the second drive link, the first parallel link, and the second parallel link are pivotally mounted to a pulley.
BRIEF DESCRIPTION OF THE DRAWINGS
[0023] FIG. 1 is an elevated perspective view of an exemplary surgical tool in accordance with the instant disclosure.
[0024] FIG. 2 is an elevated perspective view of the end effector of FIG. 1 , shown in the expanded position after having deployed an occlusion clip.
[0025] FIG. 3 is an exploded view of the end effector of FIG. 2 .
[0026] FIG. 4 is an elevated perspective view from a distal end of an exemplary clevis in accordance with the instant disclosure.
[0027] FIG. 5 is an elevated perspective view from a proximal end of the exemplary clevis of FIG. 4 .
[0028] FIG. 6 is a cross-sectional view of the exemplary clevis of FIG. 5 taken along line 6 - 6 .
[0029] FIG. 7 is a cross-sectional view of the exemplary clevis of FIG. 4 taken along line 7 - 7 .
[0030] FIG. 8 is an elevated perspective view from a distal end of an exemplary universal in accordance with the instant disclosure.
[0031] FIG. 9 is a profile view of the exemplary universal of FIG. 8 .
[0032] FIG. 10 is a cross-sectional view of the exemplary universal of FIG. 8 taken along line 10 - 10 .
[0033] FIG. 11 is a cross-sectional view of the exemplary clevis of FIG. 9 taken along line 11 - 11 .
[0034] FIG. 12 is an elevated perspective view from a distal end of an exemplary linkage housing in accordance with the instant disclosure.
[0035] FIG. 13 is a distal end view of the exemplary linkage housing of FIG. 12 .
[0036] FIG. 14 is a profile view of the exemplary linkage housing of FIG. 12 .
[0037] FIG. 15 is a cross-sectional view of the exemplary linkage housing of FIG. 14 taken along line 15 - 15 .
[0038] FIG. 16 is an elevated perspective view from a proximal end of an exemplary drive link in accordance with the instant disclosure.
[0039] FIG. 17 is an elevated perspective view from a distal end of the exemplary drive link of FIG. 16 .
[0040] FIG. 18 is a profile view of the exemplary drive link of FIG. 16 .
[0041] FIG. 19 is an elevated perspective view from a distal end of a first jaw in accordance with the instant invention.
[0042] FIG. 20 is profile view of a second jaw in accordance with the instant invention.
[0043] FIG. 21 is an elevated perspective view from a proximal end of an exemplary parallel link in accordance with the instant disclosure.
[0044] FIG. 22 is an elevated perspective view from a side of the exemplary parallel link of FIG. 21 .
[0045] FIG. 23 is a bottom view of the exemplary parallel link of FIG. 21 .
[0046] FIG. 24 is an elevated perspective view from a side showing the exemplary parallel links aligned with one another in a compact position.
[0047] FIG. 25 is an elevated perspective view from a distal end of an exemplary toggle in accordance with the instant disclosure.
[0048] FIG. 26 is an elevated perspective view from a bottom of the exemplary toggle of FIG. 25 .
[0049] FIG. 27 is a profile view of the exemplary toggle of FIG. 25 .
[0050] FIG. 28 is an elevated perspective view showing assembly of the toggles and drive links.
[0051] FIG. 29 is an elevated perspective view showing assembly of the toggles, parallel links, and drive links.
[0052] FIG. 30 is a perspective view of the interior of a left side housing in accordance with the instant disclosure.
[0053] FIG. 31 is a perspective view of the interior of a right side housing in accordance with the instant disclosure.
[0054] FIG. 32 is a profile view of the interior of the right side housing of FIG. 31 and components housed therein in accordance with the instant disclosure.
[0055] FIG. 33 is an elevated perspective view of an exterior side of a first wheel in accordance with the instant disclosure.
[0056] FIG. 34 is an elevated perspective view of an interior side of the first wheel of FIG. 33 .
[0057] FIG. 35 is an elevated perspective view from an exterior surface of a first pulley and associated wires in accordance with the instant disclosure.
[0058] FIG. 36 is an exploded view of the components of FIG. 35 , less the wires.
[0059] FIG. 37 is an elevated perspective view from an interior surface of the first pulley of FIG. 35 .
[0060] FIG. 38 is an elevated perspective view from an exterior surface of a second pulley in accordance with the instant disclosure.
[0061] FIG. 39 is an elevated perspective view from an interior surface of a second pulley and associated wires in accordance with the instant disclosure.
[0062] FIG. 40 is an exploded view of the components of FIG. 39 , less the wires.
[0063] FIG. 41 is an elevated perspective view of an exterior side of a second wheel in accordance with the instant disclosure.
[0064] FIG. 42 is an elevated perspective view of an interior side of the second wheel of FIG. 41 .
[0065] FIG. 43 is a profile view of an exemplary repositionable lock in accordance with the instant disclosure.
[0066] FIG. 44 is an exploded view of the exemplary components of FIG. 43 .
[0067] FIG. 45 is a cross-sectional view of the exemplary thumb button of FIG. 43 taken along line 45 - 45 .
[0068] FIG. 46 is an exploded view of an exemplary control for repositioning the end effector jaws in accordance with the instant disclosure.
[0069] FIG. 47 is an assembled view of the exemplary control of FIG. 46 .
[0070] FIG. 48 a cross-sectional view of the exemplary control of FIG. 47 taken along line 47 - 47 .
[0071] FIG. 49 is an elevated perspective view of an exemplary shaft assembly along with associated control and deployment wires in accordance with the instant disclosure.
[0072] FIG. 50 is an end view taken from a distal end of an exemplary repositionable tab in accordance with the instant disclosure.
[0073] FIG. 51 is an end view taken from a distal end of another exemplary repositionable tab in accordance with the instant disclosure.
[0074] FIG. 52 is an elevated perspective view of an exemplary end effector having mounted thereto an occlusion clip in a closed position.
[0075] FIG. 53 is an elevated perspective view of the exemplary end effector and occlusion clip of FIG. 52 shown without repositionable jaws.
[0076] FIG. 54 is an elevated perspective view of the exemplary end effector and occlusion clip of FIG. 52 shown without repositionable jaws, first and second drive links, and first and second parallel links.
[0077] FIG. 55 is an elevated perspective view of the exemplary end effector and occlusion clip of FIG. 52 shown without repositionable jaws, first and second drive links, first and second parallel links, and first and second toggles.
[0078] FIG. 56 is an elevated perspective view of the exemplary end effector and occlusion clip of FIG. 52 shown without repositionable jaws, first and second drive links, first and second parallel links, first and second toggles, and linkage housing.
[0079] FIG. 57 is an elevated perspective view of the exemplary end effector and occlusion clip of FIG. 52 shown without repositionable jaws, first and second drive links, first and second parallel links, first and second toggles, linkage housing, and universal.
DETAILED DESCRIPTION
[0080] The exemplary embodiments of the present disclosure are described and illustrated below to encompass devices, methods, and techniques relating to surgical procedures. Of course, it will be apparent to those of ordinary skill in the art that the embodiments discussed below are exemplary in nature and may be reconfigured without departing from the scope and spirit of the present disclosure. It is also to be understood that variations of the exemplary embodiments contemplated by one of ordinary skill in the art shall concurrently comprise part of the instant disclosure. However, for clarity and precision, the exemplary embodiments as discussed below may include optional steps, methods, and features that one of ordinary skill should recognize as not being a requisite to fall within the scope of the present disclosure.
[0081] Referencing FIG. 1 , an exemplary surgical tool 10 includes a user control 20 mounted to a shaft assembly 30 , which is mounted to an exemplary minimally invasive surgical end effector 100 . The user control 20 includes a first wheel control 40 to vary the yaw of the end effector 100 , while the user control 20 further includes a second wheel control 50 to vary the pitch of the end effector. A user of the control 20 may manipulate the roll of the end effector 100 simply by rolling the user control. In order to selectively inhibit manipulation of the wheel controls 40 , 50 , a repositionable lock 60 is also provided. A proximal end of the user control 20 further includes a repositionable tab 70 that may be utilized to, in exemplary form, disengage a left atrial appendage (LAA) occlusion clip from the end effector 100 . In addition, the user control 20 includes a lever control 80 that is operative to control repositioning of the jaws of the end effector 100 with respect to one another. Several of the components of the lever control 80 , the wheel controls 40 , 50 , and the repositionable lock 60 at least partially reside within a grip housing 90 . A more detailed discussion of the exemplary components of the surgical tool 10 will be discussed successively.
[0082] Referring to FIGS. 1-3 and 51-56 , the exemplary end effector 100 may be used in minimally invasive surgical procedures to allow deployment of an LAA occlusion clip 102 with respect to a left atrial appendage (not shown). United States Patent Application Publication number 2012/0059400, which describes an exemplary LAA occlusion clip 102 , is incorporated herein by reference. As will be apparent to those skilled in the art after reviewing the instant disclosure, the end effector 100 and surgical tool 10 may be utilized in capacities other than LAA occlusion clip deployment, each of which is within the scope of this disclosure.
[0083] The end effector 100 comprises a clevis 110 that is mounted proximally to the shaft assembly 30 and distally to a proximal portion of a universal 120 , which is rotatably repositionable within an X-Y plane with respect to the clevis. A distal portion of the universal 120 is mounted to a proximal portion of a linkage housing 130 that is rotatably repositionable within a Y-Z plane with respect to the universal. A medial portion of the linkage housing 130 has mounted to it a first pin 160 that extends through a first drive link 140 and a second drive link 150 . In this fashion, the first drive link 140 and the second drive link 150 are rotatably repositionable with respect to the linkage housing 130 and with respect to one another along a common axis longitudinally aligned with the first pin 160 . A distal portion of the linkage housing 130 has mounted to it a second pin 170 and a third pin 230 that extends through proximal ends of a first parallel link 180 and a second parallel link 190 . In this fashion, the first parallel link 180 and the second parallel link 190 are rotatably repositionable with respect to the linkage housing 130 and with respect to one another along a common axis longitudinally aligned with the second and third pins 170 , 230 .
[0084] Interposing the proximal ends of the first and second parallel links 180 , 190 are a first toggle 200 , a second toggle 210 , and a pulley 220 . The pulley 220 includes a pair of cylindrical projections extending in opposite directions along a rotational axis of the pulley, where the first toggle 200 is mounted to a first of the cylindrical projections and the second toggle 210 is mounted to a second of the cylindrical projections. A distal end of the first drive link 140 is mounted to a proximal end of a first jaw 240 , whereas a distal end of the second drive link 150 is mounted to a proximal end of a second jaw 250 . In this fashion, the first drive link 140 is rotatably repositionable with respect to the first jaw 240 along a common axis longitudinally aligned with a fifth pin 260 that concurrently extends through the first drive link and the first jaw. Similarly, the second drive link 150 is rotatably repositionable with respect to the second jaw 250 along a common axis longitudinally aligned with a sixth pin 270 that concurrently extends through the second drive link and the second jaw.
[0085] Near the proximal end of the first jaw 240 , inset distally from the location where the first drive link 140 is mounted, the distal end of the first parallel link 180 is mounted to the first jaw. In this fashion, the first parallel link 180 is rotatably repositionable with respect to the first jaw 240 along a common axis longitudinally aligned with a seventh pin 290 that concurrently extends through the first parallel link and the first jaw. In corresponding fashion, the proximal end of the second jaw 250 , inset distally from the location where the second drive link 150 , is mounted to the distal end of the second parallel link 190 . Similarly, the second parallel link 190 is rotatably repositionable with respect to the second jaw 250 along a common axis longitudinally aligned with an eighth pin 300 that concurrently extends through the second parallel link and the second jaw.
[0086] In this exemplary end effector 100 , the jaws 240 , 250 are repositioned toward and away from one another while maintaining a parallel orientation. In order to reposition the first and second jaws 240 , 250 with respect to one another, the first and second drive links 140 , 150 as well as the first and second parallel links 180 , 190 are rotated with respect to the linkage housing 130 . To facilitate this repositioning of the jaws 240 , 250 with respect to one another, the distal ends of the first and second toggles 200 , 210 are mounted to medial portions of respective drive links 140 , 150 . In particular, the distal end of the first toggle 200 is mounted to a medial portion of the first drive link 140 via a ninth pin 310 . Accordingly, the first toggle 200 is rotatably repositionable with respect to the first drive link 140 along a common axis longitudinally aligned with the ninth pin 310 . In addition, the distal end of the second toggle 210 is mounted to a medial portion of the second drive link 150 via a tenth pin 320 . Consequently, the second toggle 210 is rotatably repositionable with respect to the second drive link 150 along a common axis longitudinally aligned with the tenth pin 320 . A more detailed discussion of the component parts of the end effector 100 follows.
[0087] As shown in FIGS. 4-7 , the clevis 110 includes an outer shell 400 that defines a longitudinal passage 402 extending therethrough. A proximal end 404 of the shell 400 includes an inner, cylindrical surface 406 that circumscribes an elongated shaft 1390 of the shaft assembly 30 (see FIG. 53 ) and retains the shaft therein via a compression fit. This inner, cylindrical surface 406 abuts a dam 408 that inhibits further distal repositioning of the shaft 1390 . Extending through the dam 408 are a pair of cylindrical through holes 410 interposed by an elongated through hole 412 . In exemplary form, separate control wires control wires 1272 , 1274 (see FIG. 56 ) extend through each cylindrical hole 410 and are coupled to the universal 120 and to the first wheel control 40 so that manipulation of the first wheel control is operative to reposition the universal with respect to the clevis 110 . In addition, another group of wires 1172 , 1174 , 1364 , 1402 , 1404 (see FIG. 57 ) extend through the elongated hole 412 . A more detailed discussion of the wires and the structures to which each is mounted will be discussed hereafter.
[0088] On a distal side of the holes 410 , 412 , an overhang 416 and corresponding underhang 418 , along with corresponding interior walls 422 , partially define a distal opening. In particular, the overhang 416 and underhang 418 are mirror images of one another and include an arcuate profile that curves away from the dam 408 until terminating at opposing planar upper and lower walls 424 . Inset within each of the interior walls 422 is a C-shaped depression 426 , where the open end of the C-shape faces distally. As will be discussed in more detail hereafter, a peripheral surface 430 partially delineating the C-shaped depression 426 bridges between the interior wall 422 and a step wall 432 , and provides a camming surface against which the universal 120 rotates. In this exemplary embodiment, the interior walls 422 are planar and parallel to one another, as are the step walls 432 , in addition to the interior walls being parallel to the step walls. Interposing the upper and lower walls 424 are convex side surfaces 436 , where the convex side surfaces abut distal curved surfaces 438 that partially delineate the C-shaped depression 426 and likewise extend between the upper and lower walls. Extending proximally, the upper and lower walls 424 and the convex side surfaces 436 transition from a generally rectangular exterior cross-section to a circular cross-section at a proximal end 440 via a series of tapered walls 442 . Extending distally from the clevis 110 is the universal 120 .
[0089] Referring to FIGS. 8-11 , the universal 120 comprises a pair of projections 450 extending outward from opposing right and left side surfaces 452 . In this exemplary embodiment, the projections 450 include a plateau surface 454 that is generally planar and parallel with the planar surface of the nearest side surface 452 . A peripheral shape of each projection 450 is rounded on a proximal end and comes to a point on a distal end 451 that is generally centered with a midline extending through the universal 120 . In particular, the peripheral surface 456 of each projection 450 is intended to contact and ride against the peripheral surface 430 of the clevis 110 (see FIG. 4 ) in order to allow pivotal motion between the clevis and universal 120 . But the pointed shape of each projection 450 , as embodied by two linear segments of the peripheral surface 456 , is operative to provide opposing stops that prevent complete rotation of the universal 120 with respect to the clevis 110 . By way of example, the linear segments of the peripheral surface 456 are angled approximately ninety degrees with respect to one another so that the universal 120 can rotate ±forty-five degrees with respect to a longitudinal axis extending through the clevis 110 in the proximal-distal direction. Each projection 450 is generally centered between opposing top and bottom surfaces 460 and distally inset from a proximal end 462 .
[0090] The proximal end 462 of the universal 120 is semicircular in profile to ride against the overhang 416 and underhang 418 of the clevis 110 (see FIG. 4 ) when the universal is rotated with respect to the clevis. In particular, the proximal end 462 includes a central U-shaped channel 466 that terminates at corresponding key-shaped through openings 468 extending through the top and bottom surfaces 460 and into an interior of the universal 120 . The key-shaped opening 468 includes a cylindrical, enlarged opening 469 that is configured to accept an enlarged end of a control wire 1172 , 1174 (see FIGS. 56 and 57 ). Once passing through the cylindrical opening 469 , the enlarged end of the control wire 1172 , 1174 is retained within a capture, which is partially delineated via a depression 464 , which inhibits throughput of the enlarged end of the control wire through the smaller height aspect of the key-shaped through openings 468 . A height of the U-shaped channel 466 extending along the top and bottom surfaces is sufficient to accommodate the width of a control wire 1172 , 1174 , but not so high as to allow throughput of the enlarged end of the control wire, with the exception of through the enlarged cylindrical opening. Corresponding interior surfaces 470 delineating a portion of the U-shaped channel 466 are convex and arcuate in shape. Extending co-planar with the U-shaped channel 466 is a through opening 474 is sized to accommodate throughput of further control wires. The base of the U-shaped channel and the through opening 474 interpose opposing left and right side channels 476 , 478 .
[0091] A proximal end of each of the channels 476 , 478 is delineated by spaced apart, arcuately shaped complementary walls 482 , 484 . As mentioned previously, a peripheral surface of these walls 482 , 484 ride against the overhang 416 and underhang 418 of the clevis 110 . Each of the channels 476 , 478 tapers from proximal to distal and creates a dedicated through opening that extends through the universal 120 and into an internal region partially bounded by opposing distal extensions 490 .
[0092] Inset within each interior wall 492 of the distal extensions 490 is a C-shaped depression 496 , where the open end of the C-shape faces distally. As will be discussed in more detail hereafter, a peripheral surface 498 partially delineating the C-shaped depression 496 bridges between the interior wall 492 and a step wall 502 , and provides a camming surface against which the linkage housing 130 rotates. In this exemplary embodiment, the interior walls 492 are planar and parallel to one another, as are the step walls 502 , in addition to the interior walls being parallel to the step walls. The step walls 502 and the top and bottom surfaces 460 converge at respective distal ends of the distal extensions 490 to form a semicircular edge 504 , which is interposed by the linkage housing 130 .
[0093] As shown in FIGS. 12-15 , the linkage housing includes a pair of projections 510 extending outward from opposing top and bottom exterior surfaces 512 . In this exemplary embodiment, the projections 510 include a plateau surface 514 that is generally planar and parallel with the planar surface of the nearest top/bottom surface 512 . A peripheral shape of each projection 510 is rounded on a proximal end and comes to a point on a distal end 511 that is generally centered with a midline extending through the linkage housing 130 . In particular, the peripheral surface 516 of each projection 510 is intended to contact and ride against the peripheral surface 498 of the universal 120 in order to allow pivotal motion between the linkage housing 130 and universal 120 . But the pointed shape of each projection 510 , as embodied by two linear segments of the peripheral surface 516 , is operative to provide opposing stops that prevent complete rotation of the linkage housing 130 with respect to the universal 120 . By way of example, the linear segments of the peripheral surface 516 are angled approximately ninety degrees with respect to one another so that the linkage housing 130 can rotate ±forty-five degrees with respect to a longitudinal axis extending through the universal 120 in the proximal-distal direction. Each projection 510 is generally centered between opposing right and left sides 520 and distally inset from a proximal end 522 .
[0094] The proximal end 522 of the linkage housing 130 is semicircular in profile. In particular, the proximal end 522 includes a miniature U-shaped channel 526 that terminates at corresponding openings 528 extending through the left and right side surfaces 520 and into an interior of the linkage housing 130 . Each opening 528 is configured to allow throughput of a separate control wire, but prohibit an enlarged end of that control wire 1272 , 1274 from passing therethrough (see FIGS. 14 and 57 ). And a height of the U-shaped channel 526 extending along the left and right side surfaces 520 is sufficient to accommodate the width of a control wire, but not so high as to allow throughput of the enlarged end of the control wire. In exemplary form, each control wire is inserted through one of the openings 528 (smaller diameter end first) so that the remainder of the control wire extends proximally and a distal, enlarged end of the control wire eventually interposes respective outer retention arms 530 , 532 and inner arms 534 , 536 when the wire is tensioned. Tensioning of both control wires 1272 , 1274 is operative to seat the enlarged end of each control wire within a depression 540 formed into the linkage housing 130 .
[0095] Interposing the miniature U-shaped channel 526 and extending from the base of the U-shaped channel is a central through channel 546 that extends distally and terminates in between the inner arms 534 , 536 . The central through channel 546 is sized to accommodate a control wire 1364 coupled to the pulley 220 (see FIG. 55 ). As will be discussed in more detail hereafter, repositioning of the pulley 220 with respect to the linkage housing 130 results in component motion operative to increase or decrease the distance between the opposing jaws 240 , 250 responsive to components being pivotally connected to the outer retention arms 530 , 532 and inner arms 534 , 536 .
[0096] In exemplary form, the outer retention arms 530 , 532 each include a C-shaped depression 556 , where the open end of the C-shape faces distally, which is formed into a respective interior wall surface 552 . As will be discussed in more detail hereafter, a peripheral surface 558 partially delineating the C-shaped depression 556 bridges between the interior wall surface 552 and a step wall surface 562 , and provides a camming surface against which the parallel links 180 , 190 rotate. In this exemplary embodiment, the interior wall surfaces 552 are planar and parallel to one another, as are the step wall surfaces 562 , in addition to the interior wall surfaces being parallel to the step wall surfaces. The step wall surfaces 562 and the left and right side surfaces 520 converge at respective distal ends of the outer retention arms 530 , 532 to form a semicircular edge 564 . A distal orifice 568 extends through the step wall surface and through the entire outer retention arm 530 , 532 . The distal orifice 568 is sized to accommodate one of the second pin 170 and the third pin 230 in order to allow pivotal motion between the linkage housing 130 and the parallel links 180 , 190 . By way of example, the distal orifices 568 of the outer retention arms 530 , 532 are cylindrical and have axial centers that lie along a common axis. In addition to the distal orifice, each outer retention arm 530 , 532 also includes a proximal orifice 570 that extends entirely through the outer retention arm. The proximal orifice 570 is sized to accommodate the first pin 160 in order to allow pivotal motion between the linkage housing 130 and the drive links 140 , 150 . By way of example, the proximal orifices 570 of the outer retention arms 530 , 532 are cylindrical and have axial centers that lie along a common axis.
[0097] The inner arms 534 , 536 extend distally and are generally parallel with the outer retention arms 530 , 532 , with spacing between each set of adjacent arms. In exemplary form, the inner arms 534 , 536 each include a single hole 580 that extends laterally through the arm and is cylindrical in shape. A central axis extending through each hole 580 is coaxial with the counterpart central axis of the other hole. Likewise, the central axis of the holes 580 is coaxial with the common axis of the proximal orifices 570 so that the holes and orifices are sized to accommodate the first pin 160 in order to allow pivotal motion between the linkage housing 130 and the drive links 140 , 150 (see FIG. 2 ). The spacing between the arms 534 , 536 allows for proximal-to-distal motion of the pulley 220 therebetween, while prohibiting motion of the toggles 200 , 210 therebetween. Rather, the first arm 534 includes a triangular projection extending distally, the hypotenuse of which comprises a first surface 582 that is angled to generally face the top surface 512 . Similarly, the second arm 536 includes a triangular projection extending distally, the hypotenuse of which comprises a second surface 584 that is angled to generally face the bottom surface 512 . In this exemplary embodiment, the surfaces 582 , 584 are perpendicular to one another and, as will be discussed in more detail hereafter, the toggles 200 , 210 contact these surfaces in order to limit repositioning of the toggles as the pulley 220 is repositioned.
[0098] Referencing FIGS. 2 and 16-18 , the first and second drive links 140 , 150 as well as the first and second parallel links 180 , 190 are rotationally repositionable and mounted to the linkage housing 130 . In exemplary form, the first and second drive links 140 , 150 are structurally identical, but differ only in operation based upon the components mounted thereto. Consequently, the following discussion of the structure of a drive link is applicable to both the first and second drive links 140 , 150 .
[0099] Each drive link 140 , 150 comprises a unitary structure including a pair of spaced apart, tilted uprights 590 , 592 that are angled approximately forty-five degrees with respect to corresponding longitudinal extensions 594 , 596 . The base of the uprights 590 , 592 are joined to one another via a bridge 598 . In exemplary form, each upright 590 , 592 includes a rounded proximal end 600 that interposes opposing planar surfaces 604 , 606 . Extending completely through each upright 590 , 592 is a hole 610 partially bounded by the opposing planar surfaces 604 , 606 and having a cylindrical shape that is sized to accommodate throughput of the first pin 160 and allow rotational repositioning of each upright around the first pin. Each upright 590 , 592 also includes a step 612 recessed distally beyond the proximal end 600 and the hole 610 . The step 612 , as will be discussed in more detail hereafter, is inset to approximately half of the thickness of the widest portion of the upright 590 , 592 . Extending distally from the step 612 , each upright 590 , 592 seamlessly transitions into a respective longitudinal extension 594 , 596 . The bridge 598 is positioned approximate the transition region between the uprights 590 , 592 and the longitudinal extensions 594 , 596 and recessed with respect to bottom planar surfaces 614 of the longitudinal extensions. On the top side 616 of each drive link 140 , 150 , the bridge 598 seamlessly transitions into the longitudinal extensions 594 , 596 an embodies an arcuate, convex longitudinal profile so that the top of each longitudinal extension includes a longitudinal ridge 618 extending from the bridge 598 distally toward a distal rounded end 620 of each longitudinal extension. Along the longitudinal length of each longitudinal extension 594 , 596 is a pair of openings 622 , 624 extending completely through the longitudinal extensions between opposing lateral inner and exterior sides 628 , 630 . Each opening 622 , 624 has a cylindrical shape and is configured to receive at least one of the fifth, sixth, ninth, and tenth pins 260 , 270 , 310 , 320 . In this fashion, the first and second toggles 200 , 210 as well as the first and second jaws 240 , 250 may be rotationally repositionable with respect to one of the drive links 140 , 150 .
[0100] Referring to FIGS. 2 and 25-27 , the first and second toggles 200 , 210 as well as the first and second jaws 240 , 250 are rotationally repositionable and mounted to the drive links 140 , 150 . In exemplary form, the first and second toggles 200 , 210 are structurally identical, but differ only in operation based upon the components mounted thereto. Consequently, the following discussion of the structure of a toggle is applicable to both the first and second toggles 200 , 210 .
[0101] Each toggle 200 , 210 comprises a unitary structure including toggle connector portion 640 and a drive link connector portion 642 . In exemplary form, the toggle connector portion includes a rounded end 644 with a substantially constant width that is approximately half of the width of the drive link connector portion 642 . Along the longitudinal length of the toggle connector portion 640 , an arcuate profile exists. This toggle connector portion 640 includes a through opening 646 having a cylindrical shape and configured to receive a cylindrical projection of the pulley 220 so that the toggle 200 , 210 is rotationally repositionable about the pulley 220 .
[0102] Opposite the toggle connector portion 640 , the drive link connector portion 642 includes an offset 648 extending widthwise beyond the width of the toggle connector. An opening 650 extends through the drive link connector portion 642 and the offset 648 having a cylindrical shape and configured to receive one of the ninth and tenth pins 310 , 320 so that the toggle 200 , 210 is rotationally repositionable about a drive link 140 , 150 . A partial circumferential groove 652 exists on the rounded end 654 of the drive link connector portion 642 . This groove 652 is configured to receive a portion of a deployment wire 1402 , 1404 (see FIG. 54 ) in order to allow the deployment wire to contact and be unimpeded by motion of the toggle 200 , 210 when the toggle is repositioned and/or when the deployment wire is repositioned with respect to the jaws 240 , 250 in order to detach, for example, a left atrial occlusion clip 102 temporarily mounted to the jaws.
[0103] As shown in FIGS. 19 and 20 , the jaws 240 , 250 are structurally mirror images of one another. Consequently, the following discussion of the structure of a jaw is generally applicable to both the first and second jaws 240 , 250 .
[0104] Each jaw 240 , 250 includes a rounded proximal end 660 that transitions distally into a rectangular cross-section with a pair of openings 662 , 664 extending between opposing top and bottom surfaces 666 , 668 each having a cylindrical shape and being configured to receive at least one of the fifth, sixth, seventh, and eighth pins 260 , 270 , 290 , 300 (see FIG. 2 ). In this fashion, the first and second jaws 240 , 250 may be rotationally repositionable with respect to the drive links 140 , 150 and the parallel links 180 , 190 . The rectangular cross-section also includes one of a series of openings 670 on an interior surface 672 in communication with a plurality of openings 674 and channels 676 formed into the opposing exterior surface 678 . In this exemplary embodiment, the channels 676 are sized and configured to receive a respective deployment wire 1402 , 1404 , whereas the openings 670 , 674 are sized to accommodate throughput of a suture retainer coupled to the left atrial occlusion clip 102 . The interior surface 672 also has formed therein a LAA spring depression 676 sized and configured to receive a biasing spring of the left atrial occlusion clip 102 (see FIG. 52 ). This LAA spring depression 679 is in communication with a longitudinal depression 677 formed into the interior surface 672 and the bottom surface 668 . And this longitudinal depression 677 is sized and configured to receive occlusion bars of the left atrial occlusion clip 102 . Each jaw 240 , 250 tapers longitudinally from proximal to distal after passing beyond the LAA spring depression 679 to terminate at a rounded distal end 680 . As part of repositioning the jaws 240 , 250 with respect to one another, the parallel links 180 , 190 are also repositioned with respect to one another.
[0105] Referring to FIGS. 2 and 21-24 , the first and second parallel links 180 , 190 are structurally identical, but differ only in operation based upon the components mounted thereto. Consequently, the following discussion of the structure of a parallel link is applicable to both the first and second parallel links 180 , 190 .
[0106] Each parallel link 180 , 190 comprises a unitary structure including a pair of spaced apart heads 700 , 702 that are angled approximately forty-five degrees with respect to corresponding longitudinal legs 704 , 706 . Near a base, the heads 700 , 702 are joined to one another via a link 710 . In exemplary form, each head 700 , 702 includes a tapered proximal end 714 , which is rounded at a far proximal tip, that includes a hole 716 partially bounded by opposing interior and exterior planar surfaces 718 , 720 , as well as an arcuate exterior surface 722 . The hole 716 has a cylindrical shape that is size to accommodate throughput of at least one of the seventh and eighth pin 290 , 300 and allow rotational repositioning of a respective parallel link 180 , 190 around a respective jaw 240 , 250 . Each head 700 , 702 includes an S-shaped profile 722 on one widthwise side that is configured to track an inverse S-shaped profile 724 associated with an opposite side of the same head 700 , 702 . In this fashion, as shown in FIG. 24 when the parallel links 180 , 190 are positioned adjacent one another and the jaws 240 , 250 are least spaced apart, the S-shaped contour 722 of one side of the first head 700 of the first parallel link 180 tracks the inverse S-shaped contour 724 of a second side of the second head 702 of the second parallel link 190 . Each head 700 , 702 also includes a width that is roughly twice the width of the corresponding longitudinal legs 704 , 706 . In this fashion, the portion of heads 700 , 702 with the inverse S-shaped profile 724 is offset in a widthwise dimension from the corresponding longitudinal leg 704 , 706 .
[0107] The corresponding longitudinal legs 704 , 706 extend parallel and spaced apart from one another in the widthwise direction. The only meaningful difference between the corresponding longitudinal legs 704 , 706 is that the first longitudinal leg 704 includes a widthwise offset 728 that extends away from the second longitudinal leg 706 proximate the rounded distal tip 730 . Each longitudinal leg includes parallel, planar inner and outer surfaces 732 , 734 . A first hole 736 extends through the second longitudinal leg 706 proximate the distal tip 730 , that is generally equidistantly spaced from the distal tip 730 and corresponding upper and lower surfaces 740 , 742 . The first hole 736 has a cylindrical shape and is configured to receive at least one of the second and third pins 170 , 230 in order to allow the parallel links 180 , 190 to rotate with respect to the linkage housing 130 . A second hole 746 extends through the first longitudinal leg 704 and offset 728 proximate the distal tip 730 , that is generally equidistantly spaced from the distal tip 730 and corresponding upper and lower surfaces 740 , 742 . The second hole 746 has a cylindrical shape and is configured to receive at least one of the second and third pins 170 , 230 in order to allow the parallel links 180 , 190 to rotate with respect to the linkage housing 130 .
[0108] Referring to FIGS. 1-29 and 52-57 , an exemplary assembly sequence for the exemplary end effector 100 will now be described. Initially, the control and deployment wires 1172 , 1174 , 1272 , 1274 , 1364 , 1402 , 1404 are routed through the clevis 110 . Specifically, the longitudinal passage 402 at the proximal end 404 of the clevis receives the wires 1172 , 1174 , 1272 , 1274 , 1364 , 1402 , 1404 , which are then redirected so that the control wires 1272 , 1274 individually extend through a respective through hole 410 of the clevis, while the other wires 1172 , 1174 , 1364 , 1402 , 1404 extend through the elongated through hole 412 of the clevis. After routing the wires through the clevis 110 , the universal 120 is mounted to the clevis so that the projections 450 of the universal are received within respective C-shaped depressions 426 . In order to retain the universal 120 in an engaged position with respect to the clevis, the control wires 1272 , 1274 are individually fed through one of the cylindrical, enlarged openings 469 of the universal 120 and knotted or otherwise processed to enlarge the ends of each control wire sitting within a respective depressions 464 . The control wires 1272 , 1274 are then tensioned and mounted to the first wheel control 40 so that rotation of the wheel control 40 will cause pivoting motion of the universal 120 with respect to the clevis 110 . Likewise, the other control wires 1172 , 1174 are fed through a respective channel 476 , 478 of the universal 120 , while the other wires 1364 , 1402 , 1404 extend through the opening 474 of the universal.
[0109] After routing the wires through the universal 120 , the linkage housing 130 is mounted to the universal so that the projections 510 of the linkage housing are received within respective C-shaped depressions 496 . In order to retain the linkage housing 130 in an engaged position with respect to the universal 120 , the control wires 1172 , 1174 are individually fed through one of the openings 528 of the linkage housing and knotted or otherwise processed to enlarge the ends of each control wire sitting on the other side of the U-shaped channel 526 . The control wires 1172 , 1174 are then tensioned and mounted to the second wheel control 50 so that rotation of the wheel control 50 will cause pivoting motion of the linkage housing 130 with respect to the universal 120 . Conversely, the other wires 1364 , 1402 , 1404 extend through the channel 546 of the linkage housing 130 . At this point, the tilted uprights 590 , 592 of the drive links 140 , 150 are offset and aligned with one another to fit between the linkage housing 130 proximate the orifices 570 . More specifically the holes 610 of the tilted uprights 590 , 592 are longitudinally aligned with the holes 580 and the orifices 570 of the linkage housing 130 in order to receive the first pin 160 , which extends completely through the linkage housing and the drive links 140 , 150 .
[0110] The toggles 200 , 210 are also mounted to a respective drive link 140 , 150 , as well as concurrently to the pulley 220 . Specifically, the through opening 650 of the first toggle 200 is oriented between and coaxially aligned with the openings 622 extending through the first drive link 140 . When aligned, the ninth pin 310 is inserted through the openings 622 , 650 to mount the first toggle 200 to the first drive link 140 . Similarly, the through opening 650 of the second toggle 210 is oriented between and coaxially aligned with the openings 622 extending through the second drive link 150 . When aligned, the tenth pin 320 is inserted through the openings 622 , 650 to mount the second toggle 210 to the second drive link 150 . The opposing ends of the toggles 200 , 210 are mounted to opposing ends of the pulley 220 . More specifically, each toggle through opening 646 receives a respective cylindrical lateral end of the pulley 220 in order to rotationally mount the toggles 200 , 210 to the pulley. At this time, the pulley 220 is also mounted to the control wire 1364 so that repositioning of the lever control 80 is operative to reposition the pulley and correspondingly other components in order to move the jaws 240 , 250 toward or away from one another in a parallel open/close fashion.
[0111] Each jaw 240 , 250 is then mounted to a respective drive link 140 , 150 , and parallel link 180 , 190 . In exemplary form, a first of the openings 662 of a respective jaw 240 , 250 is aligned with a respective opening 624 of a respective drive link 140 , 150 . After being aligned, a fifth pin 260 and a respective sixth pin 270 are inserted through the openings 624 , 662 in order to pivotally mount a jaw 240 , 250 to a respective drive link 140 , 150 . Similarly, a second of the openings 664 of a respective jaw 240 , 250 is aligned with a respective hole 716 of a respective parallel link 180 , 190 . After being aligned, a seventh pin 290 and a respective eighth pin 300 is inserted through the openings 664 , 716 in order to pivotally mount a jaw 240 , 250 to a respective parallel link 180 , 190 . Also, the opposing ends of the parallel links 180 , 190 are offset and aligned with one another to fit between the linkage housing 130 proximate the orifices 568 . When aligned, second and third pins 170 , 230 are mounted to individual ends of the parallel links 180 , 190 and to the linkage housing 130 to provide for pivotal motion between the parallel links and the linkage housing. Before, during, or after mounting the jaws 240 , 250 to the drive links 140 , 150 and the parallel links 180 , 190 , the deployment wires 1402 , 1404 are respectively directed through openings 674 of the jaws 240 , 250 so that the user control 20 may be manipulated to deploy the LAA occlusion clip 102 .
[0112] Turning to FIGS. 1, 2, and 30-32 , a more detailed discussion of the user control 20 , the first wheel control 40 , the second wheel control 50 , the repositionable lock 60 , the repositionable tab 70 , the lever control 80 , and the grip housing 90 follows.
[0113] The grip housing 90 comprises respective left and right side housing halves 1000 , 1002 . The left side housing 1000 includes a generally convex exterior surface 1004 and an opposite interior concave surface 1006 . The interior and exterior surfaces 1004 , 1006 join one another at a peripheral surface 1008 that delineates the general outline of the left side housing 1000 . This left side peripheral surface 1008 cooperates with a right side peripheral surface 1010 (which bridges opposing interior and exterior surfaces 1012 , 1014 of the right side housing 1002 ) to delineate five openings 1016 - 1024 that allow through put of various components. It should be noted that the left side housing peripheral surface 1008 includes a lip that is correspondingly received within a recess of the right side housing peripheral surface 1010 to facilitate alignment of the housings when mounted to one another. More specifically, the right side peripheral surface 1010 partially overlaps the left side peripheral surface 1008 when the housings are mounted to one another as shown in FIG. 1 .
[0114] By way of example, a first opening 1016 occurs at a distal end of the housings 1000 , 1002 and is sized and shaped in a circular fashion to circumscribe and retain a proximal portion of the elongated cylindrical shaft 30 . As will be discussed in greater detail hereafter, the elongated cylindrical shaft 30 includes longitudinal cut-outs 1392 that receive a pair of retention plates 1026 extending from the interior surface 1012 of the right side housing 1002 .
[0115] The second opening 1018 occurs on an underside of the housing halves 1000 , 1002 . This second opening 1018 is sized to accommodate a portion of the lever control 80 . Inset from a distal end of the second opening is an integral, hollow axle 1028 extending from the interior surface 1012 of the right side housing 1002 . As will be discussed in more detail hereafter, a portion of the lever control 80 rotates about the axle 1028 when the lever control is repositioned. In order to retain this portion of the lever control rotating about the axle 1028 , the left side housing 1000 includes a retention pin 1030 that is received by the hollow axle 1028 and operates to mount adjacent portions of the housings 1000 , 1002 to one another. Inset from a proximal end of the second opening is an integral spring retainer projection 1032 extending from the interior surface 1012 of the right side housing 1002 . As will be discussed in more detail hereafter, a spring of the lever control 80 is mounted to the spring retainer projection 1032 . In order to retain the spring mounted to the spring retainer projection 1032 , the left side housing 1000 includes a retention cylinder 1034 that is hollow and sized to receive the spring retainer projection 1032 and mount adjacent portions of the housings 1000 , 1002 to one another.
[0116] The third opening 1020 occurs at a proximal end 1036 of the housings 1000 , 1002 and is sized to receive a portion of the repositionable tab 70 . By way of example, the third opening 1020 is circular in nature and sized to retain a cylindrical portion of the repositionable tab 70 as part of a friction fit that may be overcome by a user withdrawing the tab from a cylindrical portion from the grip housing 90 . It should be noted, however, that other shapes besides circular openings may be used as part of the third opening 1020 . As shown in FIGS. 50 and 51 , the repositionable tab 70 may embody any number of shapes including, without limitation, an hourglass shape (see FIG. 50 ), a helical thread shape (see FIG. 51 ) and a triangular shape that requires rotation of the repositionable tab 70 with respect to the grip housing 90 in order to insert and extract the repositionable tab from the grip housing.
[0117] Extending distally from the third opening 1020 , the left side housing 100 includes a linear projection 1038 , extending proximal to distal, that is configured to guide motion of a portion of the lever control 80 . Generally opposite this linear projection 1038 , extending from the interior surface 1012 of the right side housing 1002 is an oblong, hollow ridge 1040 that is sized to receive a portion of the lever control 80 , yet allow this portion of the lever control to move therein within a predetermined range of motion.
[0118] Above the second opening 1018 and extending proximally from the fourth opening 1022 of the right side housing 1002 interior surface 1012 is a control wire guide 1042 comprising three cylindrical projections spaced apart from one another vertically to allow a first gap between the first and second projections and a second gap between the second and third projections. As will be discussed in more detail hereafter, a control wire coupled to the lever control 80 extends between the second and third projections, while a pair of deployment wires coupled to the repositionable tab 70 extends between the first and second projections. In order to ensure the control wire and deployment wires stay in the aforementioned gaps, the left side housing 1000 includes ring 1044 extending from the interior surface 1006 that circumscribes the control wire guide 1042 to retain the wires within a respective gap.
[0119] The fourth opening 1022 occurs on a top side of the housings halves 1000 , 1002 . This opening 1022 is sized to accommodate a portion of the repositionable lock 60 . Positioned underneath the bounds of the fourth opening 1022 are complementary left and right ledges 1048 , 1050 upon which the repositionable lock 60 sits. Each of the housing halves 1000 , 1002 also includes a triangular cavity 1054 that is configured to receive a portion of the repositionable lock 60 .
[0120] A fifth opening 1024 also occurs on a top side of the housing halves 1000 , 1002 and distal to the fourth opening 1022 . This fifth opening 1024 is sized to accommodate a portion of the first wheel control 40 . In particular, a portion of the first wheel 1110 and the control knob 1160 extend above the housings 1000 , 1002 in order to allow a user to manipulate the control knob and resultantly rotate the first wheel.
[0121] Adjacent the fifth opening is a sixth opening 1052 that extends completely though the top surface of the right side housing 1002 . Interposing the fifth and sixth openings 1024 , 1052 is an arcuate divider comprised exclusively of the right side housing 1002 . This sixth opening 1052 is sized to accommodate a portion of the second wheel control 50 . In particular, a portion of the second wheel 1140 and the control knob 1260 extend above the housing 1002 in order to allow a user to manipulate the control knob and resultantly rotate the second wheel.
[0122] Extending outward from the interior surface 1006 of the left side housing 1000 is a pair of vertical guides 1056 that mirror a pair of vertical guides 1058 extending from the interior surface 1012 of the right side housing 1002 . The left side vertical guides 1056 are adapted to contact the exterior track 1152 of the first wheel 1110 and allow the track to rotationally slide against the vertical guides. Similarly, the right side vertical guides 1058 are adapted to contact the exterior track 1252 of the second wheel 1140 and allow the track to rotationally slide against the vertical guides. In this fashion, the vertical guides 1056 , 1058 act as lateral boundaries for the wheels 1110 , 1140 as well as the pulleys 1120 , 1130 . Interposing the vertical guides 1056 , 1058 are respective hollow cylinders 1060 , 1062 extending from respective interior surfaces 1006 , 1012 . Each hollow cylinder 1060 , 1062 is sized to receive a portion of an axle 1420 that extends through the wheels 1110 , 1140 and the pulleys 1120 , 1130 . Though not necessary, the dimensions of each hollow cylinder 1060 , 1062 may be such that the axle 1420 is retained therein via a friction fit and the axle is unable to rotate with respect to the hollow cylinders, but still allow the wheel controls 40 , 50 to be repositioned.
[0123] As discussed previously, the user control 20 includes a first wheel control 40 to vary the yaw of the end effector 100 , while the user control 20 further includes a second wheel control 50 to vary the pitch of the end effector. In order to selectively inhibit manipulation of the wheel controls 40 , 50 , a repositionable lock 60 is also provided. A proximal end of the user control 20 further includes a repositionable tab 70 that may be utilized to, in exemplary form, disengage a left atrial appendage (LAA) occlusion clip 102 from the end effector 100 . In addition, the user control 20 includes a lever control 80 that is operative to control repositioning of the jaws 240 , 250 of the end effector 100 with respect to one another. Several of the components of the lever control 80 , the wheel controls 40 , 50 , and the repositionable lock 60 at least partially reside within a grip housing 90 .
[0124] As shown in FIGS. 32-42 , the first and second wheel controls 40 , 50 rotate about an axle 1420 received within corresponding cylindrical cavities 1024 , 1056 formed within the right and left side housing halves 1000 , 1002 . The axle 1420 is cylindrical in shape and extends through the center of a first wheel 1110 , a first pulley 1120 , a second pulley 1130 , and a second wheel 1140 . The first wheel 1110 and the first pulley 1120 are components of the first wheel control 40 , whereas the second wheel 1140 and the second pulley 1130 are components of the second wheel control 50 .
[0125] In exemplary form, referring to FIGS. 33 and 34 , the first wheel 1110 comprises a unitary structure having a generally circular shape and including a central opening 1150 accommodating throughput of the axle 1420 . Radially outward from this opening 1150 and partially circumscribing the opening is a track 1152 extending outward from an exterior, side surface 1154 . Adjacent this exterior, side surface 1154 is a peripheral surface 1156 , with an arcuate transition surface 1158 interposing the side and circumferential surfaces. Extending radially outward from the peripheral surface 1156 is a control knob 1160 with indicia 1162 on the top of the control knob providing a user with an indication that rotation of the first wheel 1110 is operative to reposition the end effector 100 laterally within an X-Y plane. In order to transfer rotation of the first wheel 1110 into lateral motion of the end effector, the first wheel also includes a pair of protrusions 1166 on opposing radial sides of the opening 1150 . As will be discussed in more detail hereafter, these protrusions 1166 are received within corresponding pockets of the first pulley 1120 so that rotational motion of the first wheel 1110 is transferred into rotational motion of the first pulley. Radially outset from the opening 1150 and one of the protrusions 1166 are a plurality of teeth 1170 circumferentially inset and distributed about ninety degrees of the circumference.
[0126] Referring to FIGS. 35-37 , a second component of the first wheel control 40 , the first pulley 1120 , is operative to convert rotational motion of the first wheel 1110 into longitudinal motion of at least one of a first pair of control wires 1172 , 1174 . The control wires 1172 , 1174 are mounted to the first pulley 1120 using a clamp plate 1176 and a set screw 1178 . In exemplary form, the first pulley 1120 includes a first through opening 1180 sized and configured to receive throughput of the axle 1420 so that the first pulley may rotate about the axle, in addition to a second through opening 1182 sized and configured to receive an upstanding cylinder 1186 of the clamp plate 1176 . But the second through opening 1182 is too small to allow throughput of a backing plate 1188 of the clamp plate 1176 . Accordingly, a rear of the first pulley 1120 includes a recess 1190 sized and configured to receive the backing plate 1188 and inhibit rotation of the backing plate with respect to the first pulley 1120 . The rear of the first pulley 1120 also includes a semi-circular spacer 1191 partially delineating the first through opening and extending laterally away from a center of the first pulley. The spacer 1191 is operative to provide a gap between the first and second pulleys 1120 , 1130 .
[0127] The upstanding cylinder 1186 includes an axial through opening 1192 that is threaded to engage the threads of the set screw 1178 , as well as four radial openings 1194 that are sized and configured to receive at least one of the control wires 1172 , 1174 . By way of example, the four radial openings 1194 are circular and radially distributed to be equidistantly spaced from one another about the circumference of the upstanding cylinder 1186 . A first and second of the radial openings 1194 are located proximate first and second openings 1198 extending through a wall 1200 extending laterally outward and adjacent the second through opening 1182 .
[0128] In exemplary form, the first control wire 1172 is routed over a first arcuate surface 1202 that extends laterally outward from the first pulley 1120 so that the free end of the first control wire interposes between a radial wall 1204 and a first guide 1206 . The free end of the first control wire 1172 is then directed through a bottom opening (second opening) 1198 and directed through the nearest radial opening 1194 . After passing beyond the nearest radial opening, the free end of the first control wire 1172 is passed through the radial opening opposite (180 degrees opposed) from the radial opening the first control wire already extends through. Similarly, the second control wire 1174 is routed over a second arcuate surface 1212 that extends laterally outward from the first pulley 1120 so that the free end of the second control wire interposes between the radial wall 1204 and a second guide 1216 . The free end of the second control wire 1174 is then directed through a top opening (first opening) 1198 and directed through the nearest radial opening 1194 . After passing beyond the nearest radial opening, the free end of the second control wire 1174 is passed through the radial opening opposite (180 degrees opposed) from the radial opening that the first control wire already extends through. After both control wires 1172 , 1174 have passed through the radial openings 1194 , the set screw 1178 is threaded into the axial through opening 1192 to crimp the control wires in place. This crimping operation is undertaken while both control wires 1172 , 1174 are put into a predetermined amount of tension and the end effector 100 is in a neutral position within the X-Y and Y-Z planes.
[0129] Turning to FIGS. 38-42 , the second wheel 1140 of the second wheel control 50 comprises a unitary structure having a generally circular shape and including a central opening 1250 accommodating throughput of the axle 1420 . Radially outward from this opening 1250 and partially circumscribing the opening is a track 1252 extending outward from an exterior, side surface 1254 . Adjacent this exterior, side surface 1254 is a peripheral surface 1256 , with an arcuate transition surface 1258 interposing the side and circumferential surfaces. Extending radially outward from the peripheral surface 1256 is a control knob 1260 with indicia 1262 on the top of the control knob providing a user with an indication that rotation of the second wheel 1140 is operative to reposition the end effector 100 vertically within a Y-Z plane. In order to transfer rotation of the second wheel 1140 into vertical motion of the end effector 100 , on an opposite side of the second wheel is a cylindrical projection 1266 with three spokes equidistantly spaced from one another and radially extending around the opening 1250 . As will be discussed in more detail hereafter, the cylindrical projection 1266 and spokes are received within corresponding pockets of the second pulley 1130 so that rotational motion of the second wheel 1140 is transferred into rotational motion of the second pulley. Radially outset from the opening 1250 and the cylindrical projection 1266 are a plurality of teeth 1270 circumferentially inset and distributed about ninety degrees of the circumference.
[0130] A second component of the second wheel control 50 , the second pulley 1130 , is operative to convert rotational motion of the second wheel 1140 into longitudinal motion of at least one of a first pair of control wires 1272 , 1274 . The control wires 1272 , 1274 are mounted to the second pulley 1130 using a clamp plate 1276 and a set screw 1278 . In exemplary form, the second pulley 1130 includes a first through opening 1280 sized and configured to receive throughput of the axle 1420 so that the second pulley may rotate about the axle, in addition to a second through opening 1282 sized and configured to receive an upstanding cylinder 1286 of the clamp plate 1276 . But the second through opening 1282 is too small to allow throughput of a backing plate 1288 of the clamp plate 1276 . Accordingly, a front of the second pulley 1130 includes a recess 1290 sized and configured to receive the backing plate 1288 and inhibit rotation of the backing plate with respect to the second pulley 1130 . The front of the second pulley 1130 also includes a depression 1291 that is sized to receive the cylindrical projection 1266 and the spokes of the second wheel 1140 .
[0131] The upstanding cylinder 1286 of the clamp plate 1276 includes an axial through opening 1292 that is threaded to engage the threads of the set screw 1278 , as well as four radial openings 1294 that are sized and configured to receive at least one of the control wires 1272 , 1274 . By way of example, the four radial openings 1294 are circular and radially distributed to be equidistantly spaced from one another about the circumference of the upstanding cylinder 1286 . A first and second of the radial openings 1294 are located proximate first and second openings 1298 extending through a wall 1300 extending laterally outward and adjacent the second through opening 1282 .
[0132] In exemplary form, the first control wire 1272 is routed over a first arcuate surface 1302 that extends laterally outward from the second pulley 1140 so that the free end of the first control wire interposes between a radial wall 1304 and a first guide 1306 . The free end of the first control wire 1272 is then directed through a bottom opening (second opening) 1298 and directed through the nearest radial opening 1294 . After passing beyond the nearest radial opening, the free end of the first control wire 1272 is passed through the radial opening opposite (180 degrees opposed) from the radial opening that the first control wire already extends through. Similarly, the second control wire 1274 is routed over a second arcuate surface 1312 that extends laterally outward from the second pulley 1140 so that the free end of the second control wire interposes between the radial wall 1304 and a second guide 1316 . The free end of the second control wire 1274 is then directed through a top opening (first opening) 1298 and directed through the nearest radial opening 1294 . After passing beyond the nearest radial opening, the free end of the second control wire 1274 is passed through the radial opening opposite (180 degrees opposed) from the radial opening the first control wire already extends through. After both control wires 1272 , 1274 have passed through the radial openings 1294 , the set screw 1278 is threaded into the axial through opening 1292 to crimp the control wires in place. This crimping operation is undertaken while both control wires 1272 , 1274 are put into a predetermined amount of tension and the end effector 100 is in a neutral position within the Y-Z plane. After crimping, rotation of the wheels 1110 , 1140 is operative to change the lateral and vertical position of the end effector 100 . And these positions when achieved by user manipulation to a predetermined location may be retained using the repositionable lock 60 .
[0133] Turning to FIGS. 43-45 , the repositionable lock 60 includes a thumb button 1320 that is spring biased with respect to a base plate 1322 . In exemplary form, the thumb button 1320 includes a hollow cavity 1334 open on an underneath side of the thumb button that is sized to receive a portion of a spring 1324 and a pylon 1326 . Assembly of the repositionable lock 60 includes feeding a tapered end 1328 of the pylon 1326 through an opening 1330 extending through the base plate 1322 so that a flange 1332 at an opposing end of the pylon inhibits complete throughput of the pylon. After having the pylon 1326 extend through the base plate 1322 , the spring 1324 is positioned to circumscribe the majority of the longitudinal length of the pylon. Thereafter, the tapered end 1328 of the pylon 1326 , along with a portion of the spring 1324 , is inserted into the hollow cavity 1334 open on an underneath side of thumb button 1320 .
[0134] When the repositionable lock 60 is mounted to the housings 1000 , 1002 , a bottom of the base plate 1322 is seated upon the complementary left and right ledges 1048 , 1050 . In order to maintain the repositionable lock 60 in a biased state, the fourth opening 1022 lateral or widthwise dimension is smaller than the lateral or widthwise dimension of a base 1336 of the thumb button 1320 , thereby precluding vertical removal of the thumb button (and repositionable lock 60 internal components) from the interior of the housings 1000 , 1002 when the housings are mounted to one another. In other words, the housings 1000 , 1002 ledges 1048 , 1050 and peripheral surfaces 1008 , 1010 operate to sandwich the repositionable lock 60 components therebetween (but for a thump pad 1340 of the thumb button 1320 ). A portion of each housing 1000 , 1002 delineating the fourth opening 1022 operates as overhangs so that the triangular cavity 1054 of each housing is longitudinally aligned with corresponding triangular projections 1338 of the thumb button 1320 . In this fashion, the repositionable lock 60 is longitudinally repositionable (in a proximal-distal direction) with respect to the housings 1000 , 1002 within a predetermined range of motion. At a proximal end of the range of motion, the triangular projections 1338 of the thumb button 1320 are received within the triangular cavities 1054 of the housings 1000 , 1002 . When in this position, the repositionable lock 60 is beyond an area of travel of the first and second wheel controls 40 , 50 . But when the thump pad 1340 of the thumb button 1320 is depressed and moved distally, causing the thumb button to slide on top of the ledges 1048 , 1050 and underneath the peripheral surfaces 1008 , 1010 , the triangular projections 1338 are removed from the triangular cavities 1054 of the housings 1000 , 1002 . Upon reaching the distal end of the range of motion for the repositionable lock 60 , a distal tapered end 1342 of the base plate 1322 interposes two adjacent teeth of each plurality of teeth 1170 , 1270 , thereby inhibiting rotational motion of both wheels 1110 , 1140 and rotational motion of both pulleys 1120 , 1130 . In this distal position, the repositionable lock 60 is operative to lock the vertical position and the lateral position of the end effector 100 . It is envisioned that while in this locked position, the end effector 100 may manipulated using the lever control 80 to reposition the jaws 240 , 250 of the end effector 100 to open the occlusion clip 102 .
[0135] Referring to FIGS. 46-48 , the lever control 80 comprises a handle 1350 pivotally mounted to the hollow axle 1028 extending from the interior surface 1012 of the right side housing 1002 . A trigger 1352 is concurrently and pivotally mounted to the hollow axle 1028 and interposes spaced apart loops 1354 of the handle 1350 . The trigger 1352 is repositionable with respect to the handle 1350 in order to lock and selectively unlock a position of the handle with respect to a slide arm 1356 . In exemplary form, the slide arm 1356 is pivotally mounted to the handle 1350 using a pin 1358 and is concurrently mounted to a bobbin 1360 that is configured to slide within the oblong, hollow ridge 1040 of the right side housing 1002 in proximal and distal directions. A spring 1362 , mounted to the slide arm 1356 and to the spring retainer projection 1032 of the right side housing 1002 , operates to bias the slide arm 1356 in its most distal position. But this spring bias may be overcome by a user pulling upward on the handle 1350 (toward the second opening 1018 ), thereby causing the handle to pivot and reposition the slide arm 1356 proximally. As the slide arm 1356 is repositioned, so too is the bobbin 1360 and a control wire 1364 mounted to the bobbin. More specifically, as the bobbin 1360 is repositioned proximally from the handle 1350 being pulled toward the housings 1000 , 1002 , the control wire 1364 is repositioned proximally as a result of being placed under greater tension. Upon the bobbin 1360 reaching near or at the most proximal of its range of motion, the trigger 1352 engages the slide arm 1356 to inhibit further motion that would result in the bobbin moving distally. In this fashion, the trigger 1352 operates to lock the position of the slide arm 1356 and the bobbin 1360 , which in exemplary form corresponds to the end effector 100 opening the occlusion clip 102 for positioning about a left atrial appendage.
[0136] The handle 1350 has a generally arcuate shape, with a concave rear profile and a convex front profile. On this front profile are a series of raised juts 1366 that more readily allow a user to grip the handle 1350 . The rear profile is majorly delineated by a pair of spaced apart struts 1368 that are interposed by a series of ribs 1370 that cooperate to form a series of hollows. Each strut 1368 includes a through orifice aligned with the other strut and sized to receive the pin 1358 about which the slide arm 1356 rotates. And each strut 1368 terminates at a spaced apart loop 1354 that facilitates mounting the handle 1350 to the housings 1000 , 1002 , while concurrently unimpeding rotation of the slide arm 1356 .
[0137] In exemplary form, the slide arm 1356 includes a head 1372 with an orifice that receives the pin 1358 , where the head is connected to a body 1374 of the slide arm via neck 1376 . Proximate where the head 1372 and neck 1376 join one another on the top side of the slide arm 1356 is a V-shaped cavity 1380 , which is accompanied by a catch 1382 formed into the head. As will be discussed in more detail hereafter, the V-shaped cavity 1380 is intended to receive a portion of a rider 1384 of the trigger 1352 as the handle is in an extended position. But as the handle 1350 is rotated upward, the rider 1384 slides against the top surface of the slide arm 1356 and out of the V-shaped cavity 1380 and becomes seated within the catch cavity 1382 when the handle is fully or almost fully brought adjacent the housings 1000 , 1002 (indicative of the slide arm 1356 being positioned proximally to tension the control wire 1364 and, in exemplary form, operative to move the jaws 240 , 250 apart from one another to open the occlusion clip 102 ). In order to release the handle from this rotated position adjacent the housings 1000 , 1002 , a forward end 1386 of the trigger 1352 is depressed, thereby causing the rider 1384 to move out of the catch cavity 1380 and into the V-shaped cavity 1380 . When this occurs (in addition to slacking the control wire 1364 and move the jaws 240 , 250 toward one another), presuming the user is not pulling upward on the handle 1350 , the spring bias resulting from the spring 1362 being in tension causes the slide arm 1356 to move distally and pivot about the handle 1350 , thereby moving the handle away from the housings 1000 , 1002 . A more detailed discussion of the control and deployment wires and the shaft assembly 30 follows.
[0138] Referring to FIGS. 1, 49, and 51-56 , the shaft assembly 30 couples the end effector 100 to the user control 20 . In exemplary form, the shaft assembly includes an elongated shaft 1390 having a pair of longitudinal cut-outs 1392 sized to receive the pair of retention plates 1026 extending from the interior surface 1012 of the right side housing 1002 . The retention plates 1026 mount the shaft assembly 30 to the user control 20 and also operate to inhibit proximal-distal repositioning of the shaft assembly independent of the user control. The elongated shaft 1390 is cylindrical in shape and extends in a generally linear direction. An interior of the elongated shaft 1390 is hollow and includes opposing proximal and distal circular openings 1394 at each end. The proximal opening 1394 is sized to allow insertion of a wire alignment guide 1398 (which also has corresponding cut-outs to receive the retention plates 1026 ) having three dedicated through channels 1406 , 1408 , and 1410 . Each through channel is configured to receive at least two wires and operates to inhibit tangling of adjacent wires. More specifically, the first channel 1406 receives the control wires 1172 , 1174 mounted to the first pulley 1120 . A second channel 1408 receives the deployment wires 1402 , 1404 mounted to the repositionable tab 70 , as well as receiving control wire 1364 mounted to the bobbin 1360 . Finally, the third channel 1410 receives the control wires 1272 , 1274 mounted to the second pulley 1130 . The wire alignment guide 1398 need not extend the entire length of the elongated shaft 1390 so that the distal end opening provides for throughput of all of the wires 1172 , 1174 , 1272 , 1274 , 1364 , 1402 , 1404 where the wires are segregated using the clevis 110 , which circumscribes and mounts to the elongated shaft via friction fit. More specifically, the longitudinal passage 402 at the proximal end 404 of the clevis is sized to receive the distal end of the elongated shaft 1390 . In this manner, the control wires 1272 , 1274 individually extend through a respective through hole 410 of the clevis, while the other wires 1172 , 1174 , 1364 , 1402 , 1404 extend through the elongated through hole 412 of the clevis. Downstream from the clevis 110 , the control wires 1272 , 1274 are individually fed through one of the cylindrical, enlarged openings 469 of the universal 120 and correspondingly mounted to the universal. Likewise, the control wires 1172 , 1174 individually extend through a respective channel 476 , 478 of the universal 120 , while the other wires 1364 , 1402 , 1404 extend through the opening 474 of the universal. Downstream from the universal 120 , the control wires 1172 , 1174 are individually fed through one of the openings 528 of the linkage housing and correspondingly mounted to the linkage housing. Conversely, the other wires 1364 , 1402 , 1404 extend through the channel 546 of the linkage housing 130 . Downstream from the linkage housing 130 , the control wire 1364 is mounted to the pulley 220 , while the deployment wires 1402 , 1404 are respectively directed through openings 674 of the jaws 240 , 250 .
[0139] Turning back to FIGS. 30-57 , assembly of the exemplary user control 20 will be described in more detail. In exemplary form, the wires 1172 , 1174 , 1272 , 1274 , 1364 , 1402 , 1404 are routed through the elongated shaft 1390 and the wire alignment guide 1398 and into the interior of the housings 1000 , 1002 . In particular, the deployment wires 1402 , 1404 are routed to the proximal end of the user control 20 and attached to the repositionable tab 70 . In exemplary fashion, the repositionable tab 70 may be frictionally seated within the proximal opening 1020 or may be otherwise attached so that removal of the repositionable tab requires rotational motion. In addition to the deployment wires 1402 , 1404 being routed, so too is the deployment wire 1364 . By way of example, the trigger 1352 and the handle 1350 are aligned so that the hollow axle 1028 of the right side housing 1002 extends through both components. Likewise, the slide arm 1356 is pivotally mounted to the handle 1350 via the pin 1358 . An opposing portion of the slide arm 1356 is mounted to the bobbin 1360 so that a portion of the bobbin is seated within a cavity within the right side housing 1002 delineated by the hollow ridge 1040 . The deployment wire 1364 is mounted to the bobbin 1360 , while the slide arm 1356 and bobbin are spring biased by way of engagement between the spring 1362 , which is also mounted to the right side housing 1002 . In this fashion, the lever control 80 is spring biased and operative to open and close the jaws 240 , 250 .
[0140] Four of the control wires 1172 , 1174 , 1272 , 1274 are associated with the first and second wheel controls 40 , 50 . Specifically, assembly of the wheel controls 40 , 50 includes positioning the second wheel 1140 to extend through the sixth opening 1052 extending through the right side housing. The axle 1420 is positioned to extend through the center of the second wheel 1140 and be received within the hollow cylinder 1062 of the housings 1000 , 1002 . Before assembling the housings 1000 , 1002 , however, the axle 1420 receives in succession the second pulley 1130 , the first pulley 1120 , and the first wheel 1110 . After the pulleys 1120 , 1130 are received on the axle 1420 , the control wires 1172 , 1174 , 1272 , 1274 are mounted thereto while ensuring the end effector 100 is in a yaw and pitch neutral position. As discussed previously, two control wires 1172 , 1272 go over top of a respective pulley 1120 , 1130 , while the other two control wires 1174 , 1274 go under a respective pulley and are secured thereto via a clamp plate 1176 , 1276 and a set screw 1178 , 1278 . In this fashion, when a user decides to change the yaw of the end effector 100 , the user engages the control knob 1160 of the first wheel 1110 to rotate the first wheel clockwise or counterclockwise. In exemplary fashion, clockwise rotation of the first wheel 1110 (moving the control knob proximally) operates to pivot the universal 120 with respect to the clevis 110 to the right, whereas counterclockwise rotation of the first wheel (moving the control knob distally) operates to pivot the universal with respect to the clevis to the left. Moreover, when a user decides to change the pitch of the end effector 100 , the user engages the control knob 1260 of the second wheel 1140 to rotate the second wheel clockwise or counterclockwise. In exemplary fashion, clockwise rotation of the second wheel 1140 (moving the control knob proximally) operates to pivot the linkage housing 130 upward with respect to the universal 120 , whereas counterclockwise rotation of the second wheel (moving the control knob distally) operates to pivot the linkage housing 130 downward with respect to the universal 120 .
[0141] In order to retard unwanted rotation of the first and second wheel 1110 , 1140 , installation of the repositionable lock 60 includes seating the base plate 1336 upon the corresponding ledges 1048 , 1050 (initially upon the right side ledge 1048 ) after already having assembled the repositionable lock as discussed above. When installed properly, only the thumb pad 1340 of the thumb button 1320 extends above the housings 1000 , 1002 . And proximal and distal motion of the repositionable lock 60 are available, where a most distal position of the repositionable lock places the base plate 1342 to interpose corresponding teeth 1170 , 1270 of the wheels 1110 , 1140 , thereby inhibiting further rotation of the wheels. The repositionable lock 60 may be disengaged simply by moving the thumb pad 1340 proximally until the base plate 1342 no longer engages corresponding teeth 1170 , 1270 of the wheels 1110 , 1140 .
[0142] After the associated components have been installed and mounted to the right side housing 1002 , the left side housing 100 may be repositioned to close the interior and contain the desired portions of the components. In order to ensure continued closure of the housings 1000 , 1002 , it is within the scope of the invention to weld or otherwise fasten the peripheral surfaces of the housings using any number of options such as, without limitation, press fit, screws/fasteners adhesives, ultrasonic welding, heat welding, and laser welding.
[0143] The following comprises a description of exemplary processes for utilizing the exemplary surgical tool 10 . Initially, an incision is made on either the left or right side of the chest wall in an intercostal space that is appropriate for the desired angle of approach to a left atrial appendage (LAA). The incision may be made through the chest wall or through the abdomen (or through the back) as part of various procedures that include, without limitation, an open sternotomy, a left thoracotomy, a right thoracotomy, a left port, a right port, a subxiphoid approach, and a transdiaphragmatic approach. Post incision, a trocar (e.g., 10 mm or larger) may be inserted through the incision to extend into the thoracic cavity. In certain instances, it may be preferred to insufflate the thoracic space subsequent to trocar insertion using known techniques. Using at least one of the incision and trocar, surgical instruments are introduced into the thoracic space in order to perform a series of dissections, including dissection of the pericardium, to provide egress to the LAA. After having access to the LAA, the end effector 100 of the surgical tool 10 may be inserted into the thoracic cavity by way of the incision or trocar.
[0144] The end effector 100 is passed through the trocar or incision and the user manipulates the user controls 20 to navigate the end effector proximate the LAA. By way of example, the first wheel control 40 is operative to vary the yaw of the end effector 100 within an X-Y plane (e.g., depending upon the frame of reference, the first wheel control 40 provide lateral adjustability of the end effector 100 with respect to the housings 1000 , 1002 ), as well as the second wheel control 50 being operative to vary the pitch of the end effector within an Y-Z plane (e.g., depending upon the frame of reference, the second wheel control 50 provides up and down adjustability of the end effector with respect to the housings). Specifically, a user grasping the user control 20 is able to rotate the first wheel 1110 to change the lateral position of the end effector 100 , to which the LAA occlusion clip 102 is mounted, by tensioning a control wire 1172 , 1174 extending though the clevis 110 and mounted to the universal 120 . Likewise, the user grasping the user control 20 is able to rotate the second wheel 1140 to change the vertical position of the end effector 100 by tensioning a control wire 1272 , 1274 extending though the clevis 110 and universal 120 that is mounted to the linkage housing 130 . If desired, the user of the surgical tool 10 may use the thumb button 1320 of the repositionable lock 60 to lock the end effector 100 in place (to fix the X-Y and Y-Z orientations) to create a single position, rigid surgical tool 10 . After navigating the LAA occlusion clip 102 proximate the LAA, the occlusion clip is opened prior to deployment on the LAA.
[0145] Opening the LAA occlusion clip 102 is carried out by actuating the lever control 80 . In particular, the handle 1350 is pivotally repositioned toward the housings 1000 , 1002 , which is operative to tension the control wire 1364 and cause the end effector 100 to further separate its jaws 240 , 250 from one another and open the clip 102 . More specifically, tensioning the control wire 1364 is operative to reposition the pulley 220 proximally. Because a respective cylindrical lateral end of the pulley 220 is received in a through opening 646 of a respective toggle 200 , 210 , when the pulley 220 is repositioned proximally, so too are the toggles repositioned proximally (toward the universal 120 ) as well as rotating about an axis extending through the opening 646 . In particular, the proximal motion and rotation of the toggles 200 , 210 operates to push against the first and second drive links 140 , 150 via the ninth and tenth pins 310 , 320 causing the drive links to move away from one another. But the connection between the first and second drive links 140 , 150 and the linkage housing 130 , via the first pin 160 , causes the drive links to pivot with respect to the linkage housing about the first pin when the drive links are attempted to be moved away from one another via the motion of the toggles 200 , 210 .
[0146] The pivoting motion of the drive links 140 , 150 is transferred to the jaws 240 , 250 via the connection therebetween, facilitated by the fifth and sixth pins 260 , 270 . More specifically, the pivoting of the drive links 140 , 150 away from one another causes the jaws 240 , 250 to move away from one another. But the movement of the jaws 240 , 250 away from one another is constrained by the connection of the jaws to the first and second parallel links 180 , 190 , which are themselves pivotally mounted to the linkage housing 130 . The additional constraint offered by the parallel links 180 results in motion of the jaws 240 , 250 that maintains the jaws in a generally parallel relationship as the jaws are moved from a closed position (adjacent one another with spacing to accommodate the clip 102 ) to a fully open position (spaced away from one another to open the clip to a predetermined maximum extent necessary to position the clip on a LAA). This fully open position of the jaws 240 , 250 coincides with the surface of the toggle connector portions 640 contacting the first and second surfaces 582 , 584 of the inner arms 534 , 536 , thus stopping further proximal and pivoting motion of the toggles 200 , 210 . In other words, the inner arms 534 , 536 of the linkage housing 130 operate to limit the travel of the toggles 200 , 210 , thereby setting the maximum spacing between the jaws 240 , 250 in a fully open position (see FIG. 2 ).
[0147] As long as the jaws 240 , 250 are attached to the occlusion clip 102 , the motion of the jaws results in corresponding motion of the occlusion clip. More specifically, when the jaws are in a closed position (see FIG. 1 ) and mounted to the occlusion clip 102 , the bias of the occlusion clip retains the jaws in the closed position. But when one wants to open the occlusion clip 102 in anticipation of positioning the clip around a LAA, the user of the device 10 must overcome the bias of the occlusion clip. In order to do this, the device 10 incorporates structures that provide a mechanical advantage allowing the user to pivot the handle 1350 toward the housings 1000 and tension the control wire 1364 , which as discussed in greater detail previously, ultimately causing the jaws 240 , 250 to separate from one another and correspondingly separate the parallel beams of the occlusion clip 102 from one another.
[0148] Post opening of the LAA occlusion clip 102 , the clip is advanced over the distal tip of the LAA with the LAA passing between corresponding occlusion beams of the clip, stopping only upon reaching the base of the LAA. It should be noted that forceps may be used to grasp a portion of the LAA when positioning the LAA occlusion clip 102 . After the clip 102 has been positioned at the base of the LAA, with the LAA interposing corresponding occlusion beam surfaces of the clip, the user of the surgical tool 10 may close the clip 102 to sandwich the LAA between the occlusion surfaces.
[0149] Closing the LAA occlusion clip 102 is also carried out by actuating the lever control 80 . Specifically, the user depresses the trigger 1352 to allow the handle 1352 (which is biased to move away from the housings 1000 , 1002 ) to reposition away from the housings 1000 , 1002 and thereafter guide the handle away from the housings. By repositioning the handle 1352 away from the housings 1000 , 1002 , the control wire 1364 is repositioned and facilitates the jaws 240 , 250 of the end effector 100 moving closer to one another (from the bias of the clip 102 while the clip is mounted to the end effector 100 ), thereby sandwiching the clip around the LAA. More specifically, by repositioning the handle 1352 away from the housings 1000 , 1002 , the tension on the control wire 1364 is lessened.
[0150] Lessening the tension of the control wire 1364 causes the end effector 100 to reposition its jaws 240 , 250 toward one another, which coincides with closing the occlusion clip 102 . More specifically, lessening the tension of the control wire 1364 allows the bias of the occlusion clip 102 to become the dominant force and reposition the jaws 240 , 250 toward one another. In exemplary form, the dominant biasing force of the occlusion clip 102 is operative to reposition the jaws 240 , 250 , which in turn causes the first and second drive links 140 , 150 to pivot toward one another, coinciding with the parallel links 180 , 190 pivoting toward one another. Likewise, the toggles 200 , 210 are pivoted and repositioned distally, as is the pulley 220 , ultimately leading to the component positions shown in FIG. 1 .
[0151] After the occlusion clip 102 is positioned about the LAA, various steps may be undertaken to ensure the entire periphery of a portion of LAA is sandwiched by the clip 102 such as, without limitation, direct visual verification and utilization of a transesophageal echocardiogram. If any problems are determined with respect to the clip 102 placement, the opening and closing clip sequence may be repeated to adjust the positioning of the clip with respect to the LAA. Upon closing the LAA occlusion clip 102 around a periphery of a portion of the LAA, proximate the LAA base, as well as confirming the placement of the closed clip being operative to occlude the LAA, the surgeon may release the occlusion clip from the end effector 100 .
[0152] To release the clip 102 from the end effector 100 , the user removes the repositionable tab 70 from the proximal end of the user control 20 . This removal of the repositionable tab 70 causes the deployment wires 1402 , 1404 to be repositioned proximally and discontinue engagement with the suture loops 1412 . When the engagement with the suture loops 1412 is discontinued, the occlusion clip 102 is no longer fastened to the jaws 240 , 250 (i.e., the jaws can be opened and closed without repositioning the clip). As discussed previously, the repositionable tab 70 may be withdrawn from the user control 20 in a straight pull fashion by overcoming a friction fit force or may be withdrawn via other movements including, without limitation, rotation and a combination of rotation and a straight pull that may make use of threads or detents. After disengagement between the occlusion clip 102 and the end effector 100 , the end effector is removed from the cardiac space.
[0153] Removal of the end effector 100 from the patient's body is controlled by the user. Because the end effector 100 is open-ended, there is no need to reposition the end effector upward along the LAA because the end effector can be withdrawn laterally, thus reducing the potential for contact between the end effector and the LAA. In other words, the end effector 100 may be removed from around the LAA without having a tip of the LAA passing between the jaws 240 , 250 . As part of removing the end effector 100 from the cardiac and thoracic space, the user manipulates the user control 20 and causes repositioning of the end effector 100 to allow withdrawal from the patient's body cavity via the incision or trocar. By way of example, it is envisioned that the user repositions the first and second wheel controls 40 , 50 in order to longitudinally align the end effector 100 with the shaft assembly 30 prior to removing the end effector through the trocar or incision.
[0154] Following from the above description and invention summaries, it should be apparent to those of ordinary skill in the art that, while the methods and apparatuses herein described constitute exemplary embodiments of the present invention, it is to be understood that the inventions contained herein are not limited to the above precise embodiment and that changes may be made without departing from the scope of the invention as defined by the following proposed points of novelty. Likewise, it is to be understood that it is not necessary to meet any or all of the identified advantages or objects of the invention disclosed herein in order to fall within the scope of the invention, since inherent and/or unforeseen advantages of the present invention may exist even though they may not have been explicitly discussed herein.
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A medical instrument comprising: (a) a first joint comprising a first member and a second member, the first member configured to be repositionable with respect to the second member in a first degree of freedom; (b) a second joint operatively coupled to the first joint, the second joint comprising a third member and a fourth member, the third member configured to be repositionable with respect to the fourth member in a second degree of freedom; (c) a pair of repositionable jaws operatively coupled to the first joint and the second joint; (d) an occlusion clip detachably mounted to the pair of repositionable jaws; and, (e) a controller operatively coupled to the first joint, the second joint, and the pair of repositionable jaws, the controller including a first control configured to direct repositioning of at least one of the first member and the second member, and a second control configured to direct repositioning of at least one of the third member and the fourth member, and a third control configured to direct repositioning of the pair of repositionable jaws.
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RELATED APPLICATIONS
[0001] This application claims priority to and the benefits of U.S. Provisional Patent Application titled Rotary Peristaltic Dome Pump, Ser. No. 62/245,629, filed on Oct. 23, 2015 and which is incorporated herein in its entirety by reference.
TECHNICAL FIELD
[0002] The present invention relates generally to dispenser systems, such as soap and sanitizer dispensers and refill units.
BACKGROUND OF THE INVENTION
[0003] Dispensing systems, such as soap and sanitizer dispensers, provide a user with a predetermined amount of liquid or foam soap or sanitizer upon actuation of the dispenser.
SUMMARY
[0004] Exemplary embodiments of dispensers, refill units, and pumps with variable output are disclosed herein.
[0005] An exemplary refill unit for a foam dispenser includes a container for holding a foamable liquid and a liquid pump connected to the container and an outlet nozzle. The liquid pump has a rigid back plate and a flexible membrane. The flexible membrane and the rigid back plate form an arcuate shaped liquid pump chamber. The rigid back plate has a liquid inlet located proximate a first end of the arcuate shaped pump chamber and a liquid outlet located proximate a second end of the arcuate shaped pump chamber. The liquid pump is actuated by progressive compression of the flexible membrane against the back plate.
[0006] Another exemplary refill unit for a foam dispenser includes a container for holding a foamable liquid and a pump housing connected to the container. The pump housing has a back plate, a flexible membrane, and an outlet nozzle. The flexible membrane has a base that is accepted in a groove of the back plate. An arcuate shaped pump chamber is formed at least in part by the back plate and the flexible membrane. The arcuate shaped pump chamber includes a liquid inlet in the first end of the arcuate shaped pump chamber and a liquid outlet located in the second end of the arcuate shaped pump chamber. A liquid outlet valve is located in the liquid outlet, and an outlet nozzle extends from the liquid outlet. A foaming media is located at least partially in the outlet nozzle. One or more air inlet apertures are located downstream of the liquid outlet and upstream of the foaming media.
[0007] Still another exemplary refill unit includes a container, a pump housing, a vent valve in the pump housing to vent the container, a rigid back plate, and a flexible membrane. The flexible membrane has a raised portion and a base portion. The base portion of the flexible membrane is secured to the rigid back plate. The raised portion of the flexible membrane forms an arcuate shaped pump chamber between the flexible membrane and the rigid back plate. A mixing chamber is included downstream of the arcuate shaped pump chamber and an outlet nozzle.
[0008] An exemplary foam dispenser includes a housing, an air pump secured to the housing and an actuating mechanism secured to the housing. The actuating mechanism has a swipe gear secured to a motor. A refill unit is installed in the dispenser that has a container and a pump secured to the container. The pump has a flexible membrane and a back plate that form an arcuate pump chamber and an outlet nozzle. The swipe gear compresses the arcuate pump chamber only during actuation of the pump.
[0009] Another foam dispenser includes a housing. An air pump and an actuating mechanism are secured to the housing. The actuating mechanism has a swipe gear secured to a motor. A refill unit is installed in the dispenser. The refill unit includes a container and a liquid pump secured to the container. The liquid pump has a flexible membrane and a back plate that form an arcuate pump chamber and an outlet nozzle. The swipe gear compresses the arcuate pump chamber only during actuation of the pump. The motor drives both the liquid pump and the air pump.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] These and other features and advantages of the present invention will become better understood with regard to the following description and accompanying drawings in which:
[0011] FIG. 1 is a cross-section of an exemplary dispenser system having a refill unit;
[0012] FIG. 2A is a perspective view of an exemplary refill unit and actuation drive system;
[0013] FIG. 2B is a partial cross-section of the refill unit of FIG. 2A ;
[0014] FIG. 2C is a partial cross-section of the refill unit of FIG. 2A ;
[0015] FIG. 2D is a perspective view of the actuation drive assembly of FIG. 2A ;
[0016] FIG. 3A is a perspective view of an exemplary dispenser system having a refill unit with the housing removed;
[0017] FIG. 3B is a partial cross-section of the refill unit of FIG. 3A ;
[0018] FIG. 3C is a partial perspective view of the dispenser and refill unit of FIG. 3A with the swipe gear removed; and
[0019] FIG. 3D is a partial perspective view of an actuator drive assembly and the swipe gear that was not shown in FIG. 3C .
DETAILED DESCRIPTION
[0020] FIG. 1 illustrates an exemplary embodiment of a foam dispenser 100 . The cross-section of FIG. 1 is taken through the housing 102 to show a liquid pump 120 , an air pump 130 , a container 116 , and an actuator 140 . The dispenser 100 includes a disposable refill unit 110 . The disposable refill unit 110 includes container 116 , liquid pump 120 , premix chamber 122 , and outlet nozzle 126 . The dispenser 100 may be a wall-mounted system, a counter-mounted system, an un-mounted portable system movable from place to place, or any other kind of dispenser system. The dispenser 100 can be configured to pump liquid only with the air pump 130 removed or deactivated. Other components may also be removed for use with liquid dispensers only.
[0021] The container 116 forms a liquid reservoir that contains a supply of dispensable liquid within the disposable refill unit 110 . In various embodiments, the contained liquid could be for example a soap, a sanitizer, a cleanser, a disinfectant, a lotion, a foamable liquid, or other dispensable liquid. In the exemplary disposable refill unit 110 , the container 116 is formed by a rigid housing member. A vent (not shown) to vent the container 116 is included. A vent (not shown) may be included in a wall of the container, or may be included in the pump 120 connected to the container (e.g. vent port 218 and vent valve 219 of FIG. 2B ). In other embodiments, the container 116 may be formed by a collapsible container and can be made of thin plastic or a flexible bag-like material, or have any other suitable configuration for containing the liquid without leaking. A vent is not needed with a collapsible container.
[0022] The container 116 may advantageously be refillable, replaceable or both refillable and replaceable. In the event the liquid stored in the container 116 of the installed disposable refill unit 110 runs out, or the installed refill unit 110 otherwise has a failure, the installed refill unit 110 may be removed from the dispenser 100 . The empty or failed disposable refill unit 110 may then be replaced with a new disposable refill unit 110 .
[0023] The refill unit 110 includes the liquid pump 120 that is in fluid communication with the container 116 . A collar 114 secures the liquid pump 120 to the container 116 . The collar 114 , which may be a separate component or may be an integrally formed part of the liquid pump 120 , may secure the liquid pump 120 to the container 116 by any means, such as, for example, a threaded connection, a welded connection, a quarter turn connection, a snap fit connection, a clamp connection, a flange and fastener connection, or the like.
[0024] The outlet of the liquid pump 120 is in fluid communication with a premix chamber 122 that also receives air from the air pump 130 through an air delivery tube 134 . The premix chamber 122 is in fluid communication with an outlet nozzle 126 .
[0025] In some embodiments, the liquid pump 120 , premix chamber 122 , and outlet nozzle 126 are part of the refill unit 110 and may be disposed of upon depletion of the liquid from the container 116 . The air pump 130 and air delivery tube 134 are secured to the dispenser 100 and are not disposed of while replacing the refill unit 110 . The concept of having a foam pump that has a liquid pump portion separable from an air pump portion may be referred to as a “split pump.” Exemplary split pumps are shown and described in U.S. Pat. No. 9,089,860 entitled “Bifurcated Foam Pump, Dispenser, and Refill Units”, which is incorporated herein by reference in its entirety. The air pump 130 is generically illustrated because there are many different kinds of air pumps which may be employed in dispenser 100 . Air pump 130 may be any type of air pump, such as a rotary pump, a piston pump, a fan pump, a turbine pump, a pancake pump, a diaphragm pump, or the like.
[0026] In some embodiments, the refill unit 110 includes projections (not shown) that interface with a rotatable retention ring (not shown) on the interior of the housing 102 . These projections secure the refill unit 110 within the housing 102 and retain the liquid pump 120 in contact with an actuation assembly 144 of actuator 140 when the refill unit 110 is installed in the dispenser 100 . The retention ring is rotated to remove the refill unit 110 from the dispenser 100 . An exemplary embodiment is shown and described in U.S. Pat. No. 8,485,395 entitled “Dispenser Lock Out Mechanism”, which is incorporated herein by reference in its entirety. The refill unit 110 may be secured within the dispenser 100 by other means, such as, for example, a quarter turn connection, a threaded connection, a flange and fastener connection, a clamped connection, or any other releasable connection. In some embodiments, components of the actuator 140 , such as actuation assembly 144 , may be part of the refill unit 110 . In fact, many of the components of the actuator 140 may be part of the dispenser 100 or be part of the refill unit 110 . The actuation assembly 144 includes a swipe gear (not shown) similar to those described below and liquid pump 120 is similar to the liquid pumps described below.
[0027] The dispenser 100 also includes a sensor 150 for detecting a users hand, a processor and memory (not shown), and a power source (not shown) such as one or more batteries. The dispenser 100 may include a power system, such as that described in U.S. Published Patent Application No. 2014/0234140 entitled “Power Systems for Touch Free Dispensers and Refill Units Containing A Power Source”, which is incorporated herein by reference in its entirety.
[0028] During operation of the dispenser 100 , upon detection of a hand by sensor 150 foamable liquid is pumped from the container 116 by the liquid pump 120 into the premix chamber 122 . Simultaneously, air is drawn into the air pump 130 through an air inlet 132 and is pumped through the air delivery tube 134 into the air inlet 124 of the premix chamber 122 to mix with the liquid. The air and liquid mixture is then forced through foaming media (not shown) to dispense rich foam from the nozzle 126 . In one embodiment, foaming media includes one or more screens that generate high quality foam. Foaming media may also include porous members, sponges, baffles, or the like. An aperture 115 in a bottom plate 103 of the housing 102 allows foam dispensed from the nozzle 126 to exit the housing 102 for use by the user.
[0029] The dispenser 100 contains one or more actuators 140 to activate the liquid pump 120 and the air pump 130 . As used herein, actuator, actuating members, or mechanism includes one or more parts that cause the dispenser 100 to move liquid, air or foam. Different actuators may activate the liquid pump 120 and air pump 130 , or one actuator may be used to activate both the liquid pump 120 and air pump 130 . In some embodiments, the actuator 140 includes an electric motor 141 that turns a drive train 142 (such as one or more gears as shown) that interfaces with the actuation assembly 144 that actuates the liquid pump 120 when turned. The electric motor 141 of actuator 140 may be an AC motor or a DC motor and may be powered by a standard electrical source, such as 115 VAC or by batteries. A second motor 143 activates the air pump 130 to pump air into the premix chamber 122 to generate foam. Although the actuators are shown as the electric motors 141 , 143 for a hands-free dispenser system with touchless operation, they may be any kind of actuator capable of activating the liquid and air pumps 120 , 130 , such as a manual lever, a manual pull bar, a manual push bar, a manual rotatable crank, an electrically activated actuator, or other means for actuating the liquid pump 120 and air pump 130 .
[0030] The air pump 130 and actuators 140 may be connected to the housing 102 by any means. In an exemplary split pump embodiment, the electronics (not shown), air pump 130 , air delivery tube 134 , and actuators 140 are part of a pump house (not show) that is attached to the housing 102 . Assembling these components into the pump house allows for easier assembly of the dispenser 100 and ensures alignment of the components.
[0031] FIGS. 2A, 2B, 2C, and 2D illustrate an exemplary embodiment of a refill unit 210 and actuation drive system of an exemplary dispenser 200 . The dispenser 200 includes a housing, a sensor, batteries, and circuitry that are not shown for clarity. The refill unit 210 is removable from the dispenser 200 and includes a container 212 , a liquid pump 230 , and a nozzle 250 . The dispenser 200 includes an air pump 260 and an actuation assembly 270 for actuating the liquid and air pumps 230 , 260 . In some embodiments, both the air pump 260 and liquid pump 230 of the dispenser 200 may be included in the refill unit 210 . When arranged as a split pump, the air pump 260 is secured to the dispenser 200 and is not removed when the dispenser 200 is refilled by replacing the refill unit 210 . The actuation assembly 270 may also be included in the refill unit 210 or may be secured to the dispenser 200 .
[0032] The interior of the container 212 forms a reservoir 220 for holding foamable liquid. A neck 214 of the container 212 is received within a collar 216 of a container closure 234 . When the collar 216 is connected to the neck 214 of the container 212 , a liquid tight seal is formed between the closure 234 and the container 212 . The collar 216 may be connected to the container 212 by any means, such as, for example, a threaded connection, a welded connection, an adhesive connection, a snap fit connection, a friction fit connection, a quarter turn connection, or the like. The container 212 is non-collapsing and is formed by a semi-rigid plastic. The container 212 is vented through a vent valve 219 in a vent port 218 of the container closure 234 . In some embodiments, the container 212 is be formed by a collapsible container and can be made of thinner plastic or a flexible bag-like material, or have any other suitable configuration for containing the liquid without leaking and does not need a vent.
[0033] The liquid pump 230 includes a pump body 232 and a semi-annular flexible actuation membrane 240 which is best seen in FIG. 2C . The pump body 232 is connected to container closure 234 and the two are shown as separate components in FIG. 2B , but may also be formed integrally as a single component. The pump body 232 has an outlet 236 and a rigid back plate 238 . The flexible actuation membrane 240 has a base 241 , a resilient actuation portion 242 , a first end 244 , a second end 246 , and a direction of actuation 248 . In some embodiments first end 244 has a surface that slopes upward to the top of the flexible actuation membrane 240 . In some embodiments second end 244 has a surface that slopes downward from the top of the flexible actuation membrane 240 .
[0034] A groove 239 in the back plate 238 receives the base 241 of the flexible actuation member 240 forming an arcuate pump chamber 222 between the actuation membrane 240 and the back plate 238 . A liquid tight seal is formed between the base 241 of the actuation membrane 240 and the groove 239 of the back plate 238 . The flexible actuation membrane 240 and pump body 232 may be held together by any means, such as, for example, an adhesive, a friction fit connection, a projection and groove connection, through the use of another component to mechanically restrain the component, or the like. The flexible actuation membrane 240 may be made of any suitable flexible material, such as, for example, latex rubber, polyisoprene, TPE, silicone, EPDM rubber, nitrile rubber, or the like. In some embodiments the flexible actuation membrane 240 has a Shore D hardness of between about 30 and 60 durometer.
[0035] A fluid passage 231 extends from inlet 221 through the container closure 234 and pump body 232 to fluidly connect the reservoir 220 and the pump chamber 222 . An outlet passage 233 extends through the portion 236 of pump housing 232 to fluidly connect the pump chamber 222 to a premix chamber 226 in the nozzle 250 . A one-way outlet valve 237 is disposed in the pump housing 232 downstream of pump chamber 222 . One-way outlet valve 237 prevents fluid from flowing up into the pump chamber 222 and container 212 . It also helps prevent liquid from leaking out of the refill unit 210 during storage. The one-way outlet valve 237 is shown as a duck-bill valve but may be any kind of one-way valve, such as, for example, a ball and spring valve, a poppet valve, a flapper valve, an umbrella valve, a slit valve, a mushroom valve, or the like. In some embodiments, one-way outlet valve 237 reduces the volume of the pump chamber 222 to increase the efficiency of the pump.
[0036] In some embodiments, the outlet nozzle 250 includes a pump outlet valve 252 , an air inlet 254 , foaming media 256 , and an end cap 258 . The nozzle 250 is attached to the outlet portion 236 of pump housing 232 by any means, such as, for example, a threaded connection, a welded connection, an adhesive connection, a snap fit connection, a friction fit connection, a quarter turn connection, or the like. The outlet valve 252 is retained against the outlet portion 236 by the nozzle 250 and may be any kind of one-way valve, such as, for example, a ball and spring valve, a poppet valve, a flapper valve, an umbrella valve, a slit valve, a mushroom valve, a duck bill valve, or the like. The foaming media 256 is retained within the nozzle 250 by the end cap 258 and includes at least one mix media that generates high quality foam, such as, for example, one or more screens, porous members, sponges, baffles, or the like or combinations thereof. Foam is dispensed through a nozzle outlet 228 of the nozzle 250 . The end cap 258 is attached to the nozzle 250 by any means, such as, for example, a threaded connection, a welded connection, an adhesive connection, a snap fit connection, a friction fit connection, a quarter turn connection, or the like. In some embodiments any one of the outlet valves 237 , 252 are not used.
[0037] The air pump 260 includes an actuation shaft 262 and an air pump outlet 264 . The air pump 260 is connected to the nozzle 250 by an air delivery tube 266 . The air delivery tube 266 attaches to the air pump outlet 264 of the air pump 260 and an air inlet 254 of the nozzle 250 . An air inlet passageway 227 extends through the air inlet 254 to fluidly connect the air pump 260 to the premix chamber 226 . A one-way valve (not shown) may optionally be included in the air inlet 254 to prevent back flow of fluid from the premix chamber 226 if, for example, the nozzle outlet 228 of the refill unit 210 becomes clogged.
[0038] The actuation assembly 270 includes a motor 272 , a first drive train 274 , a second drive train 275 , and a swipe gear 276 . In the illustrated embodiment, the motor 272 is an electric motor and may be an AC motor or a DC motor and may be powered by a standard electrical source, such as 115 VAC outlets or by batteries. The motor 272 has a drive shaft 273 that connects to the first and second drive trains 274 , 275 . The first drive train 274 transmits power from the motor 272 to the swipe gear 276 to actuate the liquid pump 230 . The second drive train 275 transmits power from the motor 272 to the actuation shaft 262 of the air pump 260 to actuate the air pump 260 . The first drive train 274 also reduces the rotational speed of the motor 272 that is transmitted to the swipe gear 276 so that more than one rotation of the drive shaft 273 is required to rotate the swipe gear 276 through a complete rotation. In the illustrated embodiments, the first drive train 274 is a series of gears and the second drive train 275 is a flexible belt. In some embodiments, gears are used for both the first and second drive trains 274 , 275 . Alternatively, two different motors (not shown) may be used to actuate the liquid and air pumps 230 , 260 .
[0039] When the refill unit 210 is installed in the dispenser 200 the liquid pump 230 is positioned so that rotation of the swipe gear 276 in the direction of actuation 248 will cause the swipe projections 277 to compress the actuation portion 242 and wipe across the actuation portion 242 of the actuation membrane 240 , and therefore, the pump chamber 222 . The first end 242 and second end 244 of the flexible actuation membrane 240 are rounded and/or tapered to provide a smooth transition for a swiping projections 277 of a swipe gear 276 during actuation of the liquid pump 230 . In some embodiments, projections 277 are formed as part of swipe gear 276 . In some embodiments, projections 277 are one or more rollers. In some embodiments, projections 277 have a sloped surface. In some embodiments, there are two projections 277 . In some embodiments, there are more than two projections 277 . As the swipe gear 276 is rotated, the swiping projections 277 progressively compress the actuation portion 242 of the actuation membrane 240 against the back plate 238 of the pump body 232 causing liquid in the pump chamber 222 to be forced through the outlet valve 237 into the outlet 224 . The actuation portion 242 of the membrane 240 expands to its original uncompressed position behind each swipe projection 277 , causing the pump chamber 222 to increase in volume, drawing in liquid from the reservoir 220 through the inlet 221 . As described above, the chamber valve 237 prevents fluid from leaking out of the pump chamber 222 when the membrane 240 is not compressed. In some embodiments, in between actuation cycles, the swipe projections 277 of the swipe gear 276 do not engage the actuation membrane 240 . This allows the actuation membrane 240 to be made from thermoplastic materials rather than thermoset materials. In some embodiments, one or more projections 277 always compress a portion of pump chamber 222 and the outlet valve(s) may not be needed.
[0040] Rotation of the swipe gear 276 pushes liquid past the outlet valve 252 and into the premix chamber 226 . Simultaneously, the motor 272 causes the drive shaft 262 of the air pump 260 to rotate, pumping air through the air delivery tube 266 into the premix chamber 224 through the air inlet passageway 227 .
[0041] The liquid flow rate from the liquid pump 230 may be different than the air flow rate of the air pump 260 . In some embodiments, the air to liquid ratio between the two pumps may be between about 1 to 1 and about 20 to 1, for example, the air to liquid ratio may be about 15 to 1, 10 to 1, 8 to 1, or 5 to 1. Continued actuation of the dispenser forces the air and liquid mixture out of the premix chamber 226 through the foaming media 256 to generate and dispense rich foam from the nozzle outlet 228 .
[0042] FIGS. 3A, 3B, 3C, and 3D illustrate an exemplary embodiment of a dispenser system 300 , a refill unit 310 , and an actuator drive assembly. The dispenser 300 includes a housing, a sensor, batteries, and circuitry that are not shown for clarity. The refill unit 310 is removable from the dispenser 300 and includes a container 312 , a liquid pump 330 , and a nozzle 350 . The liquid pump 330 is oriented in a generally horizontal direction, in contrast to the vertically oriented liquid pump 230 described above. The dispenser includes an air pump 360 and an actuation assembly 370 for actuating the liquid and air pumps 330 , 360 . In some embodiments, both the air pump 360 and liquid pump 330 of the dispenser 300 may be included in the refill unit 310 . When arranged as a split pump, the air pump 360 is secured to the dispenser 300 and is not removed when the dispenser 300 is refilled by replacing the refill unit 310 . The actuation assembly 370 may also be included in the refill unit 310 or may be secured to the dispenser 300 .
[0043] The interior of the container 312 forms a reservoir 320 for holding foamable liquid. A neck 314 of the container 312 is received within a collar 316 of a container closure 334 . When the collar 316 is connected to the neck 314 of the container 312 , a liquid tight seal is formed between the closure 334 and the container 312 . The collar 316 may be connected to the container 312 by any means, such as, for example, a threaded connection, a welded connection, an adhesive connection, a snap fit connection, a friction fit connection, a quarter turn connection, or the like. The container 312 is non-collapsing and is formed by a semi-rigid plastic. The container 312 is vented through a vent valve 319 in a vent port 318 of the container closure 334 . In some embodiments, the container 312 is be formed by a collapsible container and can be made of thinner plastic or a flexible bag-like material, or have any other suitable configuration for containing the liquid without leaking and does not need a vent.
[0044] The liquid pump 330 includes a pump body 332 and a semi-annular flexible actuation membrane 340 which is best seen in FIG. 3C . The pump body 332 is connected to container closure 334 and the two are shown as separate components in FIG. 3B , but may also be formed integrally as a single component. The pump body 332 has an outlet 336 and a rigid back plate 338 . The flexible actuation membrane 340 has a base 341 , a resilient actuation portion 342 , a first end 344 , a second end 346 , and a direction of actuation 348 .
[0045] A groove 339 in the back plate 338 receives the base 341 of the flexible actuation member 340 forming an arcuate pump chamber 322 ( FIG. 3C ) between the actuation membrane 340 and the back plate 338 . A liquid tight seal is formed between the base 341 of the actuation membrane 340 and the groove 339 of the back plate 338 . The flexible actuation membrane 340 and pump body 332 may be held together by any means, such as, for example, an adhesive, a friction fit connection, a projection and groove connection, through the use of another component to mechanically restrain the component, or the like. The flexible actuation membrane 340 may be made of any suitable flexible material, such as, for example, latex rubber, polyisoprene, TPE, silicone, EPDM rubber, nitrile rubber, or the like. In some embodiments the flexible actuation membrane 340 has a Shore D hardness of between about 30 and 60 durometer.
[0046] A fluid passage 331 extends from inlet 321 through the container closure 334 and pump body 332 to fluidly connect the reservoir 320 and the pump chamber 322 . An outlet passage 333 extends through the portion 336 of pump housing 332 to fluidly connect the pump chamber 322 to a premix chamber 326 in the nozzle 350 . A one-way outlet valve 337 is disposed in the pump housing 332 downstream of pump chamber 322 . One-way outlet valve 337 prevents fluid from flowing up into the pump chamber 322 and container 312 . It also helps prevent liquid from leaking out of the refill unit 310 during storage. The one-way outlet valve 337 is shown as a duck-bill valve but may be any kind of one-way valve, such as, for example, a ball and spring valve, a poppet valve, a flapper valve, an umbrella valve, a slit valve, a mushroom valve, or the like. In some embodiments, one-way outlet valve 337 reduces the volume of the pump chamber 322 to increase the efficiency of the pump.
[0047] In some embodiments, the outlet nozzle 350 includes a pump outlet valve 352 , an air inlet 354 , foaming media 356 , and an end cap 358 . The nozzle 350 is attached to the outlet portion 336 of pump housing 332 by any means, such as, for example, a threaded connection, a welded connection, an adhesive connection, a snap fit connection, a friction fit connection, a quarter turn connection, or the like. The outlet valve 352 is retained against the outlet portion 336 by the nozzle 350 and may be any kind of one-way valve, such as, for example, a ball and spring valve, a poppet valve, a flapper valve, an umbrella valve, a slit valve, a mushroom valve, a duck bill valve, or the like. The foaming media 356 is retained within the nozzle 350 by the end cap 358 and includes at least one mix media that generates high quality foam, such as, for example, one or more screens, porous members, sponges, baffles, or the like or combinations thereof. Foam is dispensed through a nozzle outlet 328 of the nozzle 350 . The end cap 358 is attached to the nozzle 350 by any means, such as, for example, a threaded connection, a welded connection, an adhesive connection, a snap fit connection, a friction fit connection, a quarter turn connection, or the like. In some embodiments any one of the outlet valves 337 , 353 are not used.
[0048] The air pump 360 includes an actuation shaft 362 and an air pump outlet 364 . The air pump 360 is connected to the nozzle 350 by an air delivery tube 366 . The air delivery tube 366 attaches to the air pump outlet 364 of the air pump 360 and an air inlet 354 of the nozzle 350 . An air inlet passageway 327 extends through the air inlet 354 to fluidly connect the air pump 360 to the premix chamber 326 . A one-way valve (not shown) may optionally be included in the air inlet 354 to prevent back flow of fluid from the premix chamber 326 if, for example, the nozzle outlet 328 of the refill unit 310 becomes clogged.
[0049] The actuation assembly 370 includes a motor 372 , a first drive train 374 , a second drive train 375 , and a swipe gear 376 . In the illustrated embodiment, the motor 372 is an electric motor and may be an AC motor or a DC motor and may be powered by a standard electrical source, such as 115 VAC outlets or by batteries. The motor 372 has a drive shaft 373 that connects to the first and second drive trains 374 , 375 . The first drive train 374 transmits power from the motor 372 to the swipe gear 376 to actuate the liquid pump 330 . The second drive train 375 transmits power from the motor 372 to the actuation shaft 362 of the air pump 360 to actuate the air pump 360 . The first drive train 374 also reduces the rotational speed of the motor 372 that is transmitted to the swipe gear 376 so that more than one rotation of the drive shaft 373 is required to rotate the swipe gear 376 through a complete rotation. To accommodate the horizontal orientation of the liquid pump 330 and actuation membrane 340 , a beveled gear 378 of the first drive train 275 engages a beveled portion of the horizontally oriented swipe gear 376 . An annular housing 379 is also included to retain the swipe gear 376 against the actuation membrane 340 . The annular housing 379 at least partially surrounds the actuation membrane 340 and the pump housing 332 . In some embodiments, the annular housing 379 may be secured to the pump housing 332 . In the illustrated embodiments, the first drive train 374 is a series of gears and the second drive train 375 is a flexible belt. In some embodiments, gears are used for both the first and second drive trains 374 , 375 . Alternatively, two different motors (not shown) may be used to actuate the liquid and air pumps 330 , 360 .
[0050] When the refill unit 310 is installed in the dispenser 300 the liquid pump 330 is positioned so that rotation of the swipe gear 376 in the direction of actuation 348 will cause the swipe projections 377 to compress the actuation portion 342 and wipe across the actuation portion 342 of the actuation membrane 340 , and therefore, the pump chamber 322 . The first end 342 and second end 344 of the flexible actuation membrane 340 are rounded and/or tapered to provide a smooth transition for a swiping protrusions 377 of a swipe gear 376 during actuation of the liquid pump 330 . In some embodiments, protrusions 377 are rollers. As the swipe gear 376 is rotated, the swiping projections 377 progressively compress the actuation portion 342 of the actuation membrane 340 against the back plate 338 of the pump body 332 causing liquid in the pump chamber 322 to be forced through the outlet valve 337 into the outlet 324 . The actuation portion 342 of the membrane 340 expands to its original uncompressed position behind each swipe projection 377 , causing the pump chamber 322 to increase in volume, drawing in liquid from the reservoir 320 through the inlet 321 . In some embodiments, in between actuation cycles, the swipe projections 377 of the swipe gear 376 do not engage the actuation membrane 340 . As described above, the chamber valve 337 prevents fluid from leaking out of the pump chamber 322 when the membrane 340 is not compressed. This allows the actuation membrane 340 to be made from thermoplastic materials rather than thermoset materials. In some embodiments, one or more projections 377 always compress a portion of pump chamber 322 and the outlet valve(s) may not be needed.
[0051] Rotation of the swipe gear 376 pushes liquid past the outlet valve 352 and into the premix chamber 326 . Simultaneously, the motor 372 causes the drive shaft 362 of the air pump 360 to rotate, pumping air through the air delivery tube 366 into the premix chamber 324 through the air inlet passageway 327 .
[0052] The liquid flow rate from the liquid pump 330 may be different than the air flow rate of the air pump 360 . In some embodiments, the air to liquid ratio between the two pumps may be between about 1 to 1 and about 20 to 1, for example, the air to liquid ratio may be about 15 to 1, 10 to 1, 8 to 1, or 5 to 1. Continued actuation of the dispenser forces the air and liquid mixture out of the premix chamber 326 through the foaming media 356 to generate and dispense rich foam from the nozzle outlet 328 .
[0053] While the present invention has been illustrated by the description of embodiments thereof, and while the embodiments have been described in considerable detail, it is not the intention of the applicants to restrict or in any way limit the scope of the appended claims to such detail. Additional advantages and modifications will readily appear to those skilled in the art. Moreover, elements described with one embodiment may be readily adapted for use with other embodiments. Therefore, the invention, in its broader aspects, is not limited to the specific details, the representative apparatus and illustrative examples shown and described. Accordingly, departures may be made from such details without departing from the spirit or scope of the applicants' general inventive concept.
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An exemplary refill unit for a foam dispenser includes a container for holding a foamable liquid and a liquid pump connected to the container and an outlet nozzle. The liquid pump has a rigid back plate and a flexible membrane. The flexible membrane and the rigid back plate form an arcuate shaped liquid pump chamber. The rigid back plate has a liquid inlet located proximate a first end of the arcuate shaped pump chamber and a liquid outlet located proximate a second end of the arcuate shaped pump chamber. The liquid pump is actuated by progressive compression of the flexible membrane against the back plate.
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FIELD OF THE INVENTION
This invention is directed to a biocidal composition containing tetrachloroisophthalonitrile and 3-iodo-2-propynylbutylcarbamate in the form of a liquid which serves to inhibit fungal, algae and bacterial growth.
DESCRIPTION OF RELATED ART
The compound 3-iodo-2-propynyl butylcarbamate (hereinafter referred to as "IPBC") is a well-known biocide, having good fungicidal activity. It also has activity against bacterial and unicellular green algae, but has been found to be much less effective against unicellular blue green algae.
IPBC has been mixed with various biocides in combination form for various applications. U.S. Pat. No. 5,162,343 discloses IPBC with sodium 2-pyridinethiol-1-oxide in a biocidal composition. U.S. Pat. No. 5,328,926 discloses IPBC with 1,2-Benzisothiazolin-3-one for use in controlling the growth of fungi and bacteria in fluids. U.S. Pat. No. 5,591,760 discloses IPBC with 4,5-dichloro-2-octyl-3-isothiazolone in various applications. U.S. Pat. No. 5,707,929 discloses IPBC with N-Cyclopropyl-N' (1,1-dimethyl)-6-(methylthio)-1,3,5-triazine-2,4-dismine as a fungicide and algaecide.
Tetrachloroisophthalonitrile (hereinafter referred to as "CTL") has been used as a fungicide in agriculture and in architectural coating applications i.e., paints, stains, and other related coatings. It provides very good, long-term fungicidal protection in the cured coating.
U.S. Pat. No. 3,948,636 discloses the formulation of tetrachloroisophthalonitrile as a flowing aqueous dispersion. PCT WO 79/00654 discloses tetrachloroisophthalonitrile in surfactants and non-aqueous media for coating applications. U.S. Pat. No. 5,401,757 discloses tetrachloroisophthalonitrile in biocidal compositions with substituted urea and sulfoxide or sulfone.
Although the principal utility disclosed for CTL has been as a fungicide, this compound exhibits activity against gram-positive bacteria and unicellular blue green algae (Cyanophyceae family, such as Oscillatoria sp., Scytonema sp., Gloeocapsa sp., Chroococcus sp., Calothrix sp., etc.). Those species are very commonly found on substrates to be covered with exterior paints, in sea water environments, and on various coatings, and cannot be inhibited by IPBC.
SUMMARY OF THE INVENTION
In accordance with the present invention, it has now surprisingly been found that when IPBC and CTL are employed in combination in the form of a liquid dispersion, they constitute a broad-spectrum biocidal composition displaying bactericidal, fungicidal and algaecidal activity. The composition is easy to use and is an environmentally friendly mixture suitable for use in both water-based and solvent-based applications.
The combination of IPBC and CTL provides both short-term and long-term protection for coatings, as well as protection against bacteria, fungi and algae, when employed in coating applications.
Further, as will be seen from the examples which follow, the combination of IPBC and CTL produce biocidal results in combination which is greater than the sum of the biocidal results that are produced when each is used separately. In other words, a synergistic result is obtained.
DETAILED DESCRIPTION OF THE INVENTION
The present invention is directed to a biocidal composition suitable for controlling unwanted bacterial, fungal, and algae growth in water-based and solvent-based applications. The liquid biocidal compositions of the present invention comprise a synergistic mixture of CTL and IPBC. The weight ratio of CTL to IPBC in the present invention preferably ranges from about 0.01:99 to about 99:0.01, more preferably from about 1:10 to about 10:1, and most preferably from about 1:4 to about 4:1. The composition can also contain from about 0% to about 40% by weight of one or more surfactants, exemplary of which are EO IPO block copolymers, such as Witcomol®324, sulfosuccinates, naphthalene sulfonates, and acrylic graft copolymers, which serve the combined function of a wetting agent, dispersant, emulsifier, and defoamer for both the CTL and IPBC.
The composition also contains from about 0% to about 50%, by weight, of an environmentally friendly organic solvent for the purpose of functioning as a co-solvent to stabilize the dispersion which is formed. Exemplary of the solvents which can be employed are propylene glycol methyl ether, dipropylene glycol methyl ether, tripropyleneglycol methyl ether, propylene glycol methyl ether acetate, propylene glycol phenyl ether, propylene glycol propyl ether, propylene glycol butyl ether, and other common solvents which are known of or used in coating applications.
The composition can also contain from 0% to about 5% of fused silica, a modified or unmodified carbohydrate polymer, a polyurethane or an acrylic type material to function as a thickener or anti-settling agent by which the viscosity is established and maintained over time and also to avoid the settling of solids with the passage of time.
The composition of the present invention has utility for retarding microbial growth, including bacterial, fungal and algae growth, in paints, marine anti-fouling coatings, cooling towers, metal working fluids, fuel systems, swimming pools, coatings, fabric, leather, paper, wood, cosmetic formulations and other personal care products, therapeutic pharmaceutical formulations, and the like.
The examples presented below serve to illustrate the invention and to demonstrate the synergistic results obtained when CTL and IPBC are used in combination as compared with their effectiveness when used individually.
The bacterial, fungal and algae tests set forth below were conducted to demonstrate the synergism of the two-component compositions of the present invention by testing over a wide range of concentrations and ratios of CTL and IPBC. For the microorganisms listed in Tables I and II, three independent experimental determinations were done for each bacteria, two independent experimental determinations for each fungi and one experimental determination for each algae.
A. For bacterial evaluation TSA or TSB media from Sigma-Aldrich was used. The medium was autoclaved at 121° C. for 20 minutes prior to the addition of the biocides. After addition of the biocides in the indicated concentrations to the media, 100μl of a suspension of the testing bacteria (Bacillus subtilis ATCC 27328 or Staphylococcus aureus ATCC 6588) was added to a final concentration of approximately 10 6 CFU/ml. The inoculated media was incubated at 32° C. for 5-7 days.
B. For fungal evaluations, a mineral salts-glucose was used as a liquid medium. Malt agar from Sigma-Aldrich was used as a solid medium. The mineral salts-glucose medium contained: 0.7 g of KH 2 PO 4 , 0.7 g of MgSO 4 .7H 2 O, 1.0 g of NH 4 NO 3 , 0.005 g NaCl, 0.002 g FeSO 4 .7H 2 O, 0.002 g Z n SO 4 .7H 2 O, 0.001 g of glucose, dissolved in 1.0 liter of deionized water. The pH of the medium was adjusted to 6 with 1N NaOH. Both media were autoclaved at 121° C. for 20 minutes prior to the addition of biocides. Each fungi (Aspergillus niger ATCC 6275, A. orizae ATCC 10191, Aureobasidium pullulans ATCC 9348 or Gliocladium virens ATCC 9645), was grown on Malt agar for 10 days and a spore suspension was prepared by washing the spores from the plate into a sterile water solution. After the addition of the biocides in the indicated concentrations to the medium, the fungal spore suspension was added. The final spore concentration was approximately 10 6 spores/ml. The inoculated media was incubated at 28° C. for 7-10 days.
C. For algae evaluations, modified Allen's medium was used. To prepare the medium, the following ingredients were added to 1.0 liter of deionized water: 1.5 g of NaNO 3 , 0.039 g of K 2 HPO 4 , 0.075 g of MgSO 4 .7H 2 O, 0.027 g of CaCl 2 .2H 2 O, 0.02 g of Na 2 CO 3 , 0.058 g of Na 2 SiO 3 .9H 2 O, 0.006 g of Ferric Citrate (autoclaved separately and added after cooling), 0.006 g of citric acid, 0.001 g of EDTA and 1.0 ml of Allen's trace-element. The trace-element solution was prepared by adding to 1.0 liter of deionized water: 2.86 g of H 3 BO 3 , 1.81 g of MnCl 2 .4H 2 O, 0.222 g of ZnSO 4 .7H 2 O, 0.391 g of Na 2 MoO 4 .2H 2 O, 0.079 g of CuSO 4 .5H 2 O and 0.0494 g of Co(NO 3 ) 2 .6H 2 O. The pH of the medium was adjusted to 7.8 with 1 N NaOH. For solid media, 1.5% of bacto agar (Sigma-Aldrich) was added. The medium was autoclaved at 121° C. for 20 minutes prior to the addition of the biocides. Each algae (Chlorella sp. ATCC 7516, Calothirx sp. ATCC 27914 or Gloeocapsa sp. ATCC 29115) was grown on 3N Bold's Basal Medium for 10 days and the cell suspension prepared by washing the cells from the plate into a sterile water solution. After the addition of the biocides in the indicated concentration to the medium, the algae suspension was added to a final concentration of 10 6 cells/ml. The inoculated media was incubated at 25° C. for 10-15 days under a light-dark cycle of 14-10 hours.
The lowest concentration of each compound or mixture of compounds sufficient to inhibit visible growth was taken as the minimum inhibitory concentration (MIC). The MIC were taken as end points of activity. End points for the mixture of CTL and IPBC were then compared with the end points for the pure active compound when employed individually.
Synergism was determined by a commonly used and accepted method described by Kull A. C,; Eisman, P. C.; Sylwestrowicz, H. D. and Mayer, R. L. 1961. Applied Microbiology, 9:538-541 using the ratio determined by:
Qa/QA+Qb/QB=Synergy Index
wherein:
QA is the concentration of compound CTL in parts per million (PPM), acting alone, which produced an end point.
Qa is the concentration of compound CTL in PPM, in the mixture, which produced an end point.
QB is the concentration of compound IPBC in PPM, acting alone, which produced an end point.
Qb is the concentration of compound IPBC in PPM, in the mixture, which produced an end point.
When the sum of Qa/QA+Qb/QB is greater than one, antagonism is indicated.
When the sum is equal to one, additivity is indicated. When the sum is less than one, synergism is demonstrated.
The results which serve to demonstrate the synergism of this biocidal combination are compiled in Tables I and II below. Each of the tables demonstrates mixtures of CTL and IPBC in various concentrations and ratios which shows:
1. Test Organism (Bacteria, Fungi, and Algae).
2. The end-point activity in PPM measured by MIC for the compound A alone (QA), for compound A in the mixture (Qa), for compound B alone (QB), for compound B in the mixture (Qb).
3. The weight ratio of compound A to Compound B in that particular combination and the Synergy Index (SI) based on the formula SI=Qa/QA+Qb/QB.
TABLE I______________________________________Combination of CTL with IPBC (Solid Media) CTL(A) CTL(a) IPBC(B) IPBC(b) Ratio Microorganism (PPM) (PPM) (PPM) (PPM) A:B SI______________________________________Bacteria: B. subtilis 50 0.25 250 0.25 1:1 0.002 50 16.6 250 8.3 2:1 0.36 50 1.7 250 3.3 1:2 0.047 S. aureus 25 0.25 100 0.25 1:1 0.012 25 16.6 100 8.33 2:1 0.74 25 16.6 100 33.3 1:2 0.99 Fungi: A. niger 5.0 0.25 0.5 0.25 1:1 0.55 5.0 0.33 0.5 0.17 2:1 0.40 5.0 0.17 0.5 0.33 1:2 0.69 A. orizae 1.0 0.5 1.0 0.5 1:1 1.0 0.33 1.0 0.17 2:1 0.50 1.0 0.17 1.0 0.33 1:2 0.50 A. pullulans 100 2.5 2.0 2.5 1:1 100 3.33 2.0 1.67 2:1 0.87 100 1.67 2.0 3.33 1:2 G. virens 10.0 0.25 1.0 0.25 1:1 0.28 10.0 0.66 1.0 0.33 2:1 0.40 10.0 0.33 1.0 0.66 1:2 0.69 Algae: Calothrix sp. 2.5 1.25 25 1.25 1:1 0.55 2.5 1.67 25 0.83 2:1 0.70 2.5 0.83 25 1.67 1:2 0.40 Gloeocapsa sp. 2.5 5 25 5 1:1 2.5 1.67 25 0.83 2:1 0.70 2.5 3.33 25 1.67 1:2______________________________________
TABLE II______________________________________Combination of CTL with IPBC (Liquid Media) CTL(A) CTL(a) IPBC(B) IPBC(b) Ratio Microorganism (PPM) (PPM) (PPM) (PPM) A:B SI______________________________________Bacteria: B. subtilis 1.95 0.625 125 62.5 1:100 0.82 Fungi: A. niger 2.5 1.25 250 250 1:200 Algae: Chlorella sp. 100 0.78 25 6.25 8:1______________________________________ 0.26
As can be seen from the data presented in Tables I and II, the compositions of the invention demonstrated synergistic microbiocidal activity against bacteria, fungi and algae. Thus, the combination of the two biocides not only lowers the use-level of the biocide but broadens the spectrum of activity. This is especially useful in situations where either biocide component alone does not achieve the best results due to weak activity against certain organisms.
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The invention is directed to a biocidal composition for inhibition fungal, bacterial and algae growth which comprises a mixture of tetrachloroisophthalonitrile and 3-iodo-2-propynly butyl carbamate.
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BACKGROUND OF THE INVENTION
The invention is based on a regulating device for control of variables of an internal combustion engine and more particularly relates to providing an intervention capability responsive to knocking signals for developing frequency and amplitude information for evaluation to control ignition adjustment or ignition onset.
A motor vehicle ignition system of the prior art is known which evaluates signals of a knocking sensor for the purpose of adjusting the instant of ignition; this is accomplished in such a fashion that as knocking becomes more pronounced, the instant of ignition is adjusted toward "late". In this known regulating device for the instant of ignition, the signal of a knocking sensor is evaluated directly. It has now been demonstrated that the known device is extremely vulnerable to disturbance voltage variables and responses, and it is thus found to be incapable of producing reliable results.
OBJECT AND SUMMARY OF THE INVENTION
It is an object and advantage of the invention to provide a regulating device for control variables of an internal combustion engine having the advantage over the prior art that disturbance variables which occur arbitrarily are to the greatest possible extent without influence on the variable to be regulated. Optimal operation of the internal combustion engine is thus assured.
During the course of the work leading to the invention, the combination of characteristics of the system of the invention has proved to be particularly suitable. By applying these characteristics, it is possible to attain the desired precise results on the part of a regulating device.
The invention has as its object the filtering out of the individual peaks in the course of the pressure which occur in the trailing edge of the pressure signal, then appropriately preparing and evaluating them, and finally, in accordance therewith, adjusting the individual control variables of the engine, especially the fuel metering and the instant of ignition. The goal is to keep combustion in the individual cylinders as close as possible to the knocking limit, for reasons of economy.
The invention will be better understood and further objects and advantages thereof will become more apparent from the ensuing detailed description of preferred embodiments taken in conjunction with the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a rough schematic representation of the regulating device according to the invention, in combination with an internal combustion engine;
FIG. 2 shows pulse diagrams relating to the signal evaluation;
FIG. 3 is a block circuit diagram of the regulating device itself;
FIGS. 4, 5 and 6 show details of the regulating device according to FIG. 3; and
FIG. 7 is a schematic representation of a Diesel engine used with the regulating device of the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1, in a basic schematic layout, shows an internal combustion engine 10 having externally supplied ignition, together with regulating devices for the ignition and for the fuel injection. The internal combustion engine has an intake tube 11 and an exhaust line 12. A fuel metering system includes a control device 13 as well as an injection nozzle 14, the fuel metering signal being determined on the basis of rpm, load and the output signal of a knocking-signal evaluation circuit 15. In corresponding fashion, an ignition system 16 processes various input variables and at the output side sends high-voltage signals to spark plugs 17. The knocking-signal evaluation circuit 15, at its input side, receives signals from knocking sensors 18, of which four are shown in FIG. 1, which can be dialed by means of a switch 19. In this manner, the knocking signals can be ascertained and processed cylinder by cylinder of the internal combustion engine, or in multiplexing operation they may be made available serially to the knocking-signal evaluation circuit 15.
FIG. 2 contains four diagrams. In FIG. 2a, the pressure in the combustion chamber is plotted over time; FIG. 2b shows the closing-angle signal of the ignition system; FIG. 2c shows a signal for the duration of measurement; and, finally, FIG. 2d shows the knocking signal which has been filtered out of FIG. 2a.
It may be seen in FIG. 2a that there is a zigzag signal course in the trailing edge of the pressure signal. These superimposed peaks are caused by engine knocking; that is, localized ignition cycles in the combustion chamber, and the pressure waves caused thereby, produce this overall course of the pressure signal.
Thus, the invention has as its object the filtering out of the individual peaks in the course of the pressure which occur in the trailing edge of the pressure signal, then appropriately preparing and evaluating them, and finally, in accordance therewith, adjusting the individual control variables of the engine, especially the fuel metering and the instant of ignition. The goal is to keep combustion in the individual cylinders as close as possible to the knocking limit, for reasons of economy.
The so-called knocking frequency, which may be seen in FIG. 2a, for example, is specific for each engine type. For this reason, an exact adaptation of the knocking-signal evaluation circuit to the particular engine type being used is required.
According to FIG. 2d, the knocking frequency signal is filtered out of the signal course according to FIG. 2a and prepared for the purpose of a further signal processing.
One example of a knocking-signal evaluation circuit is shown in FIG. 3. The signal from one or more knocking sensors is present at the input of a pulse-shaper circuit 20. A parallel arrangment of a frequency recognition circuit 21 and an amplitude recognition circuit 22 follows, these being connected at the output side to an AND gate 23. A series circuit comprising the synchronizing flip-flop 24, a knocking pulse counter 25 and a memory flip-flop 26 follows the AND gate 23. The ignition system of the engine is identified by reference numeral 27. One of its output signals controls a measurement-duration circuit or measurement-time control circuit 28, and this circuit, in turn, controls the knocking pulse counter 25 via a second input. Finally, leading to the frequency recognition circuit 21 and the amplitude recognition circuit 22 are the respective multi-polar lines 29 and 30, which symbolize control variables for the respective recognition circuit of FIG. 3.
It is essential in the subject of the application that the output signal of the knocking sensor is examined both as to its frequency and to its amplitude. Only if both variables have attained or exceeded values characteristic of the particular engine being used, and in addition if a predetermined number of knocking signals have occured, is there an intentional manipulation of the control variables of the engine. In the case of FIG. 1, these are the fuel metering and ignition characteristics.
FIG. 4 shows one example of a digital amplitude recognition circuit, such as may be used in the subject of FIG. 3. It includes a comparison circuit 32. Via a first input 33, input signals are delivered directly to the comparison circuit 32 via a rapidly-functioning analog-digital converter 34 from a terminal point 35, while via a second input 36 the comparison circuit 32 receives a controllable threshold signal. This signal originates in an adding circuit 37, in which the threshold is formed in accordance with a value taken from a performance graph 38 and in accordance with the input variables. A low-pass filter 39 and, in series therewith, a slow analog-digital converter 40 between the input terminal 35 and the adding circuit 37 serve to provide control of the threshold in accordance with the input variables.
By reason of its design, the amplitude recognition circuit 22 substantially produces the curve of the pulse course shown in FIG. 2a, and the individual signal peaks in the trailing edge of this input signal are filtered out and thus put into a form which can be further processed. The values stored in the performance graph 38 are adapted to the particular engine type being used, and they assure that only the peaks in the signal course of FIG. 2a will be detected, in a manner which is as independent as possible of the load status and the rpm of the engine.
FIG. 5a shows one example of the frequency recognition circuit 21 of FIG. 3, together with a subsequently disposed knocking pulse counter 65. The subject of FIG. 5a, in detail, has the following structure. An input 45 is followed by a pulse-shaper circuit 46, the output of which is connected in turn with the charge input of a counter 47, with the J-input of a JK flip-flop 48, and with a first input 49 of a NAND gate 50. The overflow output 53 of the counter 47 leads to the charge input 51 of a subsequent counter 52, the counter range of which determines the band width of the signal which is to be recognized. The two counters 47 and 52 have multi-polar inputs 54 and 55, with which a respective initial counter status may be pre-specified for the counting procedure. Further inputs 56 and 57 are so-called countenable inputs, by way of which the counting process in general can be controlled. The actual counting signal proceeds via inputs 58 and 59 to the counters 47 and 52.
While the Q output of the flip-flop 48 is connected with the counting input 56 of the first counter 47, the Q output of a second JK flip-flop 60 precedes the counting input 57 of the subsequent counter 52. This flip-flop 60, for the F input, receives the output signal from the overflow output 62 of the counter 52, and the K input is connected with both the overflow output 53 of the counter 47 and the K input of the flip-flop 48. A clock signal is received by both flip-flops 48 and 60 via clock lines, indicated by the arrow but not shown in further detail, from a clock signal source.
The second input 63 of the NAND gate 60 receives its signal from the Q output of the second flip-flop 60. On the output side, the NAND gate 50 is linked with the counting input of a subsequent counter 65, which is followed in turn by a pulse-shaper circuit 66. Both the counter 65 and the pulse-shaper circuit 66 receive, as a further control signal, a signal which comes by way of example from the measurement-duration circuit 28 according to FIG. 3.
The mode of operation of the subject of FIG. 5a will now be appropriately explained with the aid of the pulse diagrams of FIG. 5b.
In FIG. 5b, the letter a identifies the input signal at the input terminal 45, and b identifies the output signal of the pulse-shaper circuit 46. The counter status in the counter 47 is shown at c, and it becomes clear that with each positive forward edge of the input signal at the input 45, the counter is set to a specific counter status. If the counter status reaches a value of zero, and thus the overflow point, then the counting process ceases, and it is only reinitiated upon the next occurrence of a forward edge. Upon the attainment of a counter status of zero in the first counter, however, the counting process in the second counter 52 is initiated and ended in accordance with signal course d, once this counter has traversed a predetermined range of values. If, during the counting process in the second counter 52, a forward edge in the input signal appears, then this is recognized in terms of the desired input frequency, by means of the NAND gate 50, and an output signal appears which corresponds to e in FIG. 5b. The output signal of the measurement-duration circuit 28 is designated by letter f; this means that the only input signals to be examined as to their frequency are those occuring during the course of the corresponding signal f. The signals according to g are counted in the counter 65; if, for example, two such pulses appear, then an adjustment signal for the ignition is produced according to letter h. The purpose of this delay in response is to prevent disturbance signals which by coincidence have the same frequency as the knocking signal from having any effect.
The pulse diagrams of FIG. 5b make it clear that at an excessively high input frequency, the full counting range of the first counter 47 is never traversed, and thus no overflow pulse appears. This overflow occurs only if the input frequency fails to exceed or attain a specific upper threshold value. This upper threshold value is thus established with the aid of the counting range of the first counter.
The band width of the detectable frequency spectrum may be established by means of the counting range of the second counter. Specifically, an output signal appears only when, upon the appearance of the next input pulse, the first counter is no longer counting, but the second counter is still counting.
If the input frequency fails to attain a lower threshold value, then the forward edge of the next input pulse arrives only after the termination of the counting process in the second counter, and the corresponding logic circuitry no longer emits an output signal.
With the circuit layout shown in FIG. 5a, it is thus possible to interrogate input signals as to the occurrence of a very specific frequency range. Since the knocking frequency in an internal combustion engine is specific for a particular engine type, the occurrence of knocking can be detected quite precisely and processed in an appropriate manner with the proposed circuitry.
A second, somewhat modified exemplary embodiment of a frequency recognition circuit, or more precisely a frequency band recognition circuit, is shown in FIG. 6. Once again, there is the series circuit comprising the pulse-shaper circuit 46 and the first and second counters 47 and 52. The transmit outputs of both counters are carried to a flip-flop 70, the output signal of which, like the output signal of the pulse-shaper circuit 46, is carried to an AND gate 71. Following the AND gate 71 is the counter 65, the output counter status of which corresponds to a pre-selectable disturbance interval, and the charge input 72 of which is furnished with the output signal of the measurement-duration circuit 28. With a view to attaining a constant output signal at an output terminal 74, a flip-flop 75 is also furnished with signals from the transmit output of the counter 65 and from the measurement-duration circuit 28. Here, as well, what is essential is that the clock frequency of the counters 47 and 52 is substantially higher than the input frequency at the input terminal 45.
The two subjects of FIGS. 5a and 6 correspond to one another in terms of their fundamental type. What is different between them is solely the manner of signal linkage; the mode of operation and the results produced by the logical signal linkage, however, are identical.
It should be added that the invention is not restricted to its application in internal combustion engines having externally supplied ignition; the invention can also be used in Diesel engines having an injection system, such as shown in FIG. 7 in which corresponding elements are designated similar numerical references. In the latter case, the corresponding feature for the ignition signal means 16 is an injection onset control unit 16a, and for the ignition adjustment means 13 it is the adjustment of injection onset fuel quantity control unit 14a.
The foregoing relates to preferred exemplary embodiments of the invention, it being understood that other embodiments and variants thereof are possible within the spirit and scope of the invention, the latter being defined by the appended claims.
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A regulating device is proposed for control variables of an internal combustion engine, in particular for the fuel metering signal and the ignition signal, which has an intervention capability for signals of at least one knocking sensor on the engine via a knocking-signal evaluation circuit; this knocking-signal evaluation circuit includes a frequency recognition circuit and preferably an amplitude recognition circuit, and it detects and evaluates the knocking signal only during specific times or angles relating to the ignition signal. The frequency recognition circuit is realized by means of two counters. The counting range of the first counter marks the value of the upper threshold frequency which can be recognized, while the counting range of the second counter characterizes the frequency band. Finally, by means of a third counter, a specific disturbance interval can be established, in order to cause the frequency recognition circuit to respond only after the appearance of a predetermined number of pulses of the predetermined frequency, thus bringing about an adjustment of the control variables.
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BACKGROUND OF THE INVENTION
The present invention relates to ceramic metal composites and to processes for the production thereof. More particularly, but not exclusively, it relates to metal-ceramic composites of biocompatible metals and bioactive ceramics.
DESCRIPTION OF THE PRIOR ART
It is known that, in order to assemble components by bonding their metal pads, it is essential for the metal contact surfaces of said pads to be oxidation-free.
Now, such contact surfaces naturally oxidize on contact with oxygen from the ambient air and consequently are already oxidized before bonding. They also undergo substantial oxidation while the components are being heated during bonding, which impairs the quality of this bonding.
The object of the present invention is to remedy these drawbacks.
BRIEF DESCRIPTION OF THE INVENTION
For this purpose, according to the invention, the device for assembling components having metal bonding pads, especially microelectronic components, said device comprising a first plate and a second plate facing each other and capable of being moved relative and parallel to each other so as to be able to bring said first and second plates closer together and further apart, said first and second plates bearing at least one such first component and at least one such second component respectively and comprising heating means for heating said first and second components respectively, said components facing each other and their respective metal pads being able to be brought into contact with each other by bringing said first and second plates together, is noteworthy in that:
said first plate has a first outer zone surrounding said first component and provided with at least:
a first orifice radially close to said first component and capable of being supplied with a deoxidizing gaseous fluid, a second orifice radially far from said first component and capable of being supplied with an inert gaseous fluid, and a third orifice placed radially between said first orifice and said second orifice and capable of being connected to suction means;
said second plate has a second outer zone surrounding said second component and is capable of covering at least all of said first plate; and when said first and second components are in contact with each other, said first and second plates leave between them a flat chamber surrounding said first and second components.
Thus, when the components are in contact with each other, the first orifice may inject a deoxidizing gas mixture, for example an acid/nitrogen-based mixture, into the flat chamber so as to saturate the space surrounding the components, thereby making it possible, on the one hand, to deoxidize said metal contact surfaces and, on the other hand, to preserve them from any oxidation by oxygen from the air. Furthermore, the second orifice may inject an inert gas, for example nitrogen, into the peripheral space of the flat chamber so as to form an obstacle to ingress of air into said flat chamber. In this way, by maintaining within the flat chamber an oxygen-free gaseous environment, oxidation of said metal contact surfaces is prevented. Finally, the deoxidizing gas mixture and the inert gas that are thus injected into the flat chamber may be sucked out via the third orifice, inserted between the first and second orifices. Thus, the gas mixture in the flat chamber is replenished, thereby guaranteeing that there is no oxygen in said chamber. Sucking the deoxidizing gas mixture also prevents said mixture from escaping from the flat chamber, thus enabling the assembly device to be used without any risk to the health of the operators.
For this purpose, it is advantageous for the flowrate of said gas sucked in via said third orifice to be less than the sum of the flowrates of the gases introduced into said flat chamber. Thus, the pressure of the gaseous fluid in the flat chamber, injected via the first and second orifices, is at least slightly above the atmospheric pressure of the air, thereby preventing any ingress of air via the perimeter of the flat chamber.
Advantageously, each of said first, second and third orifices takes the form of a ring surrounding said first component and said rings are concentric.
Thus, the gaseous fluids are injected into the flat chamber uniformly and sucked out therefrom very effectively.
To further improve the nonoxidizing quality of the gaseous environment between said plates, said first plate may also include a fourth orifice capable of injecting an inert gas with a low flowrate, making it possible to saturate a zone surrounding said first component with inert gas and possibly capable of retaining oxygen.
Preferably, said second plate bears on the perimeter of said second outer zone means capable of at least partially sealing the perimeter of said flat chamber when said first and second components are in contact with each other.
Thus, the sealing means create an additional barrier that forms an obstacle to the air surrounding the assembly device of the invention. Furthermore, owing to the perimeter of the flat chamber being at least partially sealed, the pressure rises substantially in the latter, thus preventing ingress of oxygen from the air into the flat chamber.
Said sealing means may be formed by a rigid ring captive with said second plate, whilst still being free to slide, in a limited manner, parallel to the relative displacement of said first and second plates and said rigid ring is advantageously mounted freely on the rods of actuators capable of retracting said ring into said second plate.
The figures of the appended drawings will make it clearly understood how the invention can be realized. In these figures, identical references denote similar elements.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic view, in cross section, of the assembly device in one embodiment according to the present invention, when the first and second plates of the device are away from each other.
FIG. 2 shows, in a schematic top view along the arrow 11 of FIG. 1 , the first plate of the device of the invention.
FIG. 3 shows, in a view similar to FIG. 1 , the device of the invention when the rigid ring of the sealing means is in contact with the first plate, the first and second components themselves being spaced from each other.
FIG. 4 is similar to FIG. 3 , where the first and second components are in contact with each other.
FIG. 5 is an enlarged schematic view of the sealing means of FIG. 1 , when the two plates are spaced apart.
FIG. 6 is a figure similar to FIG. 5 , where the first and second plates are together.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The device 1 for assembling the components having metal bonding pads, shown in FIGS. 1 , 3 and 4 , comprises a first plate 2 and a second plate 3 facing each other, for example of circular shape, which bear first 4 and second 5 components having metal bonding pads respectively. In these figures, said metal bonding pads have not been shown.
The two plates 2 and 3 are capable of moving relative and parallel to each other along the axis X-X, so as to be able to occupy one of the following two positions:
a separated position ( FIG. 1 ) in which the first 2 and second 3 plates are away from each other. In this position, a microscope 7 may be inserted, into the internal space 6 formed between the two plates 2 and 3 , so as to precisely align the first 4 and second 5 components. Such an alignment may for example be carried out by moving the second plate 3 along two orthogonal directions (one of which is shown symbolically by the arrow 23 ) forming a plane parallel to the first plate 2 ; and a bonding position ( FIG. 4 ) in which the metal pads of the first 4 and second 5 components are brought into contact with each other, ready to be bonded.
Furthermore, each plate 2 and 3 includes heating means placed beneath the component to be assembled. These heating means consist of a heating plate 8 on which the component rests.
According to the present invention, as shown in FIGS. 1 to 4 , the first plate 2 also includes a first outer zone 9 which surrounds the first component 4 .
The first outer zone 9 comprises:
a first orifice 10 , radially close to the first component 4 . The first orifice 10 can be supplied with a deoxidizing gas (shown symbolically by the arrow G 1 in FIG. 4 ), by means of first supply means 11 , when the first 2 and second 3 plates occupy the bonding position ( FIG. 4 ). The first orifice 10 runs into an annular space 24 surrounding the heating plate 8 bearing the first component 4 ; a second orifice 12 , radially away from the first component 4 . The second orifice 12 can be supplied with an inert gas (shown symbolically by the arrow G 2 in FIG. 4 ), by means of second supply means 13 , when the two plates 2 and 3 are in the bonding position. The second orifice runs into the surface of the first outer zone 9 of the first plate 2 ; a third orifice 14 , on the surface of the first outer zone 9 , placed radially between the first orifice 10 and the second orifice 12 and connected to suction means 15 ; and a fourth orifice 16 , inserted between the first orifice 10 and the heating plate 8 supporting the first component 4 . The fourth orifice 16 is capable of injecting an inert gas with a low flowrate (shown symbolically by the arrow G 3 in FIG. 4 ) capable of saturating said annular space 24 with inert gas.
The first, second and third orifices 10 , 12 and 14 take the form of a ring surrounding the first component 4 and are concentric.
As shown in FIGS. 1 to 4 , the first 11 and second 13 supply means are provided with a gas reservoir ( 11 a and 13 a respectively) of annular shape, housed in the first plate 2 and supplied with gas via a feed channel ( 11 b and 13 b respectively). The orifice of flow from the reservoir of the first 11 and second 13 supply means corresponds to the first 10 and second 12 orifices respectively.
Moreover, the suction means 15 consist of an annular gas recovery zone 15 a provided within the first plate 2 and connected to a discharge channel 15 b.
According to the invention, the second plate 3 includes a second outer zone 17 surrounding the second component 5 and is capable of completely covering the first plate 2 in the bonding position ( FIG. 4 ).
Advantageously, as shown in FIG. 4 , in the bonding position, the first and second plates 2 , 3 leave between them a flat chamber 18 , which surrounds the first 4 and second 5 components in contact via their respective metal pads.
According to the embodiment of the invention shown, the second plate 3 bears sealing means 19 capable of sealing the perimeter of said flat chamber 18 in the bonding position.
As shown in FIGS. 1 , 3 and 4 , the sealing means 19 are formed by a rigid ring 20 captive with the second plate 3 whilst still being free to slide, in a limited manner, parallel to the relative displacement of the two plates 2 and 3 .
More precisely, as illustrated in FIGS. 5 and 6 , the rigid ring 20 is mounted freely on the rods 21 of first and second actuators 22 placed in diametrically opposed positions on the peripheral upper part of the second plate 3 . The actuators 22 are capable of retracting the rigid ring 20 into the second plate 3 .
Thus, during the relative separating movement of the plates 2 and 3 from the bonding position to the separated position, the rod 21 of each of the two actuators 22 retracts, causing the rigid ring 20 to enter the second plate 3 ( FIG. 1 ).
In contrast, during the relative closing movement of the two plates 2 and 3 in order to reach the bonding position, the rods 21 of the two actuators 22 deploy, causing the rigid ring 20 to leave, by gravity, the second plate 3 .
As shown in FIGS. 3 and 4 , upon contact with the first outer zone 9 of the first plate 2 , the rigid ring 20 retracts slightly into the second plate 3 ( FIG. 3 ) before the two plates 2 and 3 reach the bonding position ( FIG. 4 ).
Once the bonding position has been reached, the rigid ring 20 at least partially seals the perimeter of the flat chamber 18 and the deoxidizing gas G 1 , the inert gas G 2 and the inert saturating gas G 3 can then be injected into the flat chamber 18 via the first 10 , second 12 and fourth 16 orifices respectively.
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A device for assembling components having metal bonding pads includes plates that can move relative to each other, bearing metal components respectively and leaving between them a flat chamber surrounding the components when the latter are in contact with each other. The flat chambers can be saturated with deoxidizing gaseous fluid.
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BACKGROUND OF THE INVENTION
The present invention concerns an interlacing apparatus and process for the interlacing of multifilament yarns in accord with the generic concept of using a flow of a medium through a specially designed jet nozzle to entwine multifilament yarns.
Interlacing apparatuses and processes of the kind discussed here, have been brought into common knowledge by DE 37 11 759 C2. The apparatus and process serve to improve the integrity of the filaments of the multifilament yarns and thereby better their further workability. The reason for this is that the single multifilament yarn, which is comprised of substances which are preferably thermoplastic or other material, upon being fed to the interlacing apparatus is yet untwisted or possesses only a minimum protective twist, which still has insufficient integrity for further processing. The required integral strength is obtained by the multifilament yarn only by the interlacing of its filaments. By means of the interlacing apparatus, the filaments of several multifilament yarns can be commonly intertwined into one unified multifilament yarn.
The interlacing quality, or the outcome of the interlacing, is characterized by certain points. The plaiting/interlacing tendencies of the filaments and also the spacing lying between the said intertwined filaments define these points. Within these points, the possibility exists for essentially non-entwined or open places in the yarn. When an interlacing of the multifilament yarn occurs, in addition a very weak interlacing can be achieved, in which no interlacing points arise. In this situation, only a light, scarcely visible commingling of the filaments takes place. Such yarns exhibit only a small degree of thread closure and without additional expensive measures, cannot be subjected to further processes such as imparting twist, spindle whorling or finishing. At the most, these yarns can only be further worked under certain limiting conditions.
"Thread closure" is a customary designation for the compactness of multifilament yarns and describes the integrity, i.e. the cohesiveness of the filaments.
The known interlacing apparatus possesses a yarn conduit through which a multifilament yarn passes which has a plurality of filaments. As this takes place, the filaments are commingled by means of an air flow issuing from a jet nozzle opening. The jet nozzle exhibits normally a circular or elliptically shaped cross-section, which is designed symmetrically to the longitudinal axis of the yarn conduit. In many cases, the commingling of the filaments of the multifilament yarn from this apparatus does not result in a desirable degree of interlacing. The multifilament yarn exhibits irregularities, for example lengthy, faulty stretches, which indicate unentwined yarn portions. Further processing of the multifilament yarn, for instance weaving, tufting, knitting, or sewing, leads to damage to these open, unprotected yarn stretches. Single filaments break and open out, whereby a thread breakage or break in neighboring threads and/or faults in textile surface formation occurs.
OBJECTS AND SUMMARY OF THE INVENTION
It is therefore a principal object of the present invention to avoid these disadvantages of the technology and to create an interlacing apparatus and a process, which will improve the quality of the entwined yarn, and which will enhance the process of comparing the node periods and the open yarn places. Furthermore, the interlacing apparatus should be simple in construction and operate economically in regard to the consumption of air. Additional objects 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.
By means of DE 28 13 368 C2, it is indeed already known that vortex jets can be used to employ a main flow and at the same time a pulsating adjoining flow, which are caused to flow counter-currently or at right angles to one another in the yarn conduit in order to influence each other therein. This process has, however, not achieved the result expected of it and consequently has not been accepted in practice.
Further, DE 41 13 927 has made known the introduction of a main air flow into the yarn conduit by means of a jet nozzle, the cross-section of the opening of which is designed generally symmetrical to the longitudinal axis of the yarn conduit. Further, paired side flows are provided, whereby one side flow enters into the outer peripheral zone and the other side flow enters into another peripheral zone of the yarn conduit. Even in this case, the side flows are introduced into the principal flow on opposite sides of the yarn conduit. This type of construction is expensive because an air feed for the side flows requires a removable cover. Beyond this, it has been surprisingly revealed that the air flows do not flow as described in accord with the proposed purpose of DE 41 13 927. The main and side flows run in the same direction and do not, as called for by the current state of the technology, flow in opposition to one another. Obviously, this brings about a disturbance of the main air flow, which leads to increased air consumption and poor interlacing results.
CH-PS 415 939 makes known a provision for the medium feed inlet to have a circular cross-section or any other appropriate shape, such as rectangular, oval or the like.
In the present invention, the emphasis is on a jet nozzle opening, the shape of which is designed so that the medium, in particular, compressed air, flows in the more central zone of the yarn conduit, and paired side flows are injected into the peripheral zones thereof. A teaching of this principle is not to be inferred from any suggestion of CH-PS 415 939.
In the apparatus according to the present invention, the main and side flows are caused to flow in essentially the same direction, the main flow in the central region acts more intensively on the yarn. This main flow, entering the yarn conduit, divides into two, generally equally strong partial flow vortices, which actuate the interlacing of the filaments. The incoming side flows, which always enter the yarn conduit in a peripheral zone, because of the common direction of flow, surprisingly support the flow vortexing and assure that the filaments remain a minimum time in the said peripheral zones (dead zones).
In these peripheral zones, practically no interlacing can occur, but consistently said filaments are displaced by the side flows into the principal air flow. In this way, the number of the unentwined, open yarn places is lessened and the length of the these faulty sections is shortened. By this advantageous interactivity of the main flow and the side flows, the costs of the interlacing can be reduced, while at the same time maintaining advantageous, uniform and satisfactory results in entwining from the given consumption of the medium. Further an increase of both the rate of production and the running speed of the filaments is brought about. As a result, economy of the interlacing apparatus is achieved along with a satisfactory quality of the interlacing.
In regard to "dividing" the main medium flow, it is to be understood that the main flow and the side flows need not be physically divided. The division into main and side flows can also be effected by the shaping of the cross-section of the jet nozzles. By coordinating the main flow and the side flows in such a manner that the main flow, when compared to either of the side flows, always carries the greatest volume flow of the medium, the above described action of the interlacing is strengthened, since side flows which are too strong can lead to impairment of the main flow.
In accord with another embodiment, the cross-section of the opening of the side flow is separated from the cross-section of the main flow. The flow of the medium is thus apportioned into several separate partial flows, which, at least upon point of entry into the yarn conduit, exhibit this separateness, one from the other. In other words, the jet nozzle arrangement possesses, according to the first embodiment variant, principally one jet nozzle, and in accord with the second embodiment variant, exhibits at least two jet nozzles. These two jet nozzles (as a minimum) activate the physical separation of the partial flows of the medium.
In a preferred embodiment example of an interlacing apparatus, the cross-section of the opening of a jet nozzle is constructed from one jet nozzle. In this case, it is simple to design both the cross-section of the opening and the inlet of the medium feed (preferably compressed air) which feed the jet nozzle must handle under pressure.
However, it can be required, that the cross-section of the opening be designed from several, preferably two or three, jet nozzles. Respectively, separate flows of the medium flow issue from these nozzles. Thereby, a greater flexibility and independence is given
to the relationship of the main flow and the side flows to one another;
to their direction of injection, into the central zone as well as into the peripheral areas of the yarn conduit; and
to consideration of different injection air pressures.
In addition, an embodiment of the interlacing apparatus is favored, which is comprised of a main flow seen in the running direction of the filaments which follows the side flows. The side flows injected into the outer periphery area pick up the filaments passing through the yarn conduit in that area and carry these to the central zone of the yarn conduit in which the filaments subsequently are entwined by the main flow. In this manner, thick and long interlacing points, that is nodes, are formed, which exhibit a high degree of uniformity. If, contrarily, the main flow is placed ahead of the side flows as seen in the running direction of the filaments, experience has shown that in general shorter and thinner interlacing points are formed, wherein simultaneously a higher interlacing frequency is attained. This results from the average length of the interlacing points and the average width of the interstitial space between filaments and provides the number of the interlacing points per meter.
Except by the multifilament yarn itself, the interlacing frequency is additionally influenced by:
the thread speed upon interlacing;
the adjusted thread tension; and
the fineness and structure of the filaments, which can be smooth or crinkled.
Further advantageous embodiments of the apparatus are derived from the remaining subordinate claims.
The purpose of the invention will also be achieved by a process, which in the present invention includes. Because of the fact that the medium flow is divided into a main flow and into a pair of side flows, which all are moving generally in one direction, the main flow is actively reinforced in the central zone of the filament conduit while the side flows in the two peripheral zones prevent an excessive dwell time in these zones, which are ineffective for interlacing. Very strong interlacing points are produced and faulty places are avoided. By means of the coactivity of the main flow and the side flows, a high entwining quality with a minimum medium consumption is achieved.
In the following, the invention is examined more closely with the aid of the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 a side view of an embodiment of an interlacing apparatus;
FIG. 2 a schematic plane view of a yarn conduit;
FIGS. 3 to 15 respectively, a plane view of a cross-section of the opening of a first embodiment variant of the jet nozzle arrangement in accord with the invention, wherein the main flow and side flows are produced by the shape of the cross-section of a jet nozzle;
FIGS. 16 to 19 respectively, a plane view of a cross-section of the opening to of a second embodiment variant of the jet nozzle arrangement, in which the main and side flows are physically separated;
FIGS. 20 to 21 respectively, a plane view of a cross-section of the opening of a further embodiment variant of the jet nozzle arrangement with two main flows;
FIG. 22 a sectional view of the yarn conduit; and
FIG. 23 a schematic cross-section of the interlacing apparatus.
DETAILED DESCRIPTION
Reference will now be made in detail to the presently preferred 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, and not meant as a limitation of the invention. For example, features illustrated or described as part of one embodiment can be used on another embodiment to yield a still further embodiment. It is intended that the present application include such modifications and variations.
The interlacing apparatus described in the following can be universally installed for the entwining of multifilament yarns. Smooth as well as crinkled multifilament yarns, are to be understood as being considered in connection with the present invention. The crinkled multifilament yarns are produced, for instance, by imitation twist, stuffing box crimping, or edge drawing. The multifilament yarn is comprised of a number of filaments, which advantageously consist of thermoplastic plastics, for instance, polyamides, polyester, polypropylene, polyethylene. However, viscose, glass, Kevlar®, carbon or other high modular fibers are also included. With the aid of the interlacing apparatus, it is also possible to entwine the filaments of several individual multifilament yarns commonly into one multifilament yarn. Further, special effect yarns can be produced, such as mixtures of multifilament yarns with fiber yarns or elastic yarns.
The interlacing apparatus can, for instance, be installed on texturing machines, as well as other machines or equipment, machines for spinning, stretching, or bobbin winding. The multifilament yarns entwined on the interlacing apparatus are further processed on machines for weaving, knitting, tufting, and similar textile machines. This further processing is without the necessity of a compulsory subsequent treatment of the multifilament yarn, such as sequential winding, interlacing, smoothing or the like for the production of the required thread closure.
FIG. 1 shows a schematic profile view of an embodiment of an interlacing apparatus 1 that includes a housing 3 of which the latter possesses several, here a total of two, housing parts 5 and 25. The second housing part 25 is pivotable by means of a swinging arm 7 on a hinge 9, linked to the first housing part 5, forming thereby a cover. By means of a hand grip 11 affixed to the second housing part 25, this second housing part 25 is pivotable upward out of its closed position, which is designated with solid lines, into an open position represented in FIG. 1 by dotted lines.
The interlacing apparatus 1 includes moreover, a yarn conduit 13 which penetrates the housing 3, which, as said, is comprised of the components 5 and 25. When the second housing component 25 is placed in its closed position, then the yarn conduit 13 is circumferentially closed with the exception of the cross-section of the opening of a (not shown) jet nozzle arrangement. Under these conditions, only on the entry and exit openings of the yarn conduit 13 is the said conduit open.
In order to introduce a (not shown in FIG. 1) multifilament yarn into the yarn conduit 13 or to be able to take the same out without cutting it, then the second housing part 25 is swung up, so that the yarn conduit, throughout its entire length is exposed. The jet nozzle arrangement is connected by means of a feed piping line 14 with a source of the medium, from which source the jet nozzle is supplied with a compressed medium, preferably air. The multifilament yarn is subjected to a flow of said medium, that entwines its filaments together, upon the yarn running through the straight yarn conduit 13. A more detailed description of this is provided later.
A U-shaped yoke 15 is affixed onto the second housing part 25 to serve as a rigid carrier. Installed on each of the bowed arms thereof, of which only the arm 17 is visible in FIG. 1, is a yarn guide 19. As viewed in a vertical direction, the two guides 19 are formed by inverted U-shaped members that open downward, which possess on the upper sides of their interior spaces guiding surfaces 21 for directional change of the multifilament yarn.
In this embodiment example, the yarn conduit 13 is machined into the first housing part 5 in the shape of a channel/groove, which exhibits along its entire length a uniform, semicircular, open cross-section. The top 23 of the yarn conduit 13 is constructed from the flat underside of the second housing part 25, which said part is affixed to the pivoting arm 7. The cross-sectional shape of the yarn conduit 13 can, of course, be designed in a different manner.
FIG. 2 schematically shows a plane view of the first housing part 5 of the interlacing apparatus 1, in which the yarn conduit is machined in. Figuring from the longitudinal central axis 26, as seen at right angles to the running direction of the filaments (arrow 27), this view is subdivided into two figurative, cross-hatched depicted zones, namely, divided into a middle zone 29, and an outer peripheral zone 33. The outer peripheral zone 33 lies between the interior sides of the yarn conduit 13 and the middle zone 29. The peripheral zone 33 is looked upon as a "dead zone".
In order to achieve a desired degree of interlacing, the cross-section of the opening 37 of the jet nozzle arrangement presented in FIG. 2 is so designed that the medium flow is separated into one main flow and two side flows. The main flow H passes in the central zone 29 and divides itself by impact against the underside of the housing part, i.e. the top 25, into two partial flow vortices with different directions of turning (FIG. 23). These vortices activate the desired localized interlacing/twisting of the filaments of the multifilament yarn. The produced filament interlacing can show different local patterns, for instance, braided or plaited patterns. The two side flows, N, which contribute basically nothing to the interlacing of the filaments, flow each in the peripheral zone 33 and lead the filaments which have migrated into the said peripheral zone back into the middle zone 29 of the yarn conduit 13, where these are again seized by the main flow H and are thereby entwined. In this way, the duration of the travel of the filaments in the peripheral zone 33 through the yarn conduit 13 is minimized, so that unentwined, open yarn places are avoided or at least reduced in number. Through the interlacing of the filaments by the medium flow, a structuring of the multifilament yarn comes about that optically changes the multifilament yarn. By the apportionment of the medium flow into several partial flows, in accord with the invention, the produced effect on interlacing points and looping of the individual filaments can be definitely influenced and thereby brought into desired form.
In the following, with the aid of FIGS. 3 to 15, a first embodiment of the jet nozzle arrangement is more closely explained, in which the cross-section of the opening of a single jet nozzle 37 is described. The FIGS. 3 to 15 show respectively a plane view of an embodiment example of the jet nozzle 37 as it vertically enters into the yarn conduit 13. The multifilament yarn (not shown) runs through the yarn conduit 13 in the direction of an arrow 27, thus corresponding to the presentation in the FIGS. 3 to 15, from right to left.
FIG. 3 shows a jet nozzle 37a, the cross-section of the opening of which is designed symmetrically to the longitudinal center axis 26 of the yarn conduit 13 and to a cross axis 41, which makes a right angle (90°) with the said axis 26.
The intersection point of the longitudinal central axis 26 and the cross-axis 41 that lies orthogonally thereto, lies about in the center of the yarn conduit 13 when seen at right angles to the longitudinal extension of the yarn conduit 13. This is also in accord with another embodiment which is not shown. In connection with this present invention, if statements as to symmetry are made regarding a cross-section of a jet nozzle opening arrangement, then the basis thereof must be on a vertical view direction down onto the respective cross-section of the jet nozzle opening, that is, the viewing line coincides with the longitudinal axis of the jet nozzle 37 which opens into the yarn conduit 13. Thus, a symmetry statement is only valid in the case of a plane view of the cross-section of the opening of the jet nozzle. The cross-section of the opening of the jet nozzle 37a is designed to be shaped as a cross. The one figurative arm of the cross lies along the central longitudinal axis and the other figurative arm on the cross axis 41. The intersection of the figurative cross arms is rounded off in such a way that the part of the cross-section of the opening that extends itself into the peripheral zones 33 of the yarn conduit 13 of the jet nozzle 37a is smaller than the part of the cross-section of the opening in the central zone 29 of the jet nozzle 37a.
Looking across the running direction of the multifilament yarn, because of the differently sized parts of the cross-section of the opening, the medium flow entering the yarn conduit through the cross-section of the opening of said yarn conduit subdivides itself into the main flow H and the pair of side flows N.
As is obvious from FIG. 3, the main flow defines the central zone. The cross-sections for the main flow H are so chosen, that the main flow always carries a greater volume flow of the medium in comparison to each of the side flows N. As mentioned above and as shown in detail in FIG. 23, the main flow H impacts against the under side of the top 25 which forms the inner top side of the yarn conduit 13. When this happens, two parts of the flow become vortices, which entwine the filaments of the multifilament yarn.
The side flows N, entering into the peripheral zone 33 of the yarn conduit 13, take care that the filaments, migrating into the peripheral zone because of the vortexing, are returned as quickly as possible to the central zone 29. In this way, there has been brought about a minimizing of the dwell time in which the filaments find themselves in the peripheral zone in which practically no entwining occurs. An excellent entwining result is achieved, since the number of the unentwined, open yarn places has been reduced and the lengths of the faulty locations are shortened.
FIG. 4 shows a jet nozzle 37b, the cross-section of the opening of which is basically V-shaped, whereby, between the arms of the V, a reinforcement 61 of the main flow H is provided. By means of this reinforcement, the V-shape is generally changed to somewhat of a "W" shape, which together with a triangle forms the cross-section of the opening. The arms of the V-shape, i.e. the "W" shape, extend also in this case into the peripheral zone 33 of the yarn conduit.
FIG. 5 presents a jet nozzle 37c, which exhibits again a cross shaped or better an elongated X-shaped, cross-section of the opening. The X shape, lying along the longitudinal axis of the conduit, possesses, along that said axis 26 of the conduit 13, a central flow 45 which carries the main flow H and is broader than the cross-arms 47 and 49. These cross arms extend into the peripheral zone 33 and carry the side flow N. The jet nozzle 37c is designed as symmetric to the longitudinal central axis 26 and to the cross axis 41. The side flows issuing from the cross-arms 47 and 49 of the X-shaped cross-section of the opening carry respectively a smaller volume flow than that in the central zone of the cross-section of the opening. That is, the volume is less than the flow from the central partial cross-section of the opening flow 45 designed for the main flow. By means of the arrow 27, the running direction of the thread through the thread canal becomes evident. From this, the situation is such that the side flows issuing from the ends of the cross-arms 47 and 49 precede the main flow. At the same time, the ends of the cross-arms 47' and 49' which are arranged in mirror image to the cross axis 41 yield a lagging pair of flows.
By means of this arrangement, a very good return transport of the filaments from the peripheral zones 33 is achieved, accompanied by a minimum disturbance of the main flow, which brings about an exceptionally good and uniform quality of the interlacing nodes.
The jet nozzle 37d depicted in FIG. 6 exhibits an equilateral triangular, cross-sectional opening and is so installed in the yarn conduit 13 that an apex 51, formed by two sides of the equilateral triangle, lies on the longitudinal central axis 26 of the yarn conduit 13. The jet nozzle 37d is designed to be symmetric to the longitudinal central axis 26. The multifilament yarn led through the yarn conduit in the direction of arrow 27 first contacts the entering main flow H in the area of the apex 51 of the cross-section of the opening. The main flow H becomes increasingly greater and is subsequently impacted by the side flows N, which issue from the areas 51' and 51" of the triangular cross-section of the opening. In this case, experience has shown that a higher interlacing frequency is realizable, when the side flows N extend further into the peripheral zone 33 of the yarn conduit 13. The higher interlacing situation arises, because the interlacing points occur at shorter spatial intervals than those produced by a jet nozzle with the cross-section of the opening of the side flows N extending less into the peripheral zone.
The jet nozzle shown in FIG. 7, again depicts a cross-sectional opening in the shape of an equilateral triangle, wherein the apex 53 thereof, which lies on the longitudinal central axis 26 and is formed by two sides, trails the main flow issuing out of the central area of the cross-section of the opening of the jet nozzle 37e as seen in the running direction of the multifilament yarn (arrow 27). The multifilament yarn is also first carried over the base of said equilateral triangle. Thereby, contrary to the arrangement of the depicted jet nozzle 37d of FIG. 6, a more intensive and more uniform interlacing of the filaments with long spaced interlacing nodes is achieved. Also, the cross-section of the opening of the jet nozzle 37e is designed symmetric to the longitudinal central axis 26 (which is true in all other embodiment examples of a jet nozzle in accord with the invention).
FIG. 8 shows a jet nozzle 37f, which exhibits a cross-section in the shape of an isosceles triangle, wherein the triangle has two equal sides and, contrary to the triangles of FIGS. 6 and 7, is very narrow. Because of this arrangement of the jet nozzle, the central part of the cross-section of the opening of the jet nozzle 37f is very unusual, in particular when compared with those with side zones, which intrude into the peripheral areas of the cross-section of the opening. From this arrangement, there arises a stronger main flow as opposed to the pair of side flows. The apex 55, formed from the equal sides of this isosceles triangle, lies on the longitudinal central axis 26 in such a way that the multifilament yarn carried through the yarn conduit 13 is first picked up by the main flow. However, simultaneously the pair of side flows becomes active, which flow into the peripheral zone 33 of the yarn conduit from the area of the base of the triangularly shaped partial cross-section of the opening 13.
FIG. 9 demonstrates a jet nozzle 37g with a T shaped cross-section of the opening., wherein the top cross arm 57 of the T-shaped designed partial cross-section opening precedes that partial cross-section opening formed from the stem of the T as seen in the running direction of the multifilament yarn (arrow 27). The cross arm 57, which is narrower than the stem 59 of the T, reaches into the peripheral zone 33 of the yarn conduit 13. The incoming multifilament yarn first reaches the top of the T shaped cross-sectional opening in which both main flow and side flows are effective. This arrangement creates a more uniform entwining, since simultaneously, by means of the side flow pair, a migration of the multifilament yarn into the dead zone 33 is prevented.
FIG. 10 shows a jet nozzle 37h, the opening of which is in the shape of a Y, whereby the essentially V-shaped part of the Y-shape, precedes that cross-section portion formed from the lower stem of the Y as seen in the running direction of the multifilament yarn (arrow 27). The upper ends of the V-shaped part of the Y design reach far into the peripheral zones 33 of the yarn conduit 13. Thereby, the filaments of the multifilament yarn conducted through the yarn conduit 13 are first seized by the side flows emitted from the V-shaped portion of the cross-section of the opening of the jet nozzle 37h and returned to the middle area 29 of the yarn conduit 13. Subsequently, the filaments are picked up by the main flow which is issuing out of the stem of the Y-shaped designed partial cross-sectional opening of the jet nozzle 37h and thereby entwined. By means of this Y-design, of the cross-section of the opening, the main flow is less disturbed by the side flows and thus said main flow becomes immediately effective, as is the case with the jet nozzle 37h.
In the embodiment shown in FIG. 11, the jet nozzle 37i differentiates itself from the jet nozzle presented in FIG. 10 principally therein, in that the Y-shape of the cross-section of the opening has been altered. The two arms which together form the V-shape of the Y combine in a more acute angle, so that these arms do not extend themselves so far into the peripheral zone 33 of the yarn conduit 13 as do the arms of the Y-shaped cross-section of the opening as shown in FIG. 10.
FIG. 12 presents a jet nozzle 37k which possesses a cross-section of the opening which has evolved from the Y-shape. The stem of the Y, which coincides with the longitudinal central axis 26, is broader in comparison to the Y-shape shown in FIGS. 10, 11. Further, the free ends of the stem is constructed relatively short and wedge-shaped.
FIG. 13 presents a fish shaped jet nozzle 37l that cross-sectional opening is derived from an ellipse and two arms which form a V-shape. The two arms reach into the peripheral zone 33 of the yarn conduit 13, while the ellipse lies with its major semi-axis along the longitudinal central axis 26 of the yarn conduit 13, and thus forms the main flow.
FIG. 14, shows a jet nozzle 37m, which cross-sectional opening exhibits a V-shape with outwardly curved arms. In other words, the arms of the V-shape are not straight, are bowed away from the central axis.
Furthermore, all sharp corners of the cross-section of the opening of the jet nozzle 37m have been rounded off or are in accord with a further, not shown, radius. The cross-section of the opening is expanded in the central area 29 of the yarn conduit 13. Since in this embodiment the said curved arms extend deeply into the peripheral zone, the filaments are quickly conveyed out of this dead zone.
The jet nozzle shown in FIG. 15, this being nozzle 37n, exhibits what is essentially a cross-section of the opening shape derived from a triangle in which the two arms which form a V-shape with one another. These arms reach into the peripheral zone 33 of the yarn conduit 13.
FIGS. 16 to 19 show, respectively, a plane view of the cross-section of the opening of an additional embodiment variant, with a jet nozzle arrangement 35, in which are designed cross-sectional openings for several, in this case a total of three, jet nozzles, designated 37/1, 37/2 and 37/3 respectively. These embodiments have openings spatially distanced, one from another in the yarn conduit 13 and each shows a partial cross-section of the opening, which together form the cross-section of the opening of the jet nozzle arrangement 35. The partial cross-section of the opening of the jet nozzle 37/1 from which the main flow of the medium emerges into the yarn conduit 13 is in any case greater than those of the jet nozzles 37/2 and 37/3 out of which the side flows are injected. The cross-sections of the opening of the nozzles in all embodiments is independent of the number of the jet nozzles and the jet nozzle arrangement is designed symmetrical to the longitudinal axis 26 of the yarn conduit 13, as seen from a view point in the direction of the axis of the jet nozzles which open into the yarn conduit.
The partial cross-section of the opening which appears in FIG. 16, features jet nozzles 37/1 to 37/3 which are circular in shape. The central location of the jet nozzle 37/1 out of which the main flow of the medium emerges lies at the intersection point between the longitudinal central axis 26 and the cross axis 41. As seen in the running of the multifilament yarn (arrow 27), the jet nozzles 37/2 and 37/3 through which, respectively, a side flow enters into the yarn conduit 13 are located before the said jet nozzle 37/1. These jet nozzles 37/2 and 37/3 lie respectively in the peripheral zone 33 of the yarn conduit 13.
The embodiment shown in FIG. 17 of the jet nozzle arrangement differentiates itself from the presented embodiment of FIG. 16 principally in that the partial cross-section of the openings of the jet nozzles 37/1 to 37/3 are designed in the shape of an ellipse. The major semi-axis of the ellipse that forms the partial cross-section of the opening 37/1 lies upon the longitudinal central axis 26. The major semi-axes of the respectively smaller elliptical, partial cross-sectional openings of the jet nozzles 37/2 and 37/3 lie at right angles to said longitudinal central axis 26 and oppositely to the partial cross-section of the opening 37/1.
In FIG. 18, we see an embodiment of the jet nozzle arrangement 35 in which the cross-section of the opening is formed from a triangular and two ellipse shaped partial cross-sectional openings. As seen in the running direction of the multifilament yarn (arrow 27), the jet nozzle 37/1, which exhibits a triangular partial cross-sectional opening, precedes over the jet nozzles 37/2 and 37/3 in such a way that one side of the partial cross-section of the opening is parallel to the cross axis 41. The multifilament yarn carried in the yarn conduit 13 is first brought over this said one side, so that simultaneously, the main flow and the side flows become effective.
The embodiment shown in FIG. 19 of the jet nozzle arrangement 35 encompasses two jet nozzles 37/2 and 37/3, the partial cross-sectional area of each being elliptic in shape, and one jet nozzle 37/1, the partial cross-section of the opening of which exhibits a V shape with a central expansion 65. This increases the partial cross-section of the opening. The jet nozzles 37/2 and 37/3 from which, respectively, a side flow of the medium emerges into the yarn conduit 13 precede the jet nozzle 37/1 as seen in the running direction of the multifilament yarn, so that the side flow pair initiates the activity. Since the jet nozzle 37/1 with its partial cross-section of the opening extends into the peripheral zone 33 of the yarn conduit 13, the situation is as if once again two side flows enter along with the main flow. The partial cross-section of the opening of the jet nozzles 37/1, 37/2 and 37/3 form in common the cross-section of the opening of the jet nozzle opening arrangement 35, wherein the symmetry to the longitudinal central axis 26 of the yarn conduit 13 remains intact.
In all the descriptions of the jet nozzle arrangement 35 made with the aid of FIGS. 3 to 19, the cross-section of the opening of which is presented with sharp corners, i.e. edges, these corners exhibit a rounding off radius, which lies in a range of 0.03 mm to 0.20 mm because of current technical manufacturing reasons.
In a close consideration of FIGS. 16, 17 and 19, it becomes clear that the jet nozzles from which the side flows of the medium enter into the yarn conduit 13 advantageously precede the jet nozzle from which the main flow of the medium enters the yarn conduit 13. That is, the filaments of the multifilament yarn are first interacted with the side flows in the peripheral zone 33 of the yarn conduit, and then subsequently are entwined by the main flow which enters into the central zone 29 of the yarn conduit 13. In the case of the embodiment in accord with FIG. 18, the filaments are seized by the main flow, but simultaneously also by the side flows. The back-setting of the side flow pair of the jet nozzles 37/2 and 37/3 reinforces the effect of the side flow action, without interfering with the main flow.
Among other effects, experience has shown, that preferentially, a good interlacing result is achieved with minimum air consumption, when the main and side flows in reference to placement do not act simultaneously.
Particularly good results were obtained for all kinds of yarns with the construction in accord with FIG. 20 or even FIG. 21. The FIG. 20 shows a plane view of an embodiment of the jet nozzle arrangement 35 in which the cross-section of the opening of a jet nozzle 37o is symmetrical to the longitudinal central axis 26. The cross-section of the opening of the jet nozzle 37o is composed of two figurative partial cross-sections of the openings, which, in this case, are run together.
The first partial cross-section of the opening is essentially C-shaped and extends itself entirely to the edges of the yarn conduit 13. The elliptic second partial cross-sectional opening follows this first partial cross-section of the opening, again seen in the running direction of the multifilament yarn (arrow 27). The main flow of the medium emerges solely from said elliptic opening into the yarn conduit 13.
In the connection area between the partial cross-section of the openings of the jet nozzle 37o, which lies in the area of the intersection of longitudinal axis 26 and the cross axis 41, the breadth of the opening cross section is less than that of the forward rear cross-sections. In accord with a preferential embodiment variant, this configuration causes the main medium flow to be divided into two main partial flows, which act on the multifilament yarn both positionally and chronologically one after another. In accord with a further (not shown) embodiment variant, the main flow of the medium is divided in more than two, even into three main partial flows. The "division" is not to be understood as physical, but is brought about especially by means of the shaping of the cross-section of the opening, such as has been realized in the embodiment presented in FIG. 20.
The filaments in the yarn conduit, which are in the peripheral zone 33 thereof, are first impelled into the central area 29 of said yarn conduit by the side flows from the C-shaped partial cross-section of the opening of the jet nozzle 37o. These filaments now are seized by the first main flow of the medium and are entwined. By this means, a desirable structuring becomes possible of the filaments, i.e. the multifilament yarn.
FIG. 21 shows another embodiment variant of the jet nozzle arrangement presented in FIG. 20 in which the cross-section of the opening of two jet nozzles 37/1 and 37/2 is designed. The partial cross-section of the opening of the jet nozzle 37/1 has a circular shape from which the main flow of the medium emerges, into the yarn conduit 13. The generally C-shaped jet nozzle 37/2 directly precedes the jet nozzle 37/1 and extends itself into the peripheral zone 33 of the yarn conduit 13. The two main flows are physically separated from one another, that is, the first main flow in combination with the side flows, and the second main flow are blown into the yarn conduit 13 by two jet nozzles separated from one another. Contrary to this arrangement, as presented in the jet nozzle 37o of FIG. 20, the main flow and the side flows are expelled in common out of one jet nozzle into the yarn conduit 13. Upon considering the FIGS. 20 and 21, it becomes clear that the cross-section of the openings of the two jet nozzle arrangement 35 are very similar to one another. Consequently, very similar action is obtained from each.
FIG. 22 presents a sectional view of an embodiment of the yarn conduit 13 through which a multifilament yarn 69 is carried; the yarn being depicted by dotted lines. Into the yarn conduit, opens a jet nozzle 37, the cross section of which is variable and, for instance, can be designed in accord with the above mentioned presentations of cross-section of the openings in FIGS. 3 to 21. The jet nozzle 37 is inclined against the longitudinal central axis 26 of the yarn conduit 13 at an angle δ, which is measured between the axis 71 of the jet nozzle 37 and the longitudinal central axis 26 of the yarn conduit 13.
In accord with an additional embodiment variant the jet nozzle 37 is inclined against the longitudinal central axis 26 by an angle δ, which measures in a range of 60°≦δ≦90°, preferably in a range of 75°≦δ≦87°. It has become evident that by the specified inclination of the jet nozzle 37 the entwining results can be additionally influenced. By the embodiment examples shown in the above discussed FIGS. 3 to 21, the jet nozzle arrangement 35 carries an angle δ of inclination as described above of basically 90°. In order to produce an optical change that is a structuring of the multifilament yarn, it has shown itself as particularly advantageous to choose the angle δ≦60°. Thus, for instance, loops and other structuring of the filaments can be produced in an optional manner. The present invention can also be employed favorably. for the texturing of filament yarns, where in the texturing of yarns, an improved interlacing result is attainable as compared to results where the inclination of the jet nozzle is contrary to the running direction of the multifilament yarn.
However, results with a jet nozzle inclined against the running direction of the multifilament yarn suffice in many cases for given requirements, so that fundamentally, the inclination of the jet nozzle 37 is practically an optional matter of choice.
In the case of a jet nozzle arrangement 35 in which a plurality of jet nozzles are involved, as described with the aid of FIGS. 16 to 19 and FIGS. 20, 21, the jet nozzles 37/1, 37/2 and 37/3 each can be differently inclined against the longitudinal central axis 26 of the yarn conduit, and also show different angles of inclination.
The main flow and the side flows act in these cases in directions varying from one another, which makes possible an optimized adjustment of the effective operation of the partial flows of the medium.
In FIG. 23, the effective action of the main flow H and the side flows N of the medium entering the yarn conduit 13 is presented with the aid of a schematic cross-section of an interlacing apparatus. In the depicted embodiment shown here, the main and side flows are not physically separated from one another. Obviously, the functional presentation may be transferred easily to physically separated main and side flows.
The jet nozzle opens at the base of the semi-circular shaped yarn conduit 13 in the central area into which the main flow of the medium, indicated with an arrow H, enters and upon impacting on the top plate 25, divides itself into two partial flow vortices, which show opposite rotation directions. By means of these vortices, the filaments of the multifilament yarn are intensively entwined, so that strong interlacing points, i.e. interlacing nodes, are formed. In any case, as this flow, vortices, or yarn proceeds, the filaments are also accelerated into the peripheral zone 33 of the yarn conduit 13, which forms a dead space where no interlacing occurs. By means of the side flows N entering the peripheral zone 33, which flows enter approximately concurrently with the main flow H into the yarn conduit 13, the filaments are seized by these side flows and brought back into the central zone 29 of the yarn conduit 13. They dwell only for a short time in said dead space of the peripheral zone 33 and are immediately placed again in the main air flow, where the interlacing occurs. As may be inferred from the right half of the FIG. 23 about the side flow N, only a portion of the peripheral zone 33 of the yarn conduit is reached by means of the cross-section of the opening. The interaction varies in accord with how far the peripheral zone 33 is penetrated by the air flow N. In the FIGS. 3 to 21, as an example, the opening in the peripheral zone 33 is shown corresponding to the right half of the FIG. 23. Obviously, the peripheral zone 33 penetrated by the side flows can extend itself beyond the yarn conduit 13, going on beneath the top cover 25.
By means of this variation, the interlacing in regard to nodes, number and thickness as well as frequency of the same can be additionally influenced in a decisive way. For this reason, the FIGS. 3 to 21 are to be understood in connection with these variations, even when it is shown in the Figure that the cross-section of the opening ends at the side of the yarn conduit.
From the description of the FIGS. 1 to 23, a process comes into being for the handling of filament yarns, in order to entwine these yarns. This process includes the apportionment of the medium flow into one main flow and a pair of side flows, wherein the main flow is introduced into the central zone of the yarn conduit and one of the side flows into the one part of the peripheral zone and the other side flow into another part of the peripheral zone of the yarn conduit, so that the directions of the different air flows do not cross. In other words, the air flows may have different directions so long as they stay in the central and outer peripheral zones, respectively, without crossing. Main and side flows are guided in essentially the same direction. The main flow generally should carry the largest volume flow as compared to each of the side flows. By means of appropriate adjustment of the size of the side flows as compared to the main flow, the dwell time in which the filaments remain in the peripheral zones of the yarn conduit can be reduced, so that the results of the interlacing by said adjustment can be positively influenced. In this manner unentwined, open yarn places of a definite size also can be reduced. Also, the node number, the size and solidity of the same can be changed with a quantitative certainty. The breadth of the central area in which the actual interlacing takes place as well as the remaining peripheral zones in which no interlacing occurs are all defined by the main flow.
In summary, it can be maintained, that by means of the apportionment of the medium flow into a plurality of flows, the interlacing quality is improved. Advantageously accompanying the continued, satisfactory interlacing results, the medium consumption is reduced so that the costs of the interlacing can be reduced. By means of the effective coactivity of the side flows with the main flow of the medium, an increase in the speed of running for the multifilament yarn and concomitant thereto an improved productivity of the interlacing apparatus becomes possible.
It will be appreciated by those skilled in the art that various modifications and variations can be made in the present invention without departing from the scope of the invention. It is intended that the present invention include such modifications and variations as come within the scope of the appended claims and their equivalents.
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An apparatus for interlacing a multifilament yarn includes a housing with a conduit defined therethrough. A jet nozzle is configured with the housing. The jet nozzle includes a main channel symmetric to the yarn conduit axis and at least two side channels. The main channel directs a greater volume of pressurized air into a central region of the yarn conduit as compared to the side channels that direct a lesser volume of pressurized air to peripheral zones where substantially no interlacing of the yarn takes place.
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FIELD OF THE INVENTION
The present invention relates to baskets and more particularly to a basket designed for releaseable mounting to a shopping cart for increasing the carrying capacity of the shopping cart and allowing shopping carts to be stored in no greater storage area than is required for storing shopping carts without such baskets and for providing attractive and functional advertising which is protected by the design of the basket.
BACKGROUND OF THE INVENTION
Supermarkets, as well as other retail establishments, both large and small, quite frequently employ wheeled shopping carts freely provided to their patrons to facilitate simple, relaxed movement through the aisles of the retail establishment, allowing patrons to collect relatively large quantities of merchandise within the cart. The cart containing the selected items is then typically brought to a check-out counter where the selected items are paid for, bagged and quite frequently replaced in the shopping carts to facilitate the removal of the purchase from the premises and transportation of the selected items to the patron's vehicle.
Since shopping carts of the type described are rather large, it is extremely advantageous to limit the storage area as much as is practicable to avoid wasting precious store space. This is typically accomplished by providing shopping carts having a tapered configuration from front to rear and having a swingably mounted gate at the rearward end thereof which is pushed upwardly to facilitate insertion of the forward end of a shopping cart. This design permits any number of shopping carts to be nested together to reduce the amount of floorspace required for storage during non-use.
It is an object of the present invention to provide a basket for mounting to the forward end of a nestable shopping cart to thereby increase the overall carrying capacity of the cart without increasing the floorspace required for storage of the nested carts. This was accomplished in the prior art by the provision of a shopping cart attachment formed of wire and having a pair of hooks for joining the top end of the attachment to the top bar of a shopping cart provided at the forward end thereof. Note, for example, U.S. Pat. No. Des. 209,279 issued Nov. 21, 1967 to the present inventor. Messages and/or advertising material were provided by means of a thin metallic plate having its side portions wrapped around two substantially vertically aligned metallic ribs of the basket. The size and location of the shopping cart attachment permit the shopping carts to be nested together in the normal fashion without increasing the floor space required for shopping cart storage. Due to the expense of such metallic basket attachments, the number of ribs employed in the formation of the basket was necessarily kept to a minimum, yielding a basket which is quite limited as to the goods it is capable of storing. In addition, the sign is totally unprotected and is scratched and dented very easily and very quickly, destroying the effectiveness thereof in quite short order. The basket attachment further failed to provide any means for securement of the shopping cart attachment to the shopping cart which assembly prevents unnecessary jostling and/or swinging of the attachment basket. In addition, the design of the prior art basket attachment for shopping carts makes it highly impractical to remove and replace the sheet bearing the advertising and/or message material.
BRIEF DESCRIPTION OF THE INVENTION
The present invention provides a novel basket attachment for nestable type shopping carts and the like which is characterized by comprising a one-piece molded plastic member which is lightweight and yet quite rugged and highly serviceable. The basket is of a lattice type design, comprised of substantially mutually perpendicularly aligned ribs, preferably arranged respectively horizontally and vertically. The basket is open at its upper end and is provided with a floor or bottom preferably having more closely spaced, mutually perpendicular ribs to facilitate the carrying of rather small items. The open upper end of the attachment basket terminates in a continuous rolled rim having a inverted, substantially U-shaped, cross-section. A pair of substantially vertically aligned ribs, arranged along the front wall of the attachment basket, together with the forward end of the floor of the basket, collectively form a three sided frame for slidably receiving and supporting a sign member in the form of a substantially flat, thin guage sheet of either metal, plastic or any other suitable material. The aforesaid vertically aligned ribs along the front wall are each provided with an elongated groove which grooves cooperate to receive the opposite parallel edges of the aforesaid planar sheet permitting the sign to be viewed from both the front and the rear while providing a bumper like protective frame surrounding the exterior surface of the sign.
S-shaped hooks are preferably used for joining the attachment basket to the top forward rib of the shopping cart front wall. An L-shaped recess, cooperating with a downwardly extending opening are integrally molded into the basket, said L-shaped recess serving as a means for guiding one hooked end into the downwardly extending opening and for receiving the intermediate portion of the S-shaped hook to prevent the S-shaped hook from twisting and from swinging, thereby stabilizing the mounting of the attachment basket upon the shopping cart.
The rearward end of the attachment basket floor is provided with a pair of integrally formed elongated projections having bores, each bore being arranged to receive one end of a resilient retainer element having yieldable enlarged ends which compress when inserted into said bores and which thereafter expand to normal size after passing out of the opposite ends of said bores, providing a bottom retainer which prevents the attachment basket from freely swinging, thereby providing a stable, yet releaseable mounting arrangement. The floor of the basket in one alternative embodiment is preferably inclined from front to rear, causing loose items placed within the basket to be urged away from the sign. An inclined member extending across the bottom edge of the sign between the vertically aligned bumper rims framing the sign urges items within the basket and immediately adjacent the sign to move rearwardly, thereby preventing items from leaning against the sign facilitating viewing of the rear surface of the sign.
The basket is preferably molded of a plastic material, such as polyethylene which is substantially unaffected by extremes in temperature. The retainer element and/or hook members may be molded integrally with the molding of the basket in a single operation and are joined thereto by an extremely thin gauge web which may further be scored to facilitate tearing away of the retainer strip (and/or hook strip) from the basket preparatory to mounting of the basket upon a shopping cart.
To further protect the sign from being scratched or damaged during use, a hot stamping technique is employed to form the sign, wherein characters and other patterns are debossed into the surface of the planar sheet and material such as a plastic foil material, preferably of a contrasting color or colors, is deposited in the debossed regions which are in the form of shallow recesses. The thickness of the plastic material deposited therein is less than the depth of said recesses so that the exposed surfaces of the deposited material is in itself recessed, thereby protecting against being damaged or scratched.
OBJECTS OF THE INVENTION AND BRIEF DESCRIPTION OF THE FIGURES
It is therefore one object of the present invention to provide a novel basket attachment for shopping carts and the like having integrally formed portions thereof serving as bumper means for protecting both the basket and a changeable sign framed by said bumper means.
Another object of the present invention is to provide a novel basket attachment for use with shopping carts and the like having integrally formed means for removably receiving fastening members and for stably retaining said fastening members to prevent moving and/or twisting of the fastening elements as well as the basket attachment.
Still another object of the present invention is to provide a novel basket attachment for shopping carts and the like provided with means for moveably mounting the sign member viewable from both the front and rear of said basket attachment and including means for urging items within said basket away from the sign to permit the sign from being scratched or damaged and to facilitate viewing thereof.
Still another object of the present invention is to provide a basket attachment for use with shopping carts and the like wherein the basket attachment and cooperating fastening elements are integrally formed during a single molding operation and are easily severable from one another by means of an extremely thin tear-away portion to thereby facilitate and simplify packaging, shipment and assembly operations.
The above as well as other objects of the present invention will become apparent when reading the accompanying description of drawings in which:
FIG. 1 is a perspective view of the basket showing the front, left and top sides.
FIG. 1a is a detailed sectional view of one of the hook mounting assemblies of FIG. 1.
FIG. 1b is a detailed perspective view of one of the hook mounting assemblies of FIG. 1.
FIG. 1c is a detailed rear elevational view of one of the hook mounting assemblies of FIG. 1.
FIG. 2 is a perspective view of the basket of FIG. 1 showing the rear and left-hand sides thereof and with portions thereof removed for simplicity of presentation.
FIG. 2a is a detailed elevational view of one of the retainer receiving members shown in FIG. 2.
FIG. 3 is a sectional view of the basket of FIG. 1 looking in the direction of arrows 3--3'.
FIG. 3a is a detailed rear perspective view of a portion of the sign holding structure shown in FIG. 1.
FIG. 3b is a simplified elevational view of another embodiment of the basket of the present invention.
FIG. 4 is a sectional view of a portion of the rear wall of the basket of FIG. 1 showing another embodiment of the present invention.
FIG. 4a is an end view of the tearaway elements looking in the direction of arrows 4a--4a' in FIG. 4.
FIG. 5 is a sectional view of a hot stamping apparatus used for forming a sign which may be employed in the basket shown in FIG. 1.
DETAILED DESCRIPTION OF THE INVENTION
Considering FIGS. 1 and 2, there is shown therein a basket attachment 10 designed in accordance with the principles of the present invention and being a unitary one piece molded member having a floor portion 12, left and right-hand side walls 14 and 16, rear wall 18 and forward wall 20. Floor 12 is provided with a plurality of mutually perpendicularly aligned ribs 12a, 12b which are integrally joined at their intersections 12c, the ribs 12a and 12b forming small rectangular shaped openings 12d. Spacing between the ribs 12a and 12b is sufficiently small to permit small items to be safely deposited within the basket.
Side walls 14 and 16 are comprised of substantially vertically aligned ribs 14a, 16a and horizontally aligned ribs 14b, 16b which are integrally joined to the aforementioned vertically aligned ribs at intersections 14c, 16c, respectively. Rear wall 18 comprises a plurality of vertically aligned ribs 18a integrally adjoined to horizontally aligned ribs 18b at intersections 18c.
Front wall 20 is provided with horizontally aligned rib 20a integrally joined to a pair of vertical ribs 20b, 20b. The horizontally and vertically aligned ribs 14a, 14b and 16a, 16b; 18a, 18b and 20a, 20b of the side walls 14 and 16, rear wall 18 and front wall 20 may be separated by larger spacing distances than the ribs 12a, 12b forming the floor 12 of basket 10.
The curved corner ribs 22, 24, 26, 28 are integrally joined to the horizontally aligned ribs of adjacent walls. For example, corner rib 22 is joined to horizontally aligned ribs 14b, 18b of side wall 14 and rear wall 18, respectively. Each of the corner ribs 22 through 28 has a curved configuration so that their exterior surfaces are convex while their interior surfaces are concave. Ribs 22 through 28 are also greater in width than the vertical ribs forming each side wall. In a similar fashion, the unitary basket attachment 10 is provided with horizontally aligned curved bottom ribs 30, 32, 34, 36, each of which are integrally joined to the vertically aligned ribs of their associated side wall and floor as well as being integrally joined to the lower ends of corner ribs 22 through 28. Ribs 30 through 36 have a curved contour which is concave along their interior surfaces and convex along their exterior surfaces.
Basket attachment 10 has an open upper end defined by upper horizontally aligned ribs 38 through 44, each forming an integral part of an associated wall and being integrally joined to vertically aligned ribs of the associated wall as well as being integrally joined to the upper ends of the corner ribs 22 through 28.
The upper horizontally aligned ribs have an inverted, U-shaped cross-section. Noting, for example, the upper rib 44 the inverted U-shaped cross-section 44a can be seen in FIG. 2 to define a downwardly extending flange whose outer surface extends beyond the outer surfaces of the ribs 18a of the associated side wall 18. Each of the upper horizontally aligned ribs 38 through 44 are integrally joined to one another at their ends, forming the rounded corners 46, 48, 50, 52. The ribs 38 and 42, corners 48, 50 and the front rib 40 collectively form a rolled bumper rim which, due to its inverted U-shaped cross-section enhances the integrity and structural strength of the basket attachment 10 and further serves as a bumper to cushion any impact experienced by the basket attachment 10 during use.
The vertically aligned ribs 20b, forming part of front wall 20, are rounded, raised, ribs which extend outwardly and away from the imaginary planar surface defining front wall 20. These raised ribs, together with the rolled bumper rim 40 extend forwardly of a sign 60 which may provide advertising and/or messages, and serve to protect the sign against being scratched, dented or damaged.
FIG. 3 shows a sectional view of ribs 20b looking in the direction of arrows 3, 3' of FIG. 1. Each of the ribs is provided with an elongated groove 20d for slidably receiving opposing vertical sides of sign 60 which is preferably a rectangularly shaped substantially planar plate of relatively thin guage material and may be formed of wood, plastic, metal or any other suitable material capable of being stamped or pressed or printed upon to carry and hence display a sign and/or message on both the forward and rearward surfaces thereof. If desired, both the sign and the frame receiving the sign can depart from a rectangular shape and can have a trapezoidal shape, for example.
The vertically aligned, elongated grooves 20d cooperate with a horizontally aligned groove 32a provided along the upper interior surface of bottom rib 32 and positioned to receive and support the bottom edge of sign member 60. The top edge 60a of sign 60, shown best in FIG. 3a is preferably rounded or smoothed to avoid the possibility of any injury.
Due to the open weave basket design, the rearward surface of sign 60 may be viewed through rear wall 18 of basket attachment 10. The interior portion of each rib 20b extends inwardly as shown best in FIG. 3a to serve as a bumper to protect the interior surface 60b of sign 60 from being damaged.
As shown in FIG. 3b, a ramp 62 is provided along the interior side of wall 20, inclined surface 62 extending between ribs 20b and serving to urge articles placed within basket attachment 10 away from sign member 60 to prevent the items placed within basket attachment 10 from obscuring the exterior surface 60b of sign 60. In addition thereto, floor 12' is perferably arranged in an inclined fashion causing items within basket attachment 10 to be urged toward rear wall 18 or alternatively to lean rearwardly so as to cause items within basket attachment 10 to be urged rearwardly or to lean in a rearward direction to facilitate unhindered observation of the rear surface 60b of sign member 60. The inclined floor 12' and ramp 62 may be used together or independently of one another.
Referring to FIGS. 1 and 1a through 1c, the upper horizontal rib 44, extending along the top end of rear wall 18, is provided with a pair of notches 44a, 44a which provide clearance for the S-shaped mounting hooks 64 provided for joining the upper end of basket attachment 10 to the topmost bar 66 provided at the forward end of a shopping cart (not shown for purposes of simplicity). The S-shaped hooks 64 are preferably formed of metal and are each provided with hook-shaped ends 64a, 64b integrally joined with a substantially straight center portion 64c. The upper horizontal rib 44 has a hook receiving arrangement 44a, integrally molded into rib 44 which is comprised of a substantially L-shaped recess 70, having a horizontally aligned recess portion 70a and a vertically aligned recess portion 70b. The downwardly extending opening 72 communicates with the horizontally aligned recess portion 70a and is designed to receive and be supported by the free end of hook portion 64b as shown best in FIGS. 1a and 1b. The hook portion 64b extends substantially into the horizontally aligned recess 70a and opening 72 while the substantially straight central portion 64c of S-shaped mounting hook 64 extends into the vertically aligned portion 70b of recess 70. The upper hook portion 64a is suspended upon the topmost horizontally aligned rib 66 of the shopping cart which may be comprised of additional horizontally aligned ribs 74, 76 joined with vertically aligned ribs, such as, for example, the vertically aligned rib 78.
The free end 64a-1 of upper hook portion 64a is preferably urged inwardly in the direction shown by arrow 80 to cause the upper hook 64a to substantially surround upper horizontal rib 66, preventing basket attachment 10 from being easily removed from the shopping cart.
Vertically aligned recess 70b cooperates with opening 72 to prevent the S-shaped mounting hook member 64 from rotating about the lower end as shown by arrow 84 and also prevents the mounting hook 64 from rotating or swinging about the upper hook shaped member 64a as shown by arrow 86. In addition thereto, the vertically aligned recess 70b further cooperates with opening 72 to prevent the S-shaped mounting hook 64 from rotating about its longitudinal axis represented by dotted line 64c so as to prevent rotation of the S-shaped mounting hook in the direction represented by arrow 88. Thus each L-shaped recess 70 and cooperating opening 72 provided for each of the S-shaped mounting hooks 64 stably mount the basket attachment 10 to the forward end of a shopping cart.
In order to further stabilize basket attachment 10 so as to prevent it from swinging in the direction shown by arrow 90 about the upper horizontal rib 66 of the shopping cart, the basket attachment 10 is provided with elongated, horizontally aligned retainer receiving projections 92 and 94 integrally formed as part of the basket floor 12 and arranged at the rearward end thereof. Since both of the retainer receiving projections 92, 94 are substantially identical, a description of retainer receiving projection 94 will be given hereinbelow, for purposes of simplicity. As can best be seen in FIGS. 2 and 2a, retainer receiving projection 94 has a substantially cylindrically shaped body 94a which is provided with a cylindrical shaped opening or bore 94b extending through the entire length of the body 94. An elongated retainer member 96, preferably formed of a flexible, resilient plastic material, comprises a wire shaped body 96a having enlarged tapered heads, 96b and 96c integrally joined to the free ends of wire-shaped body 96a. The tapered mushroom shaped heads 96b, 96c are compressible and the retainer 96 secures basket attachment 10 to the forward end of a shopping cart in the following manner:
Retainer member 96 is bent into a substantially U-shaped configuration as shown best in FIG. 2 so as to encircle a vertical rib such as for example vertical rib 78 provided at the forward end of a shopping cart. Mushroom shaped cap 96c is brought into alignment with opening 94b and is pressed into said opening. The dimensions of the mushroom shaped cap 96c are greater than the inner diameter of bore 94b, causing the mushroom shaped cap 96c to be compressed as it passes through opening 94b. As soon as the rear end 96c-1 of mushroom shaped cap 96c clears the right hand end 94a-1 of retainer body 94a, mushroom shaped end cap 96c springs back to its normal configuration, thereby serving as a means for locking one end of the retainer member 96 to basket attachment 10. The mushroom shaped end cap 96b is inserted into the retainer opening 92b in a similar fashion and assumes a locking position in a similar fashion thereby locking the lower end of basket attachment 10 to the shopping cart, preventing basket attachment 10 from swinging about upper horizontally aligned rib 66 thereby stably mounting basket attachment 10 and further preventing the items collected therein from being jostled or bounced around. If desired, retainer member 96 may be wrapped one full turn about rib 78.
In the event that it is desired to remove basket attachment 10 from a shopping cart, the plastic retainer element 96 may be cut, and its two halves pushed through the rearward ends of the respective openings 92a, 94a and discarded. Hooks 64 may be removed simply by bending the free ends of upper hook portions 64a back to the positions shown, for example, in FIGS. 1a and 1b. Alternatively, the lower hook portions 64b may be removed from the associated openings 72 each receiving a hook portion 64b, leaving hook portions 64a about horizontal rib 66.
The sign 60 may be formed of a suitable plastic material, the sign 60 being produced by a hot stamping process wherein the sheet 60 is placed upon a support 100 as shown in FIG. 5. A heated member 102 is pressed against the upper surface of sheet 60 and is provided with raised projections such as the projection 102a which is pressed into the top surface of sheet 60 to form a depression 60e which conforms to the shape of projection 102a. A foil sheet 104 of a colored plastic material such as for example mylar is placed against the projection 102a and is heated and fused to the base of recess 60e. The mylar foil 104 is preferably of a color which contrasts with the color of sheet 60. Foil sheet 104 only partially fills the recess 60e so as to be arranged a spaced distance beneath surface 60a. This debossed arrangement serves to protect the mylar foil sheet 104 from being scratched or damaged. It should be understood that the projection 102a may be in the form of numbers and/or letters and/or graphic patterns depending upon the advertising or message information desired to be conveyed to the user. The hot stamping operation may be performed upon both surfaces of sheet 60 at the same time by replacing support member 100 with a heated member having projections and similar to member 102.
It can be seen from the foregoing description that the basket attachment 10 of the present invention fulfills a multiplicity of objectives, some of which include an increase in the capacity of items capable of being carried by the shopping cart and combined basket attachment 10; a lightweight and yet rugged basket attachment which, is preferably formed of a plastic material, and wherein advertising and/or message information is provided as an integral part of the basket attachment which subject matter may be viewed from both the front and rear of the basket attachment, said basket attachment 10 being provided with integrally formed bumper portions which protect the front and rear of the sign from being damaged or scratched; and simplified, easy to use, fastening means for joining the upper and lower horizontally aligned ribs of the basket attachment to cooperating ribs of a shopping cart to stably mount the basket attachment to the shopping cart and including integrally formed recesses provided for receiving hooks which secure the upper end of the basket attachment to the shopping cart and which prevent the hooks from twisting or swinging, still further stabilizing the mounting of the basket attachment to a shopping cart.
As was mentioned hereinabove, the basket member of the present invention may be molded of a suitable plastic by a single molding operation. The basket attachment may preferably be formed of polyethylene, which is substantially unaffected by cold temperatures and hence holds up extremely well, especially for basket attachments which are used and/or stored out of doors.
Forming the basket attachment of plastic further enables the retainer element and S-shaped mounting hooks to be integrally formed with the molding of the basket attachment 10. Noting for example, FIGS. 4 and 4a, vertically aligned ribs 18a forming party of rear wall 18, shown best, for example, in FIG. 1, have integrally joined thereto a pair of S-shaped mounting hooks 64', 64', said S-shaped mounting hooks 64, 64' being formed of the same plastic material as the basket and being joined to right-hand rib 18a by extremely thin tear away webs 110, 112, 114, 116, respectively. FIG. 4a shows the manner in which extremely thin webs 110 and 114 integrally join upper hook portions 64a', 64a' to vertically aligned rib 18a. Lower ribs 112 and 116 are also extremely thin so as to be easily torn away or cut away from the S-shaped hooks 64', 64'. Since mounting hooks 64', 64' are formed of plastic, their free ends 64a'-1 and 64b'-1 are preferably in close proximity to the straight central portion 64c'. The upper hook portions 64a' may thus be joined to the upper horizontal rib 66 (see FIGS. 1a and 1c) by pulling the free end 64a'-1 outwardly and away from the straight central portion 64c', placing the hook shaped portion 64a' around the horizontally aligned rib 66 of the shopping cart and then releasing the free end 64a-1' causing it to return to its normal position in close proximity to the straight central portion 64c'.
The plastic retainer 96 is similarly joined to the left-hand vertically aligned rib 18a by extremely thin webs 118, 120. The webs 110 through 120 are sufficiently thin to permit the mounting hooks 64' and the retainer 96 to be cut away or torn away from the associated vertically aligned ribs 18. In addition, the extremely thin webs may be scored as represented by the score lines 110a and 114a as shown in FIG. 4a to further facilitate the tearing away of the members 64' and 96 from the rib 18a of basket attachment 10 preparatory to assembly thereof. This arrangement greatly simplifies handling and packaging and assures that all of the components are shipped together without fear of becoming misplaced. The tear away webs are thick enough to retain the elements 64' and 96 to the basket attachment and yet thin enough to permit their being easily cut or torn away preparatory to assembly.
A latitude of modification, change and substitution is intended in the foregoing disclosure, and in some instances, some features of the invention will be employed without a corresponding use of other features. Accordingly, it is appropriate that the appended claims be construed broadly and in a manner consistent with the spirit and scope of the invention herein.
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An unbreakable basket detachably coupled to a nestable shopping cart, has vertical and horizontal plastic ribs, certain ones protecting a detachably mounted sign on the forward face. The open end of the basket has a continuous rolled rim which enhances structural ridigity of the basket and protects the shopping cart and the sign. The upper end of the basket is mounted to the shopping cart by S-hooks. Recesses in the basket prevent the S-hooks swinging and facilitate assembly and disassembly.
Retainer receiving members arranged along the rearward end snap fittingly receive a plastic retainer securing the basket to the cart and preventing the basket from swinging. The vertical ribs and rolled bumper rim removably receive and support the sign. The basket is tapered to permit nesting during shipment or storage. Advertising material and/or messages are printed on both sides. An angle member along the bottom of the basket behind the sign urges goods away from the sign. The basket floor is aligned at an angle to the horizontal to urge goods away from the sign. The connectors for coupling the basket to a shopping car may be integrally molded with the basket and are joined thereto by thin tear-away strips to facilitate separation preparatory to mounting of the basket upon a shopping cart. The sign may be produced through the use of a hot stamping process which resists damage.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to a pressurized washing system and apparatus, and more particularly, to a self-contained washing system that is capable of simultaneously washing a plurality of vehicles used for landscape maintenance, removing the debris and oils from the vehicles, while separating and removing the oil from the debris and the wash water, utilizing recycled and filtered water, without contaminating the surrounding area.
[0003] 2. Discussion of the Relevant Art
[0004] The prior art discloses many devices for providing a pressurized washing system suitable for washing the underside and top of lawnmowers and the like. However, a pressurized washing system that is capable of simultaneously washing the debris from of a plurality of vehicles, filtering the liquids, separating the water from the oils and having a storage medium for holding the removed oil and debris for disposal elsewhere, thereby avoiding contamination of the environment proximate the washing station, does not appear in the related art and there is no showing or suggestion that such an environmentally protective apparatus is capable of performing the same functions.
SUMMARY OF THE INVENTION
[0005] Therefore, it is an object of the present invention to overcome the shortcomings of the prior art and provide a pressurized washing system, suitable for simultaneously washing a plurality of vehicles, that is safe for the environment.
[0006] It is an object of the present to provide a self-contained, pressurized washing station that filters the liquid used in the washing of a plurality of vehicles for re-use and captures the debris contained in the liquid for disposal without contaminating the environment.
[0007] It is another object of the present invention to provide a relatively inexpensive self-contained pressurized washing apparatus for a plurality of vehicles that may readily be moved and installed in another location.
[0008] It is yet another object of the present invention to provide a self-contained, pressurized washing station that filters and re-uses the washing water that washes a plurality of vehicles and stores the debris contained in the water for disposal without contaminating the environment.
[0009] It is still yet another object of the present invention to provide a pressurized washing station that may simultaneously accommodate a plurality of vehicles of different sizes, re-uses the washing water, cleans and stores the debris contained in the water for disposal, without contaminating the environment.
[0010] Yet another object of the present invention is to provide a pressurized washing station that is self-contained, does not require an external source of water or electricity or requires a sewer system and is powered by a diesel power pneumatic source that provides the required water pressure for operation.
[0011] Still yet another object of the present invention is to provide a system that captures and uses available rain water to replace and supplement needed water.
[0012] 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 a specific embodiment in which the invention may be practiced. This embodiment 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. 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. Like-reference characters are utilized to designate like or corresponding components in the various views, in order for the reader to better understand features of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] In order that the invention may be more fully understood, it will now be described by way of example, with reference to the accompanying drawings in which:
[0014] [0014]FIG. 1 is a top plan view of a washing station for a plurality of landscape maintenance equipments, according to the principals of the present invention;
[0015] [0015]FIG. 2 is an enlarged plan view of the power and control portion of the washing station described in FIG. 1; and
[0016] [0016]FIG. 3 is a flow diagram of the washing station showing the flow, recycling of the water and the storage and the disposal of the waste materials accumulated after washing the vehicles.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0017] Referring to the figures and in particular to FIG. 1, there is shown a top plan view of a washing station 10 suitable for washing a plurality of landscape maintenance equipment, not shown. Provision is made to accept up to eight different pieces of equipment of different sizes for simultaneous washing. Each piece of equipment is placed in a different parking location 12 a , 12 b , 12 c , 12 d , 12 e , 12 f , 12 g and 12 h . Preferably each parking location 12 a through 12 h is approximately eight feet (2.4 meters) wide ( 14 ) by eleven feet (3.3 meters) long ( 16 ), spaced side by side, in two rows 18 and 20 , with a walking space 22 , preferably about four feet (1.2 meters) wide, provided between each station 12 a thru 12 h . The total area of the washing station 10 being approximately 1400 square feet (126 square meters), excluding the area 34 used for the power generator and compressor 24 and the wash drums or tanks 26 , 28 , 30 and debris receptacle 32 (see FIG. 3), which require an area of approximately 24 feet (7.2 meters) long and 8 feet (2.4 meters) wide or approximately 192 square feet (17.28 square meters) of reinforced concrete.
[0018] The circumference of the washing station 10 is provided with a raised portion 38 and a surface 11 sloped towards the drain or sump tank 42 , disposed proximate one edge 40 thereof, to insure that the water and debris washed from the vehicles will flow towards the drain or sump tank 42 . The drain or sump tank 42 is adapted to receive all of the debris and grease and oil filled dirty water from the vehicles, as well as, any natural rain water that may have fallen when no washing was being done. The sump or receiving tank 42 is covered with a heavy duty porous grate or cover 44 that has a plurality of openings therein to prevent large pieces of debris from entering the sump or drain tank 42 . Drain tank 42 has disposed therein an inner removable basket 46 , that can be lifted out of the tank 42 with the aid of the overhead motorized trolley, winch and pulley system 47 , that is suspended from an overhead I-beam track 48 . The overhead winch and pulley system 47 is also capable of tilting the basket 46 to empty the contents therein, as needed.
[0019] Each parking station 12 a thru 12 h is provided with underground pressurized water hose lines 52 having release nozzles 54 disposed thereon, via ten stanchions 50 placed on either side of the parking locations 12 a thru 12 h in the walking space 22 provided between the parking locations 12 a thru 12 h.
[0020] Appended to the parking station area 11 is an area 34 of reinforced concrete approximately 8 feet wide ( 36 ) by 24 feel long ( 37 ) onto which the power generator and compressor 24 is placed, as well as, the washing drums 26 and 28 . Also included in the area 34 , is the inlet tank 62 and the outlet tank 64 . Preferably, each tank is capable of holding 1300 gallons of liquid and may reverse functions as needed. The bank of filters 68 , includes filter housings and the filter bags 70 a , 70 b , 70 c and 70 d , each provided with similar input and output control valves 72 , that permit water to flow into and out of the filter vessels, inlet and outlet tanks or drums 62 and 64 and open wash tanks or drums 26 and 28 . Also included are pressure pumps 74 , 76 and 78 and their associated control valves 72 . The function of each of these components will be set forth hereinafter.
[0021] Referring now to FIG. 2, which is an enlarged and separated for clarity, plan view of the power and control area 34 of the washing station 10 , that is fabricated of reinforced concrete and FIG. 3, which is a flow diagram of the washing station showing the flow, recycling of the water, the storage and the disposal of the waste materials accumulated after washing the vehicles.
[0022] In operation, the waste water and debris enters the below grade receiving sump 42 , which has disposed therein a mesh receiving drum or basket 46 that may be removed from the sump 42 by the overhead trolley with motorized hoist 47 affixed on the overhead I-beam 48 . The sump 42 is drained of water by suction pump 76 and discharges the water obtained into inlet tank 62 . The grass debris, with oils thereon, in the basket 46 is then moved to the open wash tank 26 or 28 . A valved compressed air wand, not shown, is inserted into basket 46 , while it is immersed in tank 26 or 28 , while the tank is filled with water and detergent. The compressed air wand is inserted into the tank and the air bubbling up from the wand washes off the oil attached to the grass. The basket 46 is raised out of the tank by the winch and pulley system 47 , moved to the grass dumping station 32 where it is tilted and emptied by the winch and pulley system 47 and aided by the compressed air wand. The debris may be dumped into a container at station 32 , spread on the ground, to be used as mulch, or dumped on the ground elsewhere, since it will not harm the environment.
[0023] With the aid of pump 74 and the proper positioning of valve 72 , the water may be washed, filtered and pumped by pump 74 through filter 70 to the open wash tank 26 or 28 , which may be repeated as needed. The filter bank 68 has three valve 72 positions and with the aid of pumps 76 and 78 and its interconnections, provides the wash water under pressure for all the wash hoses, aerates and re-filters the wash water and discharges sour or excess rain water or completely drains the tanks. Once the grease and oil are separated from the water by the filter bank 68 , the filter bags, not shown, may be removed and properly disposed of The filter housings 70 a thru 70 h all include removable filter bags, not shown, that are readily replaceable. The liquid disposed in wash tanks 26 and 28 have their own filter housing and filter bag 70 e , associated therewith and do not utilize the filter bank 68 . The liquid in wash tanks 26 and 28 may be disposed of by directing a hose 73 connected to an outlet valve, not shown, towards the drain or sump 42 . The valves disposed on housing 70 e are normally set to discharge water into or out of wash tank 26 or 28 , but may also be used to direct the water, via the hose 73 , into the sump 42 .
[0024] Hereinbefore has been disclosed a self-contained washing station for landscape maintenance equipment suitable for washing a plurality of vehicles that is efficient, saves time and is favorable to the environment.
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A washing station and method for removing debris and oil from landscape maintenance equipment vehicles includes a self-contained pressurized washing system that separates the washing water from solids, washes the solids, captures the oil and debris, recycles the filtered water and prevents contamination of the surrounding area.
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FIELD OF THE INVENTION
[0001] This invention generally relates to a process for removing one or more sulfur compounds from one or more hydrocarbons, and a vessel relating thereto.
DESCRIPTION OF THE RELATED ART
[0002] Caustic carryover in the hydrocarbon streams, such as fuel gas and liquefied petroleum gas, is one of the major causes of off-spec products, high caustic consumption, corrosion of carbon steel, and major upsets caused in processes downstream of caustic sweetening and/or extraction. Desirably, reducing caustic carryover can minimize downstream upsets. One mechanism for minimizing carryover may be avoiding hydrocarbon contamination. However, hydrocarbons, particularly liquefied petroleum gas derived from fluid catalytic cracking or coker units, can cause strong emulsions in the circulating caustic, potential gums across an oxidizing vessel, poor separation of disulfide oil from caustic in a separation vessel, and ultimately carryover of caustic into downstream units. It is desirable to avoid contaminating rich caustic with hydrocarbons at the bottom of an extractor column. Additionally, it is also preferable to coalesce lean caustic from the hydrocarbon products without the use of expensive downstream equipment. Hence, there is a desire to improve the efficiency of extraction and/or sweetening processes.
SUMMARY OF THE INVENTION
[0003] One exemplary embodiment can be a process for removing one or more sulfur compounds from one or more hydrocarbons. The process may include passing a hydrocarbon stream from a prewash zone containing a coalescing zone to an extraction zone. Often, the zones are contained within a single vessel and the coalescing zone comprises an oleophilic media.
[0004] Another exemplary embodiment may be a process for removing one or more sulfur compounds from one or more hydrocarbons. The process may include passing a combined stream having one or more hydrocarbons and an alkali to a prewash zone, obtaining from the prewash zone a hydrocarbon stream and passing the hydrocarbon stream into an extraction zone including a first coalescing zone, mixing the hydrocarbon stream with an alkali stream to obtain a hydrocarbon phase and an alkali phase, and passing at least a portion of the hydrocarbon phase to a settling zone containing a second coalescing zone to obtain a processed hydrocarbon stream.
[0005] Another exemplary embodiment may be a process for removing one or more sulfur compounds from one or more hydrocarbons. The process may include passing a combined stream having one or more hydrocarbons and an alkali to a prewash zone, obtaining from the prewash zone a hydrocarbon stream and passing the hydrocarbon stream into an extraction zone including a first coalescing zone, mixing the hydrocarbon stream with an alkali stream to obtain a hydrocarbon phase and an alkali phase, and passing at least a portion of the hydrocarbon phase to a settling zone containing a second coalescing zone to obtain a processed hydrocarbon stream.
[0006] A further exemplary embodiment can be a vessel for removing one or more sulfur compounds from one or more hydrocarbons. The vessel can include a prewash zone, an extraction zone downstream of the prewash zone containing a first coalescing zone, and a settling zone downstream of the extraction zone containing a second coalescing zone.
[0007] The embodiments disclosed herein can improve the separation between caustic and hydrocarbons in both rich caustic and hydrocarbon product streams using multi-stage coalescing media. The coalescing media may include an optionally coated mesh blanket, corrugated sheet media, or other accepted liquid-liquid coalescing media. The coalescing media installed at the bottom of the extractor column can have oleophilic properties because the caustic is often a continuous phase. The coalescing media may be at the top of an extraction and/or a settling zone and may have hydrophilic properties because the hydrocarbon may be in a continuous phase.
DEFINITIONS
[0008] As used herein, the term “stream” can include various hydrocarbon molecules, such as straight-chain, branched, or cyclic alkanes, alkenes, alkadienes, and alkynes, and optionally other substances, such as gases, e.g., hydrogen, or impurities, such as heavy metals, and sulfur and nitrogen compounds. The stream can also include aromatic and non-aromatic hydrocarbons. Moreover, the hydrocarbon molecules may be abbreviated C1, C2, C3 . . . Cn where “n” represents the number of carbon atoms in the one or more hydrocarbon molecules. Furthermore, a superscript “+” or “−” may be used with an abbreviated one or more hydrocarbons notation, e.g., C3 + or C3 − , which is inclusive of the abbreviated one or more hydrocarbons. As an example, the abbreviation “C3 + ” means one or more hydrocarbon molecules of three carbon atoms and/or more. In addition, the term “stream” may be applicable to other fluids, such as aqueous and non-aqueous solutions of alkaline or basic compounds, such as sodium hydroxide.
[0009] As used herein, the term “zone” can refer to an area including one or more equipment items and/or one or more sub-zones. Equipment items can include one or more reactors or reactor vessels, heaters, exchangers, pipes, pumps, compressors, and controllers. Additionally, an equipment item, such as a reactor, dryer, or vessel, can further include one or more zones or sub-zones.
[0010] As used herein, the term “rich” can mean an amount of at least generally about 50%, and preferably about 70%, by mole, of a compound or class of compounds in a stream. If referring to a solute in solution, e.g., one or more disulfide compounds in an alkaline solution, the term “rich” may be referenced to the equilibrium concentration of the solute. As an example, about 5%, by mole, of a solute in a solvent may be considered rich if the concentration of solute at equilibrium is about 10%, by mole.
[0011] As used herein, the term “substantially” can mean an amount of at least generally about 80%, preferably about 90%, and optimally about 99%, by mole, of a compound or class of compounds in a stream.
[0012] As used herein, the term “coupled” can mean two items, directly or indirectly, joined, fastened, associated, connected, or formed integrally together either by chemical or mechanical means, by processes including stamping, molding, or welding. What is more, two items can be coupled by the use of a third component such as a mechanical fastener, e.g., a screw, a nail, a bolt, a staple, or a rivet; an adhesive; or a solder.
[0013] As used herein, the term “coalescer” may be a media containing an optionally coated metal mesh, glass fibers, or other material to facilitate separation of immiscible liquids of similar density.
[0014] As used herein, the term “immiscible” can mean two or more phases that cannot be uniformly mixed or blended.
[0015] As used herein, the term “phase” may mean a liquid, a gas, or a suspension including a liquid and/or a gas, such as a foam, aerosol, or fog. A phase may include solid particles. Generally, a fluid can include one or more gas, liquid, and/or suspension phases.
[0016] As used herein, the term “alkali” can mean any substance that in solution, typically a water solution, has a pH value greater than about 7.0, and exemplary alkali can include sodium hydroxide, potassium hydroxide, or ammonia. Such an alkali in solution may be referred to as “an alkaline solution” or “an alkaline” and includes caustic, i.e., sodium hydroxide in water.
[0017] As used herein, the term “parts per million” may be abbreviated herein as “ppm” and “weight ppm” may be abbreviated herein as “wppm”.
[0018] As used herein, the term “mercaptan” typically means thiol and may be used interchangeably therewith, and can include compounds of the formula RSH as well as salts thereof, such as mercaptides of the formula RS − M + where R is a hydrocarbon group, such as an alkyl or aryl group, that is saturated or unsaturated and optionally substituted, and M is a metal, such as sodium or potassium.
[0019] As used herein, the term “disulfides” can include dimethyldisulfide, diethyldisulfide, and ethylmethyldisulfide, and possibly other species having the molecular formula RSSR′ where R and R′ are each, independently, a hydrocarbon group, such as an alkyl or aryl group, that is saturated or unsaturated and optionally substituted. Typically, a disulfide is generated from the oxidation of a mercaptan-containing caustic and forms a separate hydrocarbon phase that is not soluble in the aqueous caustic phase. Generally, the term “disulfides” as used herein excludes carbon disulfide (CS 2 ).
[0020] As used herein, the weight percent or ppm of sulfur, e.g., “wppm-sulfur” is the amount of sulfur, and not the amount of the sulfur-containing species unless otherwise indicated. As an example, methylmercaptan, CH 3 SH, has a molecular weight of 48.1 with 32.06 represented by the sulfur atom, so the molecule is about 66.6%, by weight, sulfur. As a result, the actual sulfur compound concentration can be higher than the wppm-sulfur from the compound. An exception is that the disulfide content in caustic can be reported as the wppm of the disulfide compound.
[0021] As used herein, the term “lean” can describe a fluid optionally having been treated and desired levels of sulfur, including one or more mercaptans and one or more disulfides for treating one or more C1-C4 hydrocarbons.
[0022] As used herein, the term “regeneration” with respect to a solvent stream can mean removing one or more disulfide sulfur species from the solvent stream to allow its reuse.
[0023] As used herein, the terms “degrees Celsius” may be abbreviated “° C.” and the term “kilopascal” may be abbreviated “KPa” and all pressures disclosed herein are absolute.
[0024] As depicted, process flow lines in the figures can be referred to, interchangeably, as, e.g., lines, pipes, branches, distributors, streams, effluents, feeds, products, portions, catalysts, withdrawals, recycles, suctions, discharges, and caustics.
BRIEF DESCRIPTION OF THE DRAWING
[0025] The FIGURE is an elevational, cross-sectional view of an exemplary vessel.
DETAILED DESCRIPTION
[0026] Referring to the FIGURE, an exemplary vessel 100 for removing one or more sulfur compounds from one or more hydrocarbons is depicted. The vessel 100 can be utilized in an extraction system for removing one or more thiol compounds from one or more hydrocarbons by, e.g., converting one or more thiol compounds into one or more disulfide compounds. Such systems are disclosed in, e.g., U.S. Pat. No. 7,381,309. The vessel 100 may include a prewash zone 140 , a first coalescing zone 180 , an extraction zone 200 , a settling zone 240 , and a second coalescing zone 280 .
[0027] A hydrocarbon stream 40 upstream of the prewash zone 140 can include one or more C4 − hydrocarbons, such as fuel gas or a liquefied petroleum gas, and be provided at a temperature of about 30-about 50° C., and a pressure of about 400-about 1,900 KPa.
[0028] Generally, the hydrocarbon stream 40 may be rich in or substantially has one or more C4 − hydrocarbons. The hydrocarbon stream 40 may be one or more liquids, gases, or a mixture of one or more gases and liquids. The hydrocarbon stream 40 can be combined with an alkaline or an alkali stream 50 including an alkali, such as at least one of an ammonia, a potassium hydroxide and a sodium hydroxide, in a water solution. Typically, the water solution includes about 10-about 20%, by weight, alkali with the balance water. The streams 40 and 50 can be added together to form a combined stream 60 provided to the vessel 100 .
[0029] The combined stream 60 is provided to the vessel 100 in the prewash zone 140 for removing hydrogen sulfide by converting to, e.g., sodium sulfide. A side-stream 260 can be withdrawn including primarily an alkaline rich in sulfur compounds, such as one or more thiol compounds. Generally, the side-stream 260 has about 1-about 100 ppm, by weight, of one or more hydrocarbons. The side-stream 260 can be sent to an alkali regeneration zone that can include an oxidation vessel and a disulfide separator. Such alkali regeneration zones are disclosed in, e.g., U.S. Pat. No. 7,381,309. A bottom or purge stream 500 , including primarily an alkaline rich in sulfur compounds, may be withdrawn for controlling the level of alkaline in the vessel 100 . The purge stream 500 can either be sent for disposal or sent to an alkali regeneration zone as discussed above for the side-stream 260 . A lean alkali stream, such as a stream 250 , may be returned to the vessel 100 from the alkali regeneration zone.
[0030] A stream 160 from the prewash zone 140 can be provided to the extraction zone 200 downstream from the prewash zone 140 . A physical barrier 150 , such as a plate 150 , can separate the zones 140 and 200 . The lean alkali stream 250 , including about 10-about 20%, by weight, alkali with the balance water may be provided to the extraction zone 200 . The stream 160 can separate into a hydrocarbon phase 210 and an alkali phase 230 forming an interface 220 . The extraction zone 200 can include a first coalescing zone 180 including an oleophilic media extending across the entire cross-sectional area of the vessel 100 . Usually, the oleophilic media includes at least one of a metal mesh that is optionally coated, one or more glass fibers, sand, or anthracite coal. In one exemplary embodiment, the oleophilic media can include an oleophilic coated mesh. Desirably, the coating may be oleophilic and/or hydrophobic usually suited for an aqueous phase. Such a coating may include at least one of a fluoropolymer and polypropylene. Suitable fluoropolymers can include one or more of polytetrafluoroethylene, fluorinated ethylene-propylene, perfluoroalkoxy, and ethylene tetrafluoroethylene. Exemplary fluoropolymers are disclosed in, e.g., U.S. Pat. No. 5,456,661 and U.S. Pat. No. 2,230,654.
[0031] A settling zone 240 can be downstream from the extraction zone 200 . Usually, there is no physical barrier between the zones 200 and 240 . Rather, the extraction zone 200 can transition to the settling zone 240 . The settling zone 240 can contain a second coalescing zone 280 including a hydrophilic or oleophobic media for coalescing water droplets extending across the entire cross-sectional area of the vessel 100 . Generally, the hydrophilic media includes at least one of a metal mesh that is optionally coated; one or more glass fibers such as fiberglass; or a metal, such as stainless steel, mesh. Desirably, the coating may be oleophobic and/or hydrophilic usually suited for an oil phase. One exemplary hydrophilic coated mesh may include a coating sold under the trade designation COALEX or KOCH-OTTO YORK™ separations technology by Koch-Glitsch, LP of Wichita, Kans.
[0032] If the hydrocarbons, such as a fuel gas, are in a gas phase instead of a liquid phase, a demister may be used instead of the second coalescing zone 280 . Such a demister may be a vane or mesh and constructed from any suitable material such as a metal, e.g., stainless steel. A processed hydrocarbon stream 300 having no more than about 1 ppm, by weight, sodium ions can be obtained from the settling zone 240 and withdrawn from the vessel 100 .
[0033] Without further elaboration, it is believed that one skilled in the art can, using the preceding description, utilize the present invention to its fullest extent. The preceding preferred specific embodiments are, therefore, to be construed as merely illustrative, and not limitative of the remainder of the disclosure in any way whatsoever.
[0034] In the foregoing, all temperatures are set forth in degrees Celsius and, all parts and percentages are by weight, unless otherwise indicated.
[0035] From the foregoing description, one skilled in the art can easily ascertain the essential characteristics of this invention and, without departing from the spirit and scope thereof, can make various changes and modifications of the invention to adapt it to various usages and conditions.
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One exemplary embodiment can be a process for removing one or more sulfur compounds from one or more hydrocarbons. The process may include passing a hydrocarbon stream from a prewash zone containing a coalescing zone to an extraction zone. Often, the zones are contained within a single vessel and the coalescing zone comprises an oleophilic media.
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BACKGROUND
1. Field of the Invention
The present invention relates generally to voice communication and, more specifically, to automated control to compensate for variable ambient noise levels.
2. Background of the Invention
Voice communication devices such as mobile telephones have become ubiquitous; they show up in almost every environment. They are used in the home, at the office, in the car, on a train, at the airport, at the beach, at restaurants and bars, on the street, and almost any other imaginable venue. As might be expected, these diverse environments have relatively higher and lower levels of background or ambient noise. For example, there is generally less noise in a quiet home than there is in a crowded bar.
Significantly, in an on-going telephone call from an environment having relatively higher ambient noise, it is sometimes difficult for the party at the other end of the connection to hear what the party in the noisy environment is saying. That is, the ambient noise in the environment often “drowns out” the mobile telephone user's voice, whereby the other party cannot hear what is being said.
SUMMARY OF THE INVENTION
The present invention provides a novel system and method for monitoring the ambient noise in the environment in which a voice communications device or mobile telephone is operating and canceling the ambient noise before the ambient noise is transmitted to the other party so that the party at the other end of the voice communication link can more easily hear what the mobile telephone user is transmitting.
The present invention preferably employs noise cancellation technology that is operable to attenuate or even eliminate pre-selected portions of an audio spectrum. By monitoring the ambient noise in the location in which the mobile telephone is operating and applying noise cancellation protocols at the appropriate time, it is possible to significantly reduce the background noise to which a party to a telephone call might be subjected.
It is therefore an object of the present invention to provide a system and method that enhances the convenience of using a mobile communications device, even in a location having relatively loud ambient noise.
It is also an object of the present invention to provide a system and method for canceling ambient noise before the ambient noise is transmitted to another party.
It is yet another object of the present invention to monitor ambient noise via a second microphone associated with a mobile telephone and thereafter cancel the monitored ambient noise.
It is still another object of the present invention to provide an enable/disable switch on a mobile communications device to enable/disable the noise cancellation features of the invention.
These and other objects of the present invention will become apparent upon reading the following detailed description in conjunction with the associated drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates an exemplary mobile telephone including an optional second microphone for sampling ambient noise and an enable/disable button in accordance with the present invention.
FIG. 2 illustrates an exemplary embodiment of the present invention.
FIG. 3 illustrates a second exemplary embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
The present invention provides a unique background noise or ambient noise cancellation feature for a communications device such as a mobile (or cellular) telephone or even a conventional wire line telephone. While the present invention has applicability to at least these types of communications devices, the principles of the present invention are particularly applicable to all types of communications devices. For simplicity, the following description employs the term “mobile telephone” as an umbrella term to describe the embodiments of the present invention, but those skilled in the art will appreciate that the use of such term is not to be considered limiting to the scope of the invention, which is set forth by the claims appearing at the end of this description.
FIG. 1 illustrates an exemplary mobile telephone 10 that comprises a microphone 11 , a speaker 12 , a display screen 13 , a keypad 14 and an antenna 15 . Optionally, a second microphone 16 for sampling ambient noise level and an ambient noise compensation enable/disable button 17 may also be provided. These latter two elements will be described more fully below. Those skilled in the art will appreciate that speaker 12 could be replaced by an ear piece (not shown) that is worn by the mobile telephone user in the conventional manner. Speaker 12 is used herein to mean the device by which sound is transferred from the mobile telephone to the user. Also, display screen 13 could be a touch screen display, which might incorporate keypad 14 as well as enable/disable button 17 .
FIG. 2 illustrates an exemplary embodiment of the present invention including microphone 11 , ambient noise compensation signal generator 20 , a mixer 22 , transmitter 24 and antenna 15 .
In accordance with the present invention, ambient noise or background noise is cancelled before being combined with the intended voice communication picked up at microphone 11 and sent to transmitter 24 and antenna 15 . More specifically, in a first embodiment, microphone 11 picks up both ambient noise as well as the intended voice communication (together, the “combined signal”). As is well known in the art of noise cancellation, it is possible (e.g., via filtering and digital signal processing (DSP) techniques) to attenuate or even cancel-out pre-selected portions of an audio signal or pre-selected bands of a frequency spectrum.
As shown in FIG. 2 , ambient noise compensation signal generator 20 is connected to microphone 11 and monitors the combined signal. Then, ambient noise cancellation generator, in accordance with well-known techniques, generates compensation signals that are operable to attenuate or altogether cancel background noise that is not intended or desirable to be transmitted to another party. These compensation signals are fed into mixer 22 where these signals are mixed with the combined signal coming directly from microphone 11 . The result is that the ambient noise or background noise is eliminated, or at least substantially reduced, before the combined signal (ambient noise plus voice signal) is passed to transmitter 24 (which, e.g., includes a radio frequency modulator, etc.) and ultimately to antenna 15 .
Optionally, a buffer 28 is provided to slow the progress of the combined signal emanating from microphone 11 so that when the combined signal reaches mixer 22 the arrival time of the combined signal and the compensation signals generated by ambient noise cancellation generator is synchronized.
In another embodiment, as shown in FIG. 3 , a second microphone 16 is provided for the principal purpose of sampling ambient noise. That is, microphone 16 is dedicated substantially to picking up ambient noise rather than a voice signal. A second microphone, especially one that is located away from mobile telephone user's mouth would be less affected by the user's own voice when taking the ambient noise level measurement and, thus, might be more desirable in certain implementations of the present invention.
More specifically, it is often the case that microphone 11 , which is used primarily for receiving voice signals from a user, is arranged to have directional characteristics, wherein the microphone is more sensitive to sound coming from predetermined directions. In contrast, second microphone 16 is preferably omni-directional such that the microphone is equally sensitive to sound emanating from any direction. A more accurate detection of ambient noise level can be obtained using such an omni-directional microphone. Also, although not shown expressly in the drawings, microphone 16 could be arranged spatially distant from mobile telephone 10 . For example, second microphone 16 could be arranged to hang from a wire that is connected to mobile telephone 10 , whereby there would be even less chance for the mobile telephone user's voice to interfere with noise cancellation signal generation.
Optionally, in the dual microphone embodiment, microphone 11 is also in communication with ambient noise cancellation signal generator 20 to provide additional signal information to generator 20 to aid in distinguishing more easily between ambient noise and voice signals.
Further in accordance with the present invention there is provided an enable/disable switch 17 ( FIG. 1 ) that is preferably operable to enable/disable ambient noise compensation signal generator 20 . For example, depending on the nature of the ambient noise in a particular environment, known noise cancellation techniques might also inadvertently attenuate the voice signal that is intended to be transmitted. In such a case, it is preferable that the noise cancellation features of the present invention be disabled, at least for a limited period, until the ambient noise is such that it can be more effectively distinguished from the voice signal and attenuated independently. For example, a mobile telephone user may want to call a friend from a noisy public event (e.g., a concert or sporting event) for the main purpose of letting the friend hear the background noise. In such a case, the switch 17 is preferably manipulated to disable the noise cancellation features of the present invention.
The foregoing disclosure of the preferred embodiments of the present invention has been presented for purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise forms disclosed. Many variations and modifications of the embodiments described herein will be obvious to one of ordinary skill in the art in light of the above disclosure. The scope of the invention is to be defined only by the claims appended hereto, and by their equivalents.
Further, in describing representative embodiments of the present invention, the specification may have presented the method and/or process of the present invention as a particular sequence of steps. However, to the extent that the method or process does not rely on the particular order of steps set forth herein, the method or process should not be limited to the particular sequence of steps described. As one of ordinary skill in the art would appreciate, other sequences of steps may be possible. Therefore, the particular order of the steps set forth in the specification should not be construed as limitations on the claims. In addition, the claims directed to the method and/or process of the present invention should not be limited to the performance of their steps in the order written, and one skilled in the art can readily appreciate that the sequences may be varied and still remain within the spirit and scope of the present invention.
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A system and method for reducing or entirely canceling background or ambient noise from a voice transmission from a communications device. A communications device, such as a mobile telephone, is configured with an ambient noise compensation signal generator that is connected between a microphone and a mixer. The original output of the microphone and a compensation signal generated by the ambient noise compensation signal generator are mixed together prior to being passed to a transmitter. In one embodiment a buffer is provided between the microphone and the mixer to help synchronize the timing of the signals to be mixed. In another embodiment a second microphone is employed to detect ambient noise.
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FIELD OF THE INVENTION
[0001] This invention relates to transition metal complexes and more particularly to transition metal complexes used in the preparation of dye-sensitized solar cells (DSSCs).
BACKGROUND OF THE INVENTION
[0002] Sensitizers are one of the most crucial components for the preparation of DSSCs because they affect not only the incident photon conversion efficiency (IPCE) of the cells but also the stability of the components.
[0003] Thus far, various sensitizers have been proposed by scientists in hopes of increasing the efficiency of DSSCs and prolonging their service life. For example, Michael Grätzel, a Swiss scientist, developed in 1999 a sensitizer named N719, which was widely used in the industry for its high IPCE.
[0004] However, because N719 cannot sustain high temperature and falls off easily after being used for a period of time, solar cells containing the same usually can no longer work normally after three years of usage.
[0005] In order to improve the stability of N719 under the existence of a heat source or in a moist condition, Grätzel further proposed in 2003 another sensitizer named Z907. Proved by experiments, Z907 can still possess 94% of its original efficiency after being operated continuously for 1,000 hours under 80° C. In contrast, the efficiency of N719 decreases 35% under the same condition.
[0006] Although Z907 demonstrates great sustainability in long-term stability testing, Z907 is not completely satisfactory because it has a molar absorption coefficient lower than N719.
[0007] Accordingly, it is highly desirable for scientists to develop novel sensitizers with high IPCE and thermal stability.
SUMMARY OF THE INVENTION
[0008] In view of the demands for developing a new generation of sensitizers in the industry, one of the objectives of this invention is to provide novel transition metal complexes and manufacturing methods thereof, wherein the transition metal complexes are applicable to the preparation of photovoltaic cells.
[0009] It is another objective of this invention to provide a transition metal complex having a general formula MXY 2 Z, wherein M is selected from iron, ruthenium, and osmium; X is a ligand shown by formula (II):
[0000]
[0000] wherein R 1 and R 1 ′ are independently selected from COOH, PO 3 H 2 , PO 4 H 2 , SO 3 H 2 , SO 4 H 2 and derivatives thereof; Y is selected from H 2 O, Cl, Br, CN, NCO, NCS and NCSe; and Z is a bidentate ligand with two or more fluorinated chains.
[0010] Preferably, M is ruthenium; R 1 and R 1 ′ are independently selected from COOH, PO 3 H 2 , and derivatives thereof; Y is NCS; Z is bipyridine with at least two fluorinated chains which are located on different pyridyl rings.
[0011] Preferably, bipyridine is substituted by a fluorinated functional group having a spacer, which is preferably an ether linkage or at least one methylene structure. In addition, Z preferably comprises at least one fluorinated chain of formula (IV):
[0000] —(CH 2 ) m —O—(CH 2 ) n —R f (IV),
[0000] wherein m and n are each independently an integer greater than zero, such as 1, 2 or 3, and R f is a fluorinated alkyl chain, such as —CF 2 —CF 2 H, —CF 2 —CF 2 —CF 3 , —CF 2 —CF 2 —CF 2 —CF 2 H, etc.
[0012] Preferably, the fluorinated chains of Z are independently substituted by 1 to 30 fluorine atoms and more preferably by 1 to 20 fluorine atoms. Most preferably, the fluorinated chains of Z are independently substituted by 4, 7, 8, 12, 13 or 19 fluorine atoms.
[0013] It is another objective of this invention to provide a transition metal complex having the following chemical structure:
[0000]
[0000] wherein FC 1 and FC 2 are each independently a fluorinated chain with a spacer.
[0014] Preferably, FC 1 and FC 2 can be substituted at position number 4 or 5 of the pyridyl ring, and FC 1 or FC 2 can be fluorinated functional group having a spacer, such as —CH 2 —O—CH 2 —R f , wherein R f is a linear or branched fluorinated alkyl chain, such as an alkyl chain containing 4, 7, 8, 12, 13 or 19 fluorine atoms.
[0015] It is another objective of this invention to provide a method of preparing the above-mentioned transition metal complexes, wherein the improvement comprises using a chelating agent of the following formula:
[0000]
[0000] wherein R f is an alkyl chain substituted by 1 to 30 fluorine atoms.
[0016] It is still another objective of this invention to provide a method of preparing photovoltaic cells, the method comprising:
[0017] providing a transition metal complex having a general formula MXY 2 Z, wherein M is selected from iron, ruthenium, and osmium; X is a ligand shown by formula (II):
[0000]
[0000] wherein R 1 and R 1 ′ are independently selected from COOH, PO 3 H 2 , PO 4 H 2 , SO 3 H 2 , SO 4 H 2 and derivatives thereof; Y is selected from H 2 O, Cl, Br, CN, NCO, NCS and NCSe; and Z is a bidentate ligand with two or more fluorinated chains; and
[0018] preparing photovoltaic cells by using the transition metal complex.
[0019] It is yet another objective of this invention to provide a photovoltaic cell, which comprises an anode having a conductive substrate and a metal-oxide-semiconductor layer formed on the conductive substrate, the metal-oxide-semiconductor layer being treated by a sensitizing dye; a counter electrode; and an electrolyte provided between the counter electrode and the metal-oxide-semiconductor layer, wherein the sensitizing dye is a bidentate ligand with at least two fluorinated chains.
[0020] It is yet another objective of this invention to provide a transition metal complex and a method of manufacturing the same. The transition metal complex has unexpectedly high IPCE and desirable thermal stability and thereby is applicable to the production of photovoltaic cells with great quality.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] The structure and the technical means adopted by the present invention to achieve the above and other objects can be best understood by referring to the following detailed description of the preferred embodiments and the accompanying drawings, wherein
[0022] FIG. 1 shows the main steps for preparing a transition metal complex of this invention;
[0023] FIG. 2 is an illustrative diagram of a DSSC containing a transition metal complex of this invention;
[0024] FIG. 3 is the plot of IPCE versus wavelength of a DSSC containing a transition metal complex of this invention; and
[0025] FIG. 4 is the plot of IPCE versus wavelength of a DSSC containing another transition metal complex of this invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Example 1
Preparation of Transition Metal Complexes
[0026] FIG. 1 shows the main steps for preparing a transition metal complex of this invention, from which it can be observed that bipyridine containing —(CH 2 ) m —O—(CH 2 ) n —R f is used to chelate the transition metal. Details for the preparation of the chelating agent can be found at N. Lu, J-Y Chen, C-W Fan, Y-C Lin, Y-S Wen, L-K Liu, J. Chin. Chem. Soc, 2006, 53, 1517-1521; N. Lu, Y-C Lin, J-Y Chen, C-W Fan, L-K Liu, Tetrahedron, 2007, 63, 2019-2023; N. Lu, Y-C Lin, J-Y Chen, T-C Chen, S-C Chen, Y-S Wen, L-K Liu, Polyhedron. 2007, 26, 3045-3053; and N. Lu, Y-C Lin, Tetrahedron Lett. 2007, 48, 8823-8828, all of which are incorporated by reference herein. In the above-mentioned formula, m and n are each independently an integer greater than zero, and when R f is —CF 2 —CF 2 H, —CF 2 —CF 2 —CF 3 , and —CF 2 —CF 2 —CF 2 —CF 2 H, the transition metal complexes produced thereby are named CT4, CT7 and CT8, respectively.
[0027] 1-1: Preparation of CT8
[0028] Dichloro(p-cymene)-ruthenium(II) dimer (Aldrich, 0.38 g, 0.62 mmol) and bipyridine having substitution of eight fluorine atoms at each ring (0.8 g, 1.24 mmol) were dissolved in 60 ml ethanol and then the solution was stirred and refluxed for 8 hours at 80° C. under N 2 atmosphere. After pumping away ethanol, Bpy-COOH (0.30 g, 1.24 mmol) and 40 mL dry DMF were added. The reaction mixture was refluxed at 140° C. for another 4 hours at dark. Excess NH 4 NCS (SHOWA, 2.92 g, 38.44 mmol) was added to the reaction mixture and heated at 130° C. for 5 hours. After reaction, the solvent was removed with a rotary vacuum pump and large amount of water was added to dissolve the excess NH 4 NCS. Then 1.18 g (1.06 mmol) dark purplish red solid product CT8 was obtained after vacuum filtration.
[0029] In order to obtain purer dye, the solid product was treated with TBAOH (tetrabutylammonium hydroxide), and the resulting TBA salt was dissolved in methanol then passed through the chromatography column (Sephadex LH20) using methanol as an eluent. The main band was collected and concentrated, and the solvent was extracted by an evaporator. The process was repeated five times; then some water was added, and 0.02 M HNO 3 was added to adjust the pH value to precipitate the product. The product was placed in a refrigerator for 24 hours, followed by vacuum filtration at room temperature to obtain CT8-TBA.
[0030] 1-2 Identification Data of CT8 and CT8-TBA
[0031] Identification Data of CT8
[0032] H-NMR (500 MHz, CD 3 OD), δ (ppm):
[0033] 9.61 (d, H 6 , 3 J HH =5.5 Hz); 9.36 (d, H 6 ′, 3 J HH =5.5 Hz); 9.01 (s, H 3 ); 8.86 (s, H 3 ′); 8.49 (s, H 3 ′″); 8.34 (s, H 3 ″); 8.21 (d, H 6 ′″, 3 J HH =6.4 Hz); 7.84 (d, H 5 , 3 J HH =5.5 Hz); 7.79 (d, H 6 ″, 3 J HH =4.6 Hz); 7.60 (d, H 5 ′, 3 J HH =5.5 Hz 7.52 (d, H 5 ′″, 3 J HH =6.4 Hz); 7.15 (d, H 5 ″, 3 J HH =4.6 Hz); 6.59 (tt, H 10 ′″, 2 J HF =50.8 Hz, J 3 HF =5.5 Hz, 2H); 6.50 (tt, H 10 ″, 2 J HF =50.8 Hz, 3 J HF =5.5 Hz, 2H); 5.06 (s, H 8 ′″, 2H); 4.79 (s, H 8 ″, 2H); 4.37 (t, H 9 ′″, 3 J HF =14 Hz, 2H); 4.17 (t, H 9 ″, 3 J HF =14 Hz, 2H)
[0034] 13 C-NMR (113 MHz, CD 3 OD), δ (ppm):
[0035] 166.9 (C 7 ); 166.6 (C 7 ′); 160.9 (C 2 ); 159.7 (C 2 ′); 159.6 (C 2 ″); 158.3 (C 2 ′″); 155.1 (C 6 ); 154.0 (C 6 ′); 153.8 (C 6 ″); 152.9 (C 6 ′″); 149.9 (C 4 ); 149.2 (C 4 ′); 139.9 (C 4 ″); 139.3 (C 4 ′″); 127.0 (C 3 ); 126.3 (C 3 ′); 125.8 (C 3 ″); 125.1 (C 3 ′″); 123.7 (C 5 ); 123.6 (C 5 ″); 122.0 (C 5 ″); 122.0 (C 5 ′″); 135.3 (C 14 of NCS); 134.5 (C 14 ′ of NCS); 106-118 (C 10 ′″˜C 13 ′″ and C 10 ″˜C 13 ′″); 73.2 (C 8 ′″); 72.8 (C 8 ″); 69.0 (C 8 ″); 68.7 (C 9 ″)
[0036] 19 F-NMR (470.5 MHz, CD 3 OD), δ (ppm):
[0037] −121.3 (t, —CH 2 CF 2 CF 2 —, 3 J HF =12.7 Hz); −121.4 (t, —CH 2 CF 2 CF 2 —, 3 J HF =13.5 Hz); −126.7 (s, —CH 2 CF 2 CF 2 —); −126.9 (s, —CH 2 CF 2 CF 2 —); −131.9 (d, —CF 2 CF 2 H); −132.0 (d, —CF 2 CF 2 H); −140.1 (t, —CF 2 H, 2 J HF =45.2 Hz); −140.1 (t, —CF 2 H, 2 J HF =40.1 Hz)
[0038] FT-IR υ (cm −1 ):
[0039] 2105 (N═C stretch, s); 1718 (C═O stretch, s); 1617, 1543, 1406 (bipyridine ring, m); 1613 (—COO − stretch, as), 1383 (—COO − stretch, s); 1258, 1230 (—C—O stretch, s); 1169 (CF 2 stretch, as); 1126 (CF 2 stretch, s)
[0040] HR-FAB M + :
[0041] C 36 H 24 F 16 N 6 O 6 RuS 2 , Calcd m/z 1105.9969, found m/z 1105.9962 (accurate to 3 decimal places)
[0042] Identification Data of CT8-TBA
[0043] 1 H-NMR (500 MHz, CD 3 OD), δ (ppm):
[0044] 9.47 (d 6 , 3 J HH =5.5 Hz, 1H); 9.42 (d 6 ′, 3 J HH =6.0 Hz, 1H); 8.98 (s, 1H); 8.82 (s, 1H); 8.98 (s, 1H); 8.33 (s, 1H); 8.18 (d, 3 J HH =5.8 Hz, 1H); 7.79 (d, 3 J HH =6.0 Hz, 1H); 5.5 Hz, 2H); 7.53 (d, 3 J HH =6.0 Hz, 1H); 7.65 (d, 3 J HH =7.52 (d, 3 J HH =6.0 Hz, 1H); 7.15 (d, 3 J HH =5.5 Hz, 1H); 6.66 (tt, H 10 ′″, 2 J HF =51.5 Hz, J 3 HF =5.5 Hz, 2H); 6.97 (tt, H 10 ″, 2 J HF =51.5 Hz, J 3 HF =5.5 Hz, 2H); 5.07 (s, H 8 ′″, 2H); 4.80 (s, H 8 ″, 2H); 4.36 (t, H 9 ′″, 3 J HF =14 Hz, 2H); 9.17 (t, H 9 ″, 3 J HF =14 Hz, 2H); 1.64 (m, 2H); 1.38 (m, 2H); 0.99 (t, 3 J HH =7.5, 3H)
[0045] 13 C-NMR (113 MHz, CD 3 OD) δ (ppm):
[0046] 170.7 (C 7 ); 170.4 (C 7 ′); 160.5 (C 2 ′); 160.0 (C 2 ′); 159.2 (C 2 ″); 158.8 (C 2 ′″); 154.3 (C 6 ); 154.1 (C 6 ′); 152.8 (C 6 ″); 152.7 (C 6 ′″); 149.2 (C 4 ); 148.6 (C 4 ′); 147.5 (C 4 ″); 146.8 (C 4 ′″); 127.0 (C 3 ); 126.2 (C 3 ′); 125.6 (C 3 ″); 125.1 (C 3 ′″); 123.6 (C 5 ); 123.4 (C 5 ′); 121.9 (C 5 ′″); 121.8 (C 5 ′″); 134.3 (C 14 of NCS); 134.2 (C 14 ′ of NCS); 106-118 (C 10 ′″˜C 13 ′″ and C 10 ″˜C 13 ″); 73.2 (C 8 ′″); 72.9 (C 8 ″); 68.9 (C 9 ′″); 68.7 (C 9 ″); 59.5 (—CH 2 CH 2 CH 2 CH 3 ); 24.8 (—CH 2 CH 2 CH 2 CH 3 ); 20.7 (—CH 2 CH 2 CH 2 CH 3 ); 14.0 (—CH 2 CH 2 CH 2 CH 3 );
[0047] 19 F-NMR (470.5 MHz, CD 3 OD), δ (ppm):
[0048] −121.3 (t, —CH 2 CF 2 CF 2 —, 3 J HF =13.1Hz); −121.5 (t, —CH 2 CF 2 CF 2 —, 3 J HF =10.8 Hz); −126.8 (s, —CH 2 CF 2 CF 2 —); −126.9 (s, —CH 2 CF 2 CF 2 —); −132.0 (d, —CF 2 CF 2 H); −132.1 (d, —CF 2 CF 2 H); −140.1 (t, —CF 2 H, 2 J HF =45.2 Hz); −140.1 (t, —CF 2 H, 2 J HF =45.1 Hz)
[0049] FT-IR υ (cm −1 ):
[0050] 2105 (N═C stretch, s); 1618, 1543, 1420 (bipyridine ring, m); 1610 (—COO − stretch, as); 1383 (—COO − stretch, s); 1259, 1229 (—C—O stretch, s); 1169 (CF 2 stretch, as); 1127 (CF 2 stretch, s)
[0051] It should be noted that the transition metal complexes of this invention may comprise a fluorinated chain substituted by different numbers of fluorine atoms, such as 4, 7, 8, 12, 13, or 19, and the synthesis method thereof is similar to FIG. 1 , except that different fluorinated chains are used in the chelating agent bipyridine ring. Accordingly, if different chelating agents are used, a person skilled in the art can synthesize the transition metal complexes with a different fluorinated chain without undue experimentation. Moreover, the substitution position of the fluorinated chain on the pyridyl ring is not limited to position number 4; a fluorinated chain of other substitution positions can also be synthesized without undue experimentation by using a similar method.
Example 2
Preparation of DSSCs
[0052] In order to measure various data of the transition metal complexes of this invention applied to DSSCs, TiO 2 thin film electrode with an active area controlled at a dimension of 0.25 cm 2 with a thickness of 16 μm was provided, heated to 80° C. and dipped into the THF solution containing 3×10 −4 M dye sensitizers for 24 hours. The counter electrode was FTO conductive glass coated with Pt electrode, and the electrolyte was composed of 0.5 M lithium iodide (LiI), 0.05 M iodine (I 2 ), and 0.5 M 4-tert-butylpyridine dissolved in acetonitrile. The electrolyte was injected onto the surface of the counter electrode, and the TiO 2 electrode and the counter electrode were tightly sealed to prevent the generation of bubbles. Then a foldback clip was used to fasten the electrodes, such that a DSSC with a sandwich-like structure shown in FIG. 2 was obtained, in which conductive glass is represented by numeral 1, dye-containing TiO 2 by 2, electrolyte by 3, Pt layer by 4 and the other conductive glass by 5.
Example 3
Measurement of Dye Performance
[0053] The performance of the dyes after incorporated into a solar cell is shown below:
[0000]
[0054] Dyes A, B and C are incorporated into three solar cells respectively, in which the maximal conversions are obtained when the wavelength of the incident light is at 540 nm. The maximum IPCE measured are A (67.7%), B (70.4%), C (70.2%) and N719 (69.5%). It can be observed that Dye B has the highest conversion efficiency greater than Dye C and Dye A, which has the lowest conversion efficiency. In addition, Dye B has an IPCE greater than that of N719 within wavelength 360 nm˜540 nm, and Dye C has an IPCE greater than that of N719 within wavelength 440 nm˜600 nm, as shown in FIG. 3 . Although Dye A does not have an IPCE greater than N719, its IPCE reaches up to 97.4% of N719. Therefore, the IPCEs of Dyes A, B and C reflect the high performance of the dyes overall.
[0055] Detailed photovoltaic parameters under AM1.5 of cells comprising Dyes A, B, C and N719 are shown in Table 1:
[0000]
TABLE 1
J sc
Dye
V oc (V)
(mA/cm −2 )
FF
η (%)
A
0.67
13.33
0.70
6.25
B
0.68
15.44
0.66
6.93
C
0.68
14.98
0.67
6.82
N719
0.71
15.37
0.67
7.31
Z907
0.68
14.16
0.66
6.36
[0056] wherein Voc represents Open Circuit Voltage; J SC represents Short Circuit Current; FF represents Fill Factor; η represents the overall efficiency of the cell.
[0057] In addition, detailed photovoltaic parameters under AM1.5 of cells comprising Dyes D, E, F and N719 are shown in Table 2:
[0000]
TABLE 2
Jsc
Dye
Voc (V)
(mA/cm 2 )
FF
η (%)
D
0.65
9.59
0.72
4.48
E
0.69
13.88
0.66
6.32
F
0.66
10.94
0.72
5.11
N719
0.72
15.24
0.64
7.02
Example 4
Measurement of Dye Performance (II)
[0058] FIG. 4 is the plot of IPCE versus wavelength of DSSCs containing CT9-TBA, CT7-TBA, and CT8-TBA respectively, and the detailed photovoltaic parameters under AM1.5 of the cells are shown in Table 3:
[0000]
TABLE 3
J sc
Dye
V oc (V)
(mA/cm 2 )
FF
η (%)
CT4-TBA
0.65
13.48
0.67
5.87
CT7-TBA
0.71
13.80
0.66
6.46
CT8-TBA
0.71
13.69
0.66
6.41
N719
0.71
15.37
0.67
7.31
Example 5
Stability Test of Dyes
[0059] I. Dye Adsorption
[0060] TiO 2 thin film electrodes (14 μm in thickness and 3 cm 2 in dimension) coated on FTO conductive glass by the sol-gel process were disposed into a 100° C. oven for 3 hours to remove water. Then 15 mL dyes (including Dye B, Dye C and N719 dissolved in DMF, 2×10 −4 M) were prepared, and 5 mL of each was used as the reference for spectrum scanning by a UV/Vis spectrophotometer (1 cm path length) to obtain the absorption of the each dye. The exact concentration of each dye before the electrodes were soaked was calculated by using the Beer-Lambert law (formula 1-1) with the molar extinction coefficient of each dye. Moreover, the electrode films coated on the conductive glasses were soaked in the residual 10 mL of each dye, which was used as the working sample, for 12 hours. After adsorption balance was reached, the electrodes were taken from the dyes, and DMF was used to wash the dyes/TiO 2 thin films to break the multi-layered bonding of physical adsorption on the thin films. Similarly, the UV/Vis spectrophotometer was used to measure the adsorption of the working samples, and the Beer-Lambert law was used to calculate the exact concentration of each dye after the electrodes were soaked. The amounts of dyes adsorbed by the electrode thin films were obtained by subtracting the number of mole of each dye after the electrodes were soaked from the number of mole of each dye before the electrode was soaked. Then the dyes/electrode thin films coated on the conductive glasses were scraped off to measure their weights, and the adsorption amount of each dye on the respective TiO 2 thin film electrode were calculated by formula 1-2:
[0000] A=εBC (1-1),
wherein A: absorption; ε: molar extinction coefficient; B: path length; C: concentration of sample
[0000] Dye adsorption amount=[amount of dye adsorbed by TiO 2 electrode/total amount of adsorbed dye and TiO 2 electrode]×2.4 (1-2)
[0062] The adsorption result is shown below:
[0000]
TABLE 4
Dye
B
C
N719
Amount of dye before TiO 2
3
3
3
electrode was soaked (×10 −6
mol)
Amount of dye after TiO 2
2.622
2.623
2.740
electrode was soaked (×10 −6
mol)
Amount of dye adsorbed by TiO 2
0.378
0.377
0.26
electrode (×10 −6 mol)
Total amount of adsorbed dye and
3.6
3.7
3.3
TiO 2 electrode (mg)
Dye adsorption calculated by
2.52
2.45
1.89
formula 1-2 (×10 −7 mol/cm 2 )
[0063] From Table 4, it can be observed that, compared with N719, which is widely known for its high performance, Dye B and Dye C have a greater adsorption amount; thus, the dyes of this invention can provide an enhanced performance.
[0064] II. Dye Desorption
[0065] Dyes/TiO 2 electrode thin films (including 3×10 −4 M Dye B, Dye C, and N719; the electrode thin films have a dimension of 0.25 cm 2 with a thickness of 16 μm) soaked in THF for 12 hours to reach adsorption balance were treated by alkali (5M NaOH solution) to completely wash off the dye adsorbed on the surface of the thin film. The desorption result is as follows:
[0000]
Dye
B
C
N719
Z907
Desorption?
No
No
Yes
Yes
[0066] As shown above, Dye B and Dye C both demonstrate long-term stability better than N719 and have stronger resistance to strong alkali, so they do not fall off easily after being used for a period of time. Particularly, even when compared with Z907, which is widely known for its long-term stability, the dyes of this invention demonstrates stability better than Z907. Therefore, solar cells using the dyes of this invention have a longer service life.
[0067] The present invention has been described with a preferred embodiment thereof and it is understood that many changes and modifications in the described embodiment can be carried out without departing from the scope and the spirit of the invention that is intended to be limited only by the appended claims.
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This invention provides a transition metal complex of formula MXY 2 Z and a manufacturing method thereof, wherein M is selected from iron, ruthenium, and osmium; X represents a ligand shown in formula (II)
wherein R 1 and R 1 ′ are independently selected from COOH, PO 3 H 2 , PO 4 H 2 , SO 3 H 2 , SO 4 H 2 , and derivatives thereof; Y is selected from H 2 O, Cl, Br, CN, NCO, NCS, and NCSe; Z represents a bidentate ligand having at least two fluorinated chains. In addition, this invention also provides photovoltaic cells and a manufacturing method thereof.
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RELATED APPLICATION
[0001] This application relies for priority under 35 U.S.C. § 119(e) upon U.S. Provisional Application Serial No. 60/412,222 filed Sep. 20, 2002.
FIELD OF THE INVENTION
[0002] The present invention relates to methods for treating conditions associated with bone loss or low bone density, particularly osteoporosis.
BACKGROUND OF THE INVENTION
[0003] Bone is a specialized dynamic connective tissue that serves the following functions: (a) mechanical, support and site of muscle attachment for locomotion; (b) protective, for vital organs and bone marrow: (c) metabolic; as reserve of ions, especially calcium and phosphate, for the maintenance of serum homeostasis, which is essential for live. To carry out these functions efficiently bone must undergo continuous resorption and renewal, a process collectively known as remodelling. Thus, the mechanical and biological integrity of bone dependents on its continuous destruction (resorption) and continuous rebuilding (formation) at millions of microscopic sites. During adult life bone remodelling is crucial to eliminate and replace structurally damaged or aged bone with structurally new healthy bone. To maintain the proper bone mass resorption and formation are kept in perfect equilibrium. With age the equilibrium between bone resorption and formation becomes altered, often in favor of resorption, resulting in a reduction in bone mass, deterioration of bone architecture, decreased resistance to stress, bone fragility and susceptibility to fractures. The compendium of these symptoms is referred to osteoporosis.
[0004] Osteoporosis is a major health problem in Western society. And even though there are other diseases that result in reduction in bone mass, i.e. Paget's disease, osteoporosis is by far the most common and the disease that is the most costly in terms of health care. Since estrogen is a hormone that regulates bone metabolism directly and indirectly, the decrease in estrogen production in post-menopausal women and the decline with age in the production of androgen, which is enzymatically converted to estrogen in men, ) is responsible for the risk of osteoporosis, which is estimated to be 85% in women and 15% in men older than 45 years of age. In the United States it is estimated that 17 million post-menopausal women have lost 10% of their peak bone mass, 9.4 million have lost 25% and 5 million have suffered a fracture as a consequence of osteoporosis. Osteoporosis costs America's health care system more than $14 billion a year from spine and hip fractures, which are often the first indication of the disease if it is left undiagnosed.
[0005] Osteoporosis, a disease endemic in Western society, typically reflects an imbalance in skeletal turnover, such that bone resorption exceeds bone formation. Bone resorption is a specific function of osteoclasts, which are multinucleated, specialized bone cells formed by the fusion of mononuclear progenitors originating from the hemopoietic compartment, more precisely from the granulocyte-macrophage colony-forming unit (GM-CFU). The osteoclast is the principal cell type,, to resorb bone, and together with the bone-forming cells, the osteoblasts, dictate bone mass, bone shape and bone structure. The increased activity and/or numbers of osteoclasts, relative to the activity and or numbers of bone-forming osteoblasts, dictates the development of osteoporosis and other diseases of bone loss.
[0006] Even though Paget's disease is not as common or as costly as osteoporosis—it affects 3% of the population over 40, and 10% of the population over 80 years of age—it is nonetheless a significant disease because aside from causing bone fractures it can lead to severe osteoarthritis and severe neurological disorders. Paget's disease is characterized by rapid bone turnover, resulting in the formation of woven bone a tissue type formed initially in the embryo and during growth and which is practically absence from the adult skeleton. Woven bone is marked by brittleness and therefore prone to fractures and bowing. Bones become enlarged and often interfere with blood flow and constrict nerves, resulting in many of the neurological symptoms associated with Paget's disease.
[0007] For a disease in which osteoclasts presumably resorb bone at abnormally high levels and osteoblasts form bone at normal levels, as in osteoporosis, the most reasonable therapeutic target would be the osteoclast: decreasing the number of osteoclasts and/or the resorption activity of the osteoclasts, should restore the equilibrium between bone resorption and formation. And, in fact, the treatments now available for osteoporosis are intended to suppress bone resorption.
[0008] Osteoclasts are derived from the monocyte-macrophage family. Upon stimulation of the CFU-GM with macrophage colony stimulating factor (M-CSF) form promonocytes which are immature nonadherent progenitors of mononuclear phagocytes and osteoclasts. The promonocytes, may proliferate and differentiate along the macrophage pathway, eventually forming a tissue macrophage, or may differentiate along the osteoclast pathway, depending on the cytokines to which they become exposed. For example, the receptor activator NF-κB ligand (RANKL) (Simonet W S, Lacey D L, Dunstan .R, Kelley M, Chang M-S, Luethi R et al 1997 Osteoprotegerin, a novel secreted protein involved in the regulation of bone density. Cell 89:309-319) a cytokine expressed on the membrane surface of osteoblasts influences promonocytes to differentiate into osteoclasts rather than macrophages, while treatment with M-CSF drives the promonocyte to develop into macrophages. Since M-CSF and other cytokines i.e., interleukin-1 or TNF-α, that support expression of RANKL are products of macrophages it may be assumed that immunomodulating substances, which alter the expression of, these cytokines and growth factors, may affect not only macrophages but also osteoclasts.
[0009] It has long been known that beta glucans, and particularly the beta glucans from yeast, activate macrophages and have profound effects on the synthesis and levels of many cytokines, which in turn are responsible for modulating the function of many other cells. (Stoy, Y. “Macrophage biology and pathobiology in the evolution of immune responses: a functional analysis,” Pathobiology, 69:179-211, 2001; Underhill D M, Ozinshy, A. “Phagocytosis of microbes: complexity in action,” Annu Rev Immunol. 20:825-52, 2002; Purohit A, Newman S P, Reed M J. “The role of cytokines in regulating estrogen synthesis: implications for the etiology of breast cancer,” Breast Cancer Res 4:65-69, 2002; Ismail N, Olano J P, Feng H M, Walker D H. “Current status of immune mechanisms of killing intracellular organisms” FEMS Microbiol Lett 207:111-120, 2002; Hubel K, Dale D C, Liles W C. “Therapeutic use of cytokines to modulate phagocyte function for the treatment of infectious diseases: current status of granulocyte colony stimulating factor, granulocyte-macrophage stimulating factor, macrophage colony stimulating factor and interferon gamma” J Inf Dis 185:1490-1501, 2002.).
[0010] Even though there are a number of therapeutic modalities for osteoporosis, which include bisphosphonates (Fleisch H, “Development of biphosphonates,” Breast Cancer Res. 4:30-34, 2002), estrogen ( Spencer, C P, Stevenson. J C “Oestrogen and anti-oestrogen for the prevention and treatment of osteoporosis.” In Osteoporosis: Diagnosis and Management, Martin Muniz, England, 1998, pp 111-123), or “Selective Estrogen Receptor Modulators,” (SERMS) most of these have significant undesirable side-effects.
[0011] Glucans are polysaccharides consisting of glucose subunits. β-(1, 6) branched β-(1,3) glucan is a naturally occurring class of polysaccharides that can be extracted from Baker's yeast and other yeast species, mushrooms, plants and some bacterial, lichen and algal species (reviewed in Chemistry and Biology of (1→3)-β-Glucans, B. A. Stone and A. E. Clarke, 1992, La Trobe University Press, Australia). β-(1, 6) branched (1,3) glucans have been shown to have immune enhancing and cholesterol-lowering capabilities. Yeast synthesizes at least three different types of beta glucans, a linear β-1,3-D-glucans, a linear β-1,6-D-glucan and a β3-(1, 6) branched β-1,3-(1,3) glucan. However, linear β-1,3-1,3-D and linear β-1,6-D-glucans do not activate or only marginally activate macrophages, NK cells or neutrophils.
[0012] As a class of polysaccharides, β-(1,6) branched β-(1,3) glucans are composed of a main chain of glucose subunits linked together in and branches linked to the main chain by a (1→6) β glycosidic linkage. Yeast β-(1,6) branched β-(1,3) glucan is composed of mostly of a main chain of glucose units linked by (1→3) beta glycosidic linkages (90% or more) with a variable number of relatively short side chains linked by β-(1 6) glycosidic linkages (10% or less); the chemical name for this glucan is poly-(1,3)-β-D-glucopyranosyl-(1,6)-β-D-glucopyranose. There are several different types of beta glucans, which vary in backbone composition, branching, type of monomers or substituents, resulting in polysaccharides that have very different physical and biological properties (Metz, Ebert, and Weicher, Chromatographia 4:345,1970; Manners et al., The structure of β-(1-3) D-glucan from yeast cell walls. Biochem. J. 135:19, 1973; U.S. Pat. No. 5,223,491).
[0013] Whereas all the β-1,3/1,6-D-glucans have been shown to activate the immune system of vertebrate as well as invertebrate organisms, the yeast-derived β-1,3/1,6-D-glucan is a most powerful activator of macrophages, NK cells, and neutrophils. Beta glucan from yeast activates the immune system by binding to a specific receptor on the cell membrane of macrophages (Czop and Kay, Isolation and characterization of β-glucan receptors on human mononuclear phagocytes. J. Exp. Med. 173:1511-1520, 1991). The activated macrophages increase their phagocytic and bactericidal activities as well as the production of a wide range of cytokines (Burgaletta, C and Golde, D W, in Immune Modulation and control of neoplasia by adjuvant Therapy (Chirigos, M. A., ed), pp195-200. Raven Press, NY, 1978; Sherwood et al., “Glucan stimulates production of antitumor cytolytic/cytostatic factors by macrophages,” J. Biol Resp. Mod., 6:358-381; Sherwood, et al., “Enhancement of interleukins 1, and interleukins 2 production by soluble glucan”; Browder et al., “Beneficial effects of enhanced macrophage function in the trauma patient,” Ann. Surg. 211:605-613). Enhanced function of macrophages, as well NK cells, appear responsible for a number of beneficial effects of yeast beta glucan, such as increased resistance of the host to infection by bacteria, viruses, fungi and protozoan parasites (Williams et al., “Protective effect of glucan in experimentally induced candidiasis,” J Reticuloendot. Soc. 23:479-490, 1978; Williams and DiLuzio. “Immunopharmacological modification of experimental viral diseases by glucan,” EOS J K Immunol Immunopharmacol 5:78-82, 1985; Babineau et al. “A phase II multicenter, double blind, randomized, placebo-controlled study of three dosages of an immunomodulator (PCG-glucan) in high risk surgical patients,” Arch. Surg., 129:601-609., 1994). In addition, the enhanced function of macrophages and NK cells appears to increase the host defenses against malignant tumors (Mansell et al. “Macrophage mediated destruction of human malignant cells in vivo,” J Natl Canc. Inst. 54:571-576, 1975; Williams et al. “Chemoimmunotherapy of experimental hepatic metastasis,” Hepatology, 7:1296-1304, 1985; Ueno. “Beta-1,3-D-glucan, its immune effect and its clinical use,” Jap. J Soc. Terminal Systemic Dis. 6:151-154, 2000).
[0014] Beta-1,3/1,6-D-glucan isolated from baker's or brewer's yeast ( Saccharomyces cerevisiae strain) as well other yeasts, is insoluble, and furthermore the variability in the number of beta-(1,6) side chains makes it extremely difficult if not impossible to determine whether the beta-1,3/1,6-D-glucan is the branched beta-1,3/1,6-D-glucan or a mixture of beta-1,3-D-glucan plus beta-1,6-D-glucan, or a mixture of all three beta glucans. Yeast makes all three types of beta glucans. Since only the branched beta-1,3/1,6-D-glucan activates macrophages, it would be desirable to have pure beta-1,3/1,6-D-glucan; in addition, insoluble beta-1,3/1,6-D-glucan is difficult to formulate for parenteral or topical administration. It would be desirable to have a beta glucan that could be easily characterized, and which could be easily formulated for topical and parenteral administration. In addition, it would be of benefit for formulation purposes to have a lower molecular weight beta glucan that retains biological activity. A low molecular weight, soluble beta-1,3/1,6-D-glucan used topically would also be able to penetrate faster and, used parenterally, would very likely reach tissue macrophages faster, resulting in an earlier activation.
[0015] To date the soluble beta glucans that have been available are all of the high molecular weight variety, and for the major part these glucans were made soluble by chemical modifications or solubilized by sequential treatments with alkali/acid/alkali. A number of soluble glucans have been obtained by derivatization of the natural, insoluble beta-1,3/1,6-D-glucan compound, such as phosphorylation (U.S. Pat. Nos. 4,739,046; 4,761,402), sulfation, amination (U.S. Pat. No. 4,707,471) or methylation. A beta-1,3/1,6-D-glucan solubilized by sequential treatment with alkali/acid/alkali of insoluble beta-1,3/1,6-D-glucan (U.S. Pat. No. 5,849,720) has been shown to be effective in humans to control infections in surgical patients (Babineau et al. A phase II multicenter, double blind, randomized, placebo-controlled study of three dosages of an immunomodulator (PCG-glucan) in high-risk surgical patients ( Arch. Surg., 129:601-609, 1994).
[0016] There is therefore a need for therapies to inhibit or prevent bone loss that have less or no side effects and offer more natural biological mechanisms.
SUMMARY OF THE INVENTION
[0017] The present invention is predicated on the surprising finding that beta glucans are able to suppress osteoclast development and may enhance the development of osteoblasts.
[0018] In one embodiment, the invention is directed to methods of treating conditions in which there is a loss or decrease in bone mass in mammals by administering a beta glucan, or a pharmaceutically acceptable salt thereof
[0019] In particular this invention is directed to such methods wherein the condition is osteoporosis, Paget's disease, a bone defect, childhood idiopathic bone loss, alveolar bone loss, or bone fracture.
[0020] In another embodiment, the invention provides methods for promoting bone growth in a mammal in need thereof comprising administering to said mammal an effective amount of beta glucan, or a pharmaceutically acceptable salt of the beta glucan, so as to promote bone formation.
BRIEF DESCRIPTION OF THE FIGURES
[0021] FIGS. 1 A-C is a series of graphs showing the effect of beta glucan upon alkaline phosphatase of rat osteoblasts of different maturation.
[0022] [0022]FIG. 2 is a graph showing inhibition of osteoclast-mediated resorption in vitro by osteoprotegerin (commercial product) and beta glucan.
[0023] [0023]FIG. 3 is a graph showing inhibition of osteoclast formation by osteoprotegerin (commercial product) and beta glucan.
[0024] FIGS. 4 A-C is a series of graphs showing the effect of media conditioned by beta glucan-treated osteoblasts and fibroblasts on formation of TRAP+multinucleated cells (MNC) and osteoclasts in vitro.
[0025] FIGS. 5 A-C is a series of graphs showing the effect of media conditioned by beta glucan-treated osteoblasts and fibroblasts on formation of osteoclastic resorption pits in vitro.
DETAILED DESCRIPTION OF THE INVENTION
[0026] The present invention provides methods and compositions for the treatment of osteoporosis, Paget's disease and other conditions which present with low bone mass or result in the loss of bone, particularly when the loss of such bone results from increased numbers of osteoclasts and/or increased bone resorbing activity of osteoclasts.
[0027] In the invention methods for treating a condition associated with low bone mass in a mammal an effective amount of beta glucan, or a pharmaceutically acceptable salt of the beta glucan, is administered so as to inhibit bone resorption and/or increase bone formation.
[0028] Methods for treating “secondary osteoporosis” are also included within the methods of this invention. “Secondary osteoporosis” includes glucocorticoid-induced osteoporosis, hyperthyroidism-induced osteoporosis, immobilization-induced osteoporosis, heparin-induced osteoporosis and immunosuppressive-induced osteoporosis in a vertebrate, e.g., a mammal (including a human being). These methods are carried out by administering to said vertebrate, e.g., mammal, a “secondary osteoporosis” treating amount of a beta glucan or a pharmaceutically acceptable salt thereof.
[0029] The inhibition of osteoclast activity in the invention methods can be the result of an inhibitory activity of the resorption mechanisms of the osteoclasts or can be the result of an inhibition of the number of osteoclasts recruited from precursor cells, or a combination of both. In an analysis of osteoclast recruitment, extremely low concentrations of beta glucan decreases the number of osteoclasts formed ( FIG. 2). At concentrations as low as 100 pg there is a decrease of 30% and at concentrations of 1 ng and 10 ng there is an inhibition of approximately 50%. Increasing the concentration of beta glucan does not increase the inhibition of osteoclast formation rather the effect diminishes. This observation is consistent with the fact that beta glucan has its effect via a receptor and that high concentrations may lead to receptor down-regulation.
[0030] In osteoporosis, which affects mostly older individuals and particularly post-menopausal women, combined with increased bone resorption there is a slow-down in bone formation by osteoblasts, which occurs normally due to the aging process. As used in the invention methods of treatment, beta glucan enhances osteoblast formation, thus also increasing bone formation.
[0031] In another embodiment, the invention provides methods for promoting bone growth in a mammal in need thereof by administering thereto an effective amount of a beta glucan, or a pharmaceutically effective amount thereof Conditions wherein promotion of bone growth is beneficial include strengthening a bone graft, inducing vertebral synostosis, enhancing long bone extension, enhancing bone healing following facial reconstruction, maxillary reconstruction and/or mandibular reconstruction in a vertebrate, e.g., a mammal (including a human being), and the like.
[0032] An “effective amount” of beta glucan for use in treating a condition associated with bone loss or in a condition wherein promotion of bone growth is beneficial is an amount sufficient to inhibit bone loss and/or increase bone formation or to inhibit osteoclast activity. Those of skill in the art will consider such factors as the mammal's age, level of activity, hormone balance, general health in determining the effective amount, which is tailored to the subject, for example by beginning with a low dosage and titrating the dosage to determine the effective amount. By the studies described herein it has been discovered that increasing the concentration of beta glucan does not necessarily increase the inhibition of osteoclast activity, and may actually reduced inhibition of osteoclast activity (FIG. 1). At 100 pg the effect is similar to the effect obtained with bisphosphonates, which in various forms are used as drugs to control osteoporosis.
[0033] The phrase “condition(s) associated with low bone mass” refers to a condition where the level of bone mass is below the age specific normal as defined in standards by the World Health Organization” Assessment of Fracture Risk and its Application to Screening for Postmenopausal Osteoporosis (1994). Report of a World Health Organization Study Group. World Health Organization Technical Series 843”. Included in“condition(s) associated with low bone mass” are primary and secondary osteoporosis, as described above. Also included is periodontal disease, alveolar bone loss, post-osteotomy and childhood idiopathic bone loss. The phrase “condition(s) associated with low bone mass” also includes long term complications of osteoporosis such as curvature of the spine, loss of height and prosthetic surgery.
[0034] The phrase “condition(s) which present with low bone mass” also refers to a vertebrate, e.g., a mammal known to have a significantly higher than average chance of developing such diseases as are described above including osteoporosis (e.g., post-menopausal women, men over the age of 50). Other bone mass augmenting or enhancing uses include bone restoration, increasing the bone fracture healing rate, replacing bone graft surgery entirely, enhancing the rate of successful bone grafts, bone healing following facial reconstruction or maxillary reconstruction or mandibular reconstruction, prosthetic ingrowth, vertebral synostosis or long bone extension. Those skilled in the art will recognize that the term bone mass actually refers to bone mass per unit area, which is sometimes (although not strictly correctly) referred to as bone mineral density.
[0035] The methods of this invention may also be used in conjunction with orthopedic devices such as spinal fusion cages, spinal fusion hardware, internal and external bone fixation devices, screws and pins.
[0036] The term “treating”, “treat” or “treatment” as used herein includes preventative (e.g., prophylactic), palliative and curative treatment. The methods of this invention result in bone formation resulting in decreased fracture rates. This invention makes a significant contribution to the art by providing methods that increase bone formation resulting in prevention, retardation, and/or regression of osteoporosis and related bone disorders.
[0037] By “pharmaceutically acceptable” it is meant the carrier, vehicle, diluent, excipients, and/or salt must be compatible with the other ingredients of the formulation, and not deleterious to the recipient thereof by the route administered.
[0038] The expression “pharmaceutically acceptable salt” refers to such nontoxic anionic salts containing anions such as (but not limited to) chloride, bromide, iodide, sulfate, bisulfate, phosphate, acetate, maleate, fumarate, oxalate, lactate, tartrate, citrate, gluconate, methanesulfonate and 4-toluene-sulfonate, and the like, that can be injected into the body.
[0039] Beta glucan is a naturally occurring class of polysaccharides that can be extracted from Baker's yeast and other yeast species, mushrooms, plants and some bacterial, lichen and algal species (reviewed in Chemistry and Biology of (1→3)-β-Glucans, B. A. Stone and A. E. Clarke, 1992, La Trobe University Press, Australia). β-(1,6) branched (1,3) glucans have been shown to have immune enhancing and cholesterol-lowering capabilities. Yeast synthesizes at least three different types of beta glucans, a linear β-1,3-1,3-D-glucans, a linear β-1,6-D-glucan and a p-(1,6) branched β-(1,3) glucan. However, linear β-1,3-D-glucans and linear β-1,6-D-glucans do not activate or only marginally activate macrophages, NK cells or neutrophils. In one embodiment of the invention methods, the beta glucan retains the biological activity of macrophage activation, such as a water soluble 1→6 branched 1→3 beta glucan. In another embodiment, the beta glucan contains 2 to 20% beta 1-6 branching and/or has a molecular weight of about 1500 to about 100,000.
[0040] For example, a yeast beta-1,3/1,6-D-glucan suitable for use in practice of the invention methods can be obtained from the yeast Saccharomyces cerevisiae . Such a beta glucan can be derived from a yeast cell wall preparation containing mostly yeast beta-1,3/1,6-D-glucan or from purified yeast beta-1,3/1,6-D-glucan by enzymatic degradation with a beta endoglucanase as described herein. Other beta glucans also have anti-resorptive activity and are suitable for use in practice of the invention methods. For example, in FIG. 3 it is evident that the insoluble yeast beta glucan (Nayad), a beta glucan isolated from the mushroom Blazei agaricus also inhibits pit formation by osteoclasts. FIG. 4 shows that all beta glucans examined (yeast soluble and insoluble (Nayad), beta glucan from Blazei agaricus, Yunzhi beta glucan and even Zymosan, which is a hot alcoholic extract of yeast with immuno-modulating activity, due to the beta glucan in Zymosan) are capable of inhibiting the formation of osteoclasts.
[0041] The utility of the beta glucans used in the methods of the present invention as medical agents in the treatment of conditions associated with low bone mass (e.g., osteoporosis) in vertebrates, e.g., mammals (especially humans and particularly female humans) is demonstrated by the activity in bone resorption assays as are known in the art and as described herein. Such assays also provide a means whereby the activities of beta glucans can be compared to each other and with the activities of other known compounds and compositions useful for treating such conditions. The results of these comparisons are useful for determining dosage levels in vertebrates, e.g., mammals, including humans, for the treatment of such diseases.
[0042] The preferred route of administration of the beta glucans as used in the invention methods is systemic administration, e.g., orally, subcutaneously, intramuscularly or via aerosol. For example, formulations or compositions containing a hydrolyzed beta glucan can be injected parenterally, for example by injection into the peripheral circulation.
[0043] In another embodiment, the invention provides methods for promoting bone growth in a mammal in need thereof by administering thereto an effective amount of a beta glucan, or a pharmaceutically effective amount thereof. Conditions wherein promotion of bone growth is beneficial include strengthening a bone graft, inducing vertebral synostosis, enhancing long bone extension, enhancing bone healing following facial reconstruction, maxillary reconstruction and/or mandibular reconstruction in a vertebrate, e.g., a mammal (including a human being), and the like.
[0044] An “effective amount” of beta glucan for use in treating a condition associated with bone loss or in a condition wherein promotion of bone growth is beneficial is an amount sufficient to inhibit bone loss and/or increase bone formation or to inhibit osteoclast activity. Those of skill in the art will consider such factors as the mammal's age, level of activity, hormone balance, general health in determining the effective amount, which is tailored to the subject, for example by beginning with a low dosage and titrating the dosage to determine the effective amount. By the studies described herein it has been discovered that increasing the concentration of beta glucan does not necessarily increase the inhibition of osteoclast activity, and may actually reduced inhibition of osteoclast activity (FIG. 1). At 100 pg the effect is similar to the effect obtained with a bisphosphonate, which in various forms are used as drugs to control osteoporosis.
[0045] The beta glucan used in the invention methods can be contained in a formulation comprising a carrier suitable as is known in the art to the desired mode of administration, i.e., injection into the peripheral circulation. The composition may also include one or more compounds known in the art to be beneficial to bone formation, such as calcium, fluoride, magnesium, boron, or a combination thereof.
[0046] Soluble beta-1,3/1,6-D-glucan for use in the invention methods of treating conditions in which there is a loss or decrease in bone mass in mammals or the need to promote bone formation can be produced and manufactured from yeast or other microorganisms containing beta-1,3/1,6-D-glucan using the following steps:
[0047] a. Yeast cells or cell walls are treated with a base at high temperature to solubilize alkali soluble components of the cell
[0048] b. After washing with water, the residue is treated with an acid at high temperature Alternatively,
[0049] a 1 . Yeast cell walls are treated with an acid
[0050] b 1 . After washing water, the residue is treated with sodium hypochlorite
[0051] c. After washing with water, the residue is hydrolyzed with a beta glucanase at a specific temperature
[0052] d. The mixture is centrifuged and the residue discarded
[0053] e. The supernatant is ultrafiltered through a membrane with a nominal weight cut-off of 100,000 daltons
[0054] f. The effluent is ultrafiltered through a membrane with a nominal molecular weight cut-off of 1000 daltons
[0055] g. The retentate is concentrated and suspended in 100% ethanol
[0056] h. The precipitate is washed with ethanol and dried.
[0057] i. If so desired, this material can further be purified and fractionated by ultrafiltration through a series of membranes with different molecular weight cut-offs or by chromatography.
[0058] The process of manufacture detailed here provides a soluble beta-1,3/1,6-D-glucan of low molecular weight, which retains the ability to activate macrophages. The manufacture of the soluble beta-1,3/1,6-D-glucan is achieved by first treating the organism containing beta-1,3/1,6-D-glucan (e.g., yeast cells or yeast cell walls) with alkali and acid solutions to remove non-beta glucan components, which makes the beta glucan available to the action of the enzyme. This treatment is then followed by enzymatic hydrolysis and purification of the solubilized beta-1,3/1 ,6-D-glucan.
[0059] Whole yeast cells or cell walls ( Saccharomyces cerevisiae ) are suspended in an alkaline solution and heated. The alkaline solution can be an alkali-metal or an alkali-earth metal hydroxide, such as sodium hydroxide or potassium hydroxide having a concentration from about 0.05 N to 10 N. This step is conducted at a temperature of 4° C. to 150° C., but preferably at 80° C. This step can be conducted at normal atmospheric pressure or at an elevated pressure, but preferably at 15 psi and 121° C. The treatment time may vary from about 10 minutes to 48 hours depending on the strength of the alkali solution and the temperature and the type of organism. Once the alkali treatment is complete, the residue is separated from the solution by an appropriate method, such as filtration or centrifugation. This alkali can be repeated one time or more.
[0060] The residue is washed with water one or more times and then extracted with an acid, such as hydrochloric acid, formic acid, acetic acid or other. An acid solution of pH 1 to 5 is usually sufficient at a temperature 4° C. to 150° C., for 15 minutes to 48 hours. The preferred conditions are extraction with acid is acetic acid at a concentration of 3% and at a temperature of 85° C. for 45 minutes. The insoluble material is separated from the solution by an appropriate procedure. The residue is then washed one or more time with water and again separated by an appropriate method.
[0061] Yeast cell walls can first be treated with an acid, such as hydrochloric acid, formic acid, acetic acid or other. An acid solution of pH 1 to 5 is usually sufficient at a temperature 4° C. to 150° C., for 15 minutes to 48 hours. The preferred conditions are extraction with acid is acetic acid at a concentration of 4% at a temperature of 85° C. for 45 minutes. The insoluble material is separated from the solution by an appropriate procedure. The residue is then washed one or more times with water and again separated by an appropriate method.
[0062] The residue is then extracted with sodium hypochlorite at a concentration from 15 to 75% at a temperature ranging from 4° C. to 150° C., for 15 minutes to 48 hours. The residue is then washed with water one or more times.
[0063] The residue is the treated with an enzyme that has endoglucanase activity at a temperature from 10° C. to 80° C., for 15 minutes to 48 hours depending on the temperature, liquid to solids ratio, and concentration of the enzyme. The soluble enzyme digest is separated from the undigested material by an appropriate technique, such as centrifugation, filtration, etc. The soluble digested material can then be fractionated into discrete fractions by ultrafiltration, chromatography, sedimentation, electrofocusing, etc.
[0064] The invention will now be illustrated by the following non-limiting examples.
EXAMPLE 1
[0065] Preparation of Soluble Beta-1,3/1,6-D-Glucan from Yeast Cells
[0066] [0066] Saccharomyces cerevisiae cells are added to 10 volumes of 1.5 N NaOH with stirring. The mixture is then heated at 60° C. for 30 minutes. The heated mixture is then autoclaved for 15 minutes at 15 psi and 121° C. The mixture is cooled and the supernatant is separated from the residue by centrifugation. The residue is washed with 10 volumes of water for 15 minutes with stirring. After separating the supernatant by centrifugation, 10 volumes of 3% acetic acid at 37° C. are added to the residue and the mixture is heated at 85° C. for 45 minutes with stirring. The mixture is cooled and the supernatant is separated from the residue by centrifugation. The residue, which is impure beta-1,3/1,6-D-glucan, is washed with water for 15 minutes with stirring.
[0067] The impure beta-1,3/1,6-D-glucan is suspended in 3 volumes of water and added to another 20-25 volumes of water at 40° C. To this mixture are added 100 ml of Viscozyme L beta-1,3-glucanase purchased from Novo Nardisk, Farnkliton, N.C. This mixture is stirred and heated to 80° C. The slurry is then pumped through a fiber filter unit equipped with a filter with a molecular weight cut-off of 100,000 daltons. The retentate is recycled continuously over a 10 hr period, always maintaining the volume constant in the reaction vessel by adding water at 80° C. The ultrafiltrate is collected continuously over the 10 hr period. Reducing sugar is checked in the ultrafiltrate every one liter collected. The ultrafiltrate is pumped through the inside of hollow fibers with a molecular weigh cut-off of 1500, to dialyze of salt and low molecular weight pigments or sugars. Dialysis is carried out by pumping water through the outer shell of the hollow fiber unit at 800 ml/min. After 10 hours 14.5 liters of ultrafiltrate is collected. The ultrafiltrate is concentrated by reverse osmosis followed by concentration with a rotary evaporator. The beta-1,3/1,6-D-glucan is precipitated from concentrated in the cold overnight ultrafiltrate with 10 volumes of 95% ethanol. The precipitate is collected, washed with 95% ethanol and dried.
[0068] The dried precipitate can be further purified by chromatography (e.g. affinity, gel permeation, chromatofocusing, etc.)., or filtration with membranes of varying molecular weight cut-offs ( Vercellotti et al. “Chemistry of membrane separation processes in sugar industry applications,” Zuckerindustrie 123:736, 1998).
[0069] [0069]FIG. 1 shows an HPLC gel permeation chromatograph of the alcohol precipitate.
[0070] Table 1 shows a typical composition of the alcohol precipitated water soluble beta-1,3/1,6-D-glucan.
TABLE 1 Component % Total carbohydrate 98 Glucose 72 Mannose 16 Protein 4 Lipid 0 Ash 2
[0071] Table 2 shows some physical characteristics of the alcohol precipitated water soluble beta-1,3/1,6-D-glucan.
TABLE 2 Molecular Weight 12,000-60,000 daltons (Gel Permeation Chromatography) Solubility 2.5 gm/ml Color in water Light beige Absorption at 280 nm (E 1% ) 2632 pH of a 1% solution in water 7.0 β (1→3) bonds (%) 83 β (1→6) bonds (%) 17 α (1→4) bonds (%) None
[0072] Table 3 shows the activation of macrophages in vitro (increase in interleukin I and H 2 O 2 production) by the soluble alcohol precipitated water soluble beta-1,3/1,6-D-glucan.
TABLE 3 IL-1 1 Bb 2 (ng) Control 0.05 4.2 Zymosan 3 ND 13 WS100 3 0.23 36
EXAMPLE 2
[0073] In Vitro Bio-Assay to Assess the Effect of Beta-Glucan on Osteoclast Formation and Activity by Beta Glucan
[0074] To determine the effect of beta glucan on osteoclast-mediated resorption a modification of the bioassay described by Collin et al was used (Collin P, Guenther H L, Fleisch H Constitutive expression of osteoclast-stimulating activity by normal clonal osteoblast-like cells: effects of parathyroid hormone and 1,25-dihydroxy-vitamin D 3 . Endocrinology 131:1181-1187, 1992). The principle of the bioassay is based on cultivating freshly isolated disaggregated osteoclasts on elephant dentin (ivory) surfaces and measure the formation of resorption lacunae excavated by actively resorbing osteoclasts.
EXAMPLE 3
[0075] Isolation and Culture of Osteoclasts
[0076] Osteoclasts were isolated from femurs of 1-day-old rats (Wistar) as outlined elsewhere (Collin P et al. 1992, see above). Briefly, after killing the animals, femurs were dissected freed of adherent soft tissue and subsequently cut across the epiphysis to remove the marrow. The femurs were then placed in a dish containing I ml MEM supplemented with 0.5% gentamicin. Osteoclasts were gently released from the femurs using in succession calibrated dental needles of size 20 and 30. Resulting osteoclast suspension was then brought to a volume of 8 ml with MEM. and 500 μl of the cell preparation were added to eight ivory slices kept individually in plastic wells (2.0×1.0 cm). After 25-min incubation at 37 C and 5% CO 2 /air, nonadherent cells were removed by lateral agitation. Next, eight slices for control and 8 for each treated group were individually transferred into single wells of a 24-well plastic tissue culture plate to which 500 μl of either control or test media were added. The cultures were carried out in MEM at 37 C and 5% CO 2 /air. After 24 h, cells cultured on ivory slices were washed with 0.5 ml PBS. Thereafter the cells were fixed and subsequently stained for TRAP according to instructions of the manufacturer (Sigma). Individual slices were then examined for TRAP+multinucleated cells (MNC) containing at least three nuclei per cell. Following enumeration the TRAP+MNC were removed by ultrasound in 70% propanol. Thereafter the dentine slices were washed, air-dried and sputter-coated with gold (SCD 004 Coater, Balzers, Liechtenstein). The number of resorption pits on each ivory slice was scored with a light microscope equipped with a tangential light, at a magnification×200. A pit was defined as a depression in the ivory surface with a continuous rim and an area of at least 250 μm 2 . Pit areas were calculated from pit images that were captured by a camera attached to the reflected light microscope with the aid of image analysis software (NIH Image).
EXAMPLE 4
[0077] Preparation of Ivory Slices
[0078] Elephant ivory (kindly obtained from Dr. B. Irrall, Bundesamt für Veterinärwesen, Berne Switzerland) was used as mineral substrate to assess osteoclast resorption activity. The ivory was cut into 4×4×0.1 mm slices with a Isomet low-speed saw (Buehler Instrument, Evanston, Ill.). Resulting slices were cleaned by ultrasound for 30 sec in de-ionized water. Thereafter the pieces were air-dried, gas sterilized and subsequently degassed under vacuum for 24 h.
EXAMPLE 5
[0079] Effect of Beta Glucan on Bone Resorption through Osteoblast as Assessory Cells
[0080] Based on the fact that the osteoclast suspension used to assay bone resorption in vitro, is contaminated with other cell types noticeably with osteoblasts, made it necessary to examine whether osteoblasts act as accessory cells in the beta glucan effect on osteoclastic resorption.
[0081] Fully functionally clonal osteoblastic CRP10/30 and clonal preosteoblastic CRP5/4 cells were cultured with and without different concentrations of “beta-G” in the presence of 2% FBS. After 5 hours incubation, media were replaced and the cells were cultured for an additional 24 hours in the absence of the test substances. The conditioned media were collected and concentrated to {fraction (1/10)} of its volume using an ultrafiltration device equipped with a filter with a molecular cutoff of 1 k. The concentrated conditioned media were reconstituted to their original volumes with fresh culture medium an subsequently tested on isolated osteoclast as described above.
[0082] The results of scoring for the number of osteoclasts (TRAP+multinucleated cells) and resorption lacunae (pits) show that at concentrations of 100 pg there is an inhibition of pit formation that could not be observed in control cultures (nontreated osteoclasts). Increasing the concentration of beta glucan does not increase inhibition of osteoclast activity; in fact, actually a reduction of the inhibition was measured. (FIG. 1). At 100 pg the effect is similar to the effect obtained with a biphosphonate; bisphosphonates are used in various forms as drugs to control osteoporosis.
[0083] An inhibition of the number of resorption pits can result from an inhibitory effect upon osteoclast resorption activity (pits formed/osteoclast, from inhibition of the number of osteoclasts recruited from precursor cells, or a combination of both. In an analysis of osteoclast recruitment, extremely low concentrations of beta glucan decreases the number of osteoclasts formed (FIG. 2). At concentrations as low as 100 pg there is a decrease of 30%, and at concentrations of 1 ng and 10 ng there is an inhibition of approximately 50%. Increasing the concentration of beta glucan does not increase inhibition of osteoclast formation, but rather the effect diminishes. This observation is consistent with the fact that beta glucan has its effect via a receptor and that high concentrations lead to receptor down regulation. In addition, based on the ratio of pits/osteoclast (resorption activity) and the average resorption (areas/pit of treated and control cultures), it is concluded that beta glucan inhibits the recruitment of osteoclasts rather than the resorption activity.
[0084] In osteoporosis, which affects mostly older individuals and particularly post-menopausal women, combined with increased bone resorption there is a slow-down in bone formation by osteoblasts, which occurs normally due to the aging process. Beta glucan moderately enhances differentiation and osteoblast formation, thus supporting bone formation.
[0085] Other beta glucans (prepared from different sources) also generate anti-resorptive activity. In FIG. 3 it is evident that the insoluble yeast beta glucan (Nayad), a beta glucan isolated from the mushroom blazei agaricus also inhibits pit formation. The inhibition appears to be the result of inhibition of osteoclast formation. FIG. 4 shows that in all beta glucans examined (yeast) soluble and insoluble (Nayad), beta glucan from Blazei agaricus, Yunzhi beta glucan and even Zymosan , which is a hot alcoholic extract of yeast with immuno-modulating activity, due to the beta glucan in Zymosan) are capable of inhibiting the formation of osteoclasts.
[0086] Both FIG. 3 and FIG. 4 show that the most potent inhibitor is the soluble yeast beta glucan.
[0087] Beta glucan also modulates the development of osteoblasts. Clonal osteoblastic CRP10/30 cells, which are mature functional osteoblasts, and clonal osteoblastic CRP5/4 cells, which are immature osteoblasts, were cultured in the presence of soluble beta glucan prepared as described herein. When the cells reached confluence, alkaline phosphatase was measured in the two types of cells. FIG. 5 shows that the alkaline phosphatase of the mature osteoblastic cells was not affected; whereas the alkaline phosphatase in the immature osteoblastic cell increased (FIG. 6), indicating that beta glucan stimulates the development of immature osteoblastic cells (CRP5/4) to mature osteoblasts.
[0088] Although the invention has been described with reference to the presently preferred embodiment, it should be understood that various modifications can be made without departing from the spirit of the invention. Accordingly, the invention is limited only by the following claims.
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The invention provides methods of using beta glucans to treat conditions associated with bone loss or low bone density as well as methods for promoting bone growth in situations where enhanced bone growth is desirable. In the invention methods beta glucans are administered so as to enhance the development of osteoblasts and the inhibition of the development and recruitment of osteoclasts. The inhibition of the recruitment and development of osteoclasts, coupled with the enhancement of osteoblast maturation by beta glucans leads to decreased bone resorption and increased bone formation, making beta glucans ideal agents for the treatment of osteoporosis and other bone resorption diseases.
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FIELD OF THE INVENTION
The disclosed invention relates to optical fiber technology and, more particularly, to methods and devices for reducing or eliminating ultraviolet and infrared radiation degradation in a large core polymer fiber (LCP) such that it may be used with available light sources without modification of the light source.
BACKGROUND OF THE INVENTION
Optical fibers made from polymers are well known. These fibers are typically fabricated from various types of known polymers. These fibers are generally constructed of two major members, an optical polymer core and a cladding member which sheathes the polymer core. LCPs are a variation of polymer optical fibers.
The function of the optical core in an LCP is to transmit light. The transmitted light is typically supplied by a light source from one end of the optical fiber and travels down the fiber to the other end, or escapes from the sides of the optical fiber. The latter type of LCP is referred to as a “side light” fiber, and the former is referred to as an “end light” fiber.
Typically, the polymer cores of LCPs have circular cross sections having diameters that can range between 3 mm to 20 mm. Thus, LCPs can be manufactured with variable thicknesses making them useful in a variety of applications. LCPs are used in architectural applications such as lighting buildings, walkways, stairs and other areas where their functions range from aesthetic enhancement of an area to providing lighting for safety reasons. Generally, LCPs are useful in providing lighting to large areas because of their ease of installation and reasonable cost.
Because the core of LCPs are made from polymer fibers, when in use, LCPs degrade as a result of long term exposure to ultraviolet and infrared radiation emanating from their light sources. Since most light sources used with LCPs produce ultraviolet and infrared radiation, degradation in the polymer core of LCPs is a recurring problem. In some cases, degradation in the polymer core occurs in a matter of weeks after the installation, thus requiring replacement of the LCP.
In cases involving exposure of an LCP's core to high density ultraviolet or infrared radiation, degradation has been known to occur in a matter of moments. To resolve the problem of ultraviolet or infrared degradation, light sources that do not project ultraviolet or infrared radiation could be used in conjunction with LCPs. This approach is expensive and complicated in that it requires the use of a special technology.
The method herein disclosed takes a different approach to the problem in that instead of modifying the light source, the disclosed method makes it possible to modify the light that emanates from a common light source such that ultraviolet or infrared radiation will not be transmitted to an LCP's polymer core. Implementation of this approach involves the positioning and placement of a material that does not transmit ultraviolet and infrared radiation, but is optically transparent otherwise, such as a glass rod of a suitable shape and size, between a light source and the core of an LCP.
There are technological obstacles in the implementation of this approach which have to be overcome. Generally, the obstacles to be overcome relate to the proper coupling of an LCP's core with a glass rod as improper coupling may unduly reduce the efficiency of the light transmitted by the fiber.
The first problem to be overcome relates to light transmission efficiency from a light supplying member being coupled to the LCP's core. Light energy may be lost at the juncture between the coupling member that is transmitting light to the LCP's core, and the end of the LCP's core, if the light receiving end of the core is not properly finished. Coupling may be improper, thus causing inefficient transmission of light, if the cross section of the end of the core of an LCP, where light is received, is not flat and smooth. It is, therefore, imperative that the core's end be flat prior to coupling.
In addition, successful coupling requires substantial alignment of the members being coupled, and some way of insuring that the two members that are being coupled will not move apart. To keep such members in appropriate alignment, glue as well as mechanical devices conventionally have been used to effect proper coupling.
OBJECTS OF THE INVENTION
The methods disclosed herein overcome the above problems by providing steps for modifying an LCP to have a flat and smooth polymer core end, and through the same steps creating a means for receiving and maintaining another member in a substantially aligned position in respect to the end of the core.
A typical LCP is comprised of a polymer core and a cladding covering the same. Generally, the method of this invention involves the removal of a portion of the core of an LCP by heating slowly the LCP from the outside and from all directions at a preselected point along its length, and then stressing the core at a relatively high rate by pulling the core apart sharply. Through carrying out these steps at the appropriate temperatures and at an appropriate stress rate, the core of the LCP will fracture leaving a flat, smooth surface.
In addition, as part of the core is removed, a void is created within the tubular cladding of the LCP. A coupling member such as a glass rod may be then inserted in the void. Such member, if suitable in shape and dimensions, will be snugly received by the LCP that is modified through the methods disclosed herein as fingers of a surgeon are securely received by a surgical glove. As such the member will be positioned in substantial alignment with the end of the LCP core, and clinched in position by the cladding of the LCP upon insertion.
The methods disclosed in this application for the construction of a device to reduce ultraviolet and infrared degradation of the polymer core of an LCP may also improve the efficiency of an LCP so constructed by eliminating the need for polishing the end of an LCP which often leaves materials in the cladding that adversely affect the efficiency of the LCP.
Moreover, the novel methods herein disclosed may be practiced by a technician on-site to modify an existing system or in installation of new systems using known materials and instruments, thereby making the novel methods disclosed herein easy to adopt by the industry.
The methods disclosed in this application have the added advantage of being capable of implementation with very little cost and through the use of known and readily available materials, thus obviating the need to implement special manufacturing practices in the manufacturing of the LCPs themselves to produce ultraviolet and infrared resistive LCPs.
A typical device so constructed in accordance with this invention comprises an LCP which, through the modifications made possible by the methods disclosed herein, includes incorporated therein a glass member functioning to prevent the transmission of ultraviolet and infrared radiation to the polymer core. The glass member in such device may be further modified to provide other beneficial characteristics for the device itself.
Other objects will be in part obvious and in part pointed out more in detail hereinafter.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a cross sectional view of a typical LCP, partly broken away;
FIG. 2 shows the LCP of FIG. 1 with a portion of its cladding removed;
FIG. 3 demonstrates a point along the length of the LCP of FIG. 2, relative to the end of the LCP, where heat is applied to remove a portion of a polymer core;
FIG. 4 shows the LCP of FIG. 3 after a portion of the polymer core is removed;
FIG. 4A is a side view of the portion of the polymer core removed from the LCP of FIG. 4;
FIG. 5 shows the LCP of FIG. 4 with a glass rod inserted within its cladding in place of the removed polymer core;
FIG. 6 is a perspective view of a typical glass rod;
FIG. 7 is a perspective view of a glass rod having one end of hexagonally shaped cross section merging with a rod portion of circular cross section, partly broken away; and
FIG. 8 is an enlarged perspective view of a bundle of glass rods of a type shown in FIG. 7 showing the packing efficiency of such glass rods.
A better understanding of the objects, advantages, features, properties and relations of the invention will be obtained from the following detailed description and accompanying drawings which set forth certain illustrative embodiments and are indicative of the various ways in which the principles of the invention are employed.
DETAILED DESCRIPTION OF THE INVENTION
Referring now in detail to the drawings, a method is disclosed for joining an LCP with a coupling member, thus providing for a novel way to construct fiber optic devices with LCPs that are resistant to ultraviolet and infrared degradation. A preferable starting material would be an LCP. A typical configuration for such material is shown at 10 in FIG. 1 .
As shown in FIG. 1, a typical LCP 10 is made of a polymer core 12 and a cladding 14 . The cladding 14 provides protection to the polymer core 12 against wear, and is necessary for effecting internal reflection of light, which helps the transmission of light through core 12 .
In the case of LCPs, an LCP is manufactured by depositing an appropriate polymer, such as butyl methacrylate, in the cladding 14 and then heating the two to form a semi-solid unit. Typically, an LCP's cladding 14 is made of material such as a fluropolymer that has a higher melting temperature than the core 12 , thus making it possible for the core 12 to be heated to a temperature where it softens by the direct application of heat onto the cladding 14 from the outside of the LCP 10 .
A preferred method for the practice of the invention herein disclosed involves stripping a portion of cladding away from one end 12 A of core 12 of a typical LCP 10 . FIG. 2 shows an LCP 10 whose end 12 A has been stripped of cladding. In a preferred embodiment for the invention herein disclosed, about 12 mm of cladding 14 may be stripped away from the LCP 10 having about a 6 mm diameter core 12 .
Another step in the practice of the invention involves applying heat to the LCP 10 at a location along the length of the LCP and spaced apart from end 12 A of its core 12 . The purpose of heating is to soften the polymer core. When the polymer core is made of butyl methacrylate, e.g., it may be heated to a temperature of at least 250° F.
The polymer core should be heated slowly from all directions as denoted by arrows 16 (FIG. 3) so that it will have a uniform temperature throughout the heated location. A preferred method for achieving uniformity is heating the LCP with a heating gun (not shown) while rotating the LCP about its longitudinal axis. Heating of the LCP should be confined to the shortest possible length for best results, typically about 12 mm to about 19 mm.
The polymer core 12 is then fractured in accordance with a further step of this invention which involves stressing the polymer core 12 at a high rate by causing it to be pulled apart very sharply upon grasping the LCP on opposite sides of the point or zone where it has been heated. To eliminate any possibility of damage to cladding 14 , it may be cooled by wiping with a damp cloth (not shown) just prior to pulling on core 12 . The rate of stressing the core must be high enough to avoid stretching the plastic core. By applying the appropriate stress rate, the polymer core 12 will not exhibit the high deformability that is normally associated with polymers; rather, it will behave in a brittle manner and fracture at the point where it has been heated. In addition, a resulting fracture surface 12 B (FIG. 4) of the core will be flat and smooth without employing any finishing methods. The LCP so modified will be ideal for coupling with a light supplying member because the core fracture surface 12 with its flat, smooth face will efficiently receive light from such member.
After the fracturing step, a removable end portion 12 C (FIG. 4A) of the polymer core 12 is removed, thus leaving a tubular void 18 defined by core fracture surface 12 B and the wall 14 A of cladding 14 extending to the right of surface 12 B as seen in FIG. 4. A cylindrical optical glass plug or rod 20 (FIG. 5) is inserted into this void 18 within the cladding 14 far enough to be in contact with, or near, the fracture surface 12 B of the core 12 in adjacent coaxially aligned end-to-end relation. The glass rod 20 may be from Schott type F and BASF families of optical glasses and may be secured in place by an adhesive or optical gel, not shown. Cyanoacrylate is an adhesive that has been found to work well. The surface 12 B or end of the core 12 that is in contact with, or near, the glass rod 20 will be the light receiving end of the polymer core 12 . Given that optical glass has an intrinsically low energy transmission in ultraviolet wavelengths and also absorbs much of infrared radiation from light sources, the LCP's core 12 is protected by the optical glass member 20 and will not be damaged as would an unprotected LCP exposed to such radiation.
The glass rod 20 may be cladded or uncladded and should be of suitable transverse cross section to fit within the void 18 inside cladding wall 14 A and also cover the fracture surface 12 B of the core 12 adequately. Moreover, glass rod 20 may be modified in order to add other features to the LCP 10 . To further reduce the exposure of the polymer core 12 to infrared radiation, one or both ends of the glass rod 20 may be coated with infrared reflective material through a process that is generally known as hot coating. A hot coated glass rod 20 will reflect infrared radiation back to a light source, thus further protecting the LCP's core 12 and preventing its degradation without requiring modification of the light source.
Another added advantage of the disclosed method is the elimination of conventional polishing of the light receiving end of an LCP. LCPs normally are manufactured by depositing one kind of polymer inside another tubularly shaped polymer member, and then heating the two together until the inner polymer becomes a semi-solid. As a result of this process, the outer polymer, namely, the cladding, is not intimately attached to the interior semi-solid polymer, namely, the polymer core.
To finish a conventional LCP before use, the end of an LCP is commonly polished. Because the core and the cladding of conventional LCPs are not intimately attached, the polishing material used in the polishing process is sometimes forced in between the core and the cladding. The presence of such material—removal of which is nearly impossible—causes contamination of the LCP which then functions less efficiently. Insertion of a prepolished glass member 20 in accordance with this invention thus improves the light transmission efficiency of LCP 10 by eliminating the necessity for polishing the end of the LCP 10 .
To improve the quality of the light transmission by LCPs, the shape of the glass rods 20 may also be modified. Typically, the transverse cross section of an LCP such as at 10 in FIGS. 1-5 will be understood to be circular. When many LCPs are bundled together as an assembly to receive light, much of the light is not transmitted by the LCP bundle because of commonly encountered inefficient packing of such conventional LCPs of circular cross section. Better packing would provide more surface area for receiving light from a light source, and thus improve the efficiency of light transmission by the bundle. Efficient packing of those ends of the LCPs may be achieved by modifying the shape of the light receiving ends of glass rods of the bundled LCPs.
More specifically, FIG. 7 shows an embodiment of such a glass rod 20 . One end, namely, the light receiving end 20 A of a glass rod insert may have a suitable polygonal cross section providing flat longitudinally extending sides such as at 20 B. In FIG. 7, the glass rod insert is shown having a hexagonal transverse cross section, although it will be appreciated that other shapes also may prove to be useful such as pentagonal, square or triangular cross sectional shapes. As shown, the rod end 20 A of polygonal cross section coaxially merges with rod portion 20 C of circular transverse cross section. In the preferred embodiment, the cross sectional dimensioning of the light receiving end 20 A is chosen such that it will encompass the circular rod portion 20 C. Thus, while the dimension between opposite faces of the hexagonal rod portion, e.g., is equal to the diameter of the rod portion 20 C of circular cross section, the cross sectional area of this hexagonal end 20 A is larger than the rod portion 20 C of circular transverse cross section. As shown in FIG. 8, use of a glass rod 20 so embodied allows better packing of a bundle of LCPs constructed through the method disclosed herein, and also increases the area that is exposed to light emanating from a light source, such as shown at 22 (FIG. 7 ), thus improving the efficiency of light transmission by such an assembly of bundled LCPs.
The glass rods 20 also may be colored thus eliminating the necessity of a colored light source or LCPs with colored polymer cores for use, for example, in architectural designs.
A variation of the method disclosed herein may be practiced on site by a field technician. A technician may carry out the steps herein disclosed, but taking care to select a prepolished glass rod 20 that is shorter in length than the length of the void 18 in the cladding 14 , placing the glass rod 20 in position, and simply removing the excess cladding 14 to make the end of the glass rod 20 flush with the end of the cladding 14 . The glass rod 20 may be secured in place by an adhesive or optical gel. Thus, existing LCP lighting systems may be modified on-site to become ultraviolet and infrared resistant without the necessity of costly replacements.
A device constructed in accordance with this invention comprises an LCP 10 modified through the methods disclosed herein and having a glass rod 20 inserted in a void 18 at one end of its cladding 14 .
Although this invention has been illustrated and described with respect to exemplary embodiments thereof, it should be understood by those skilled in the art that various changes, omissions and additions may be made without departing from the spirit and scope of the invention.
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A method and a device are disclosed for reducing ultraviolet and infrared degradation of a polymer core of large core polymer fiber. The method comprises coupling a large core polymer fiber with a glass rod resulting in the placement of the glass piece in the path of the ultraviolet and infrared radiation, thus intercepting the same and keeping the polymer core from being degraded due to long term exposure to low densities of ultraviolet or infrared radiation or from being destroyed in applications involving high density exposure to such radiation. The device comprises a large core polymer fiber having a glass rod incorporated therein to prevent exposure of the core of the fiber to ultraviolet and infrared radiation.
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FIELD OF THE INVENTION
The invention relates to a device for registering parameters of an elongated test material, said device comprising elements for generating a beam path in a region of the test material.
BACKGROUND OF THE INVENTION
From EP 0 401 600 such a device is already known for a test material in thread or wire form, wherein provision is made for a measuring gap, on each of the side walls of which a measuring electrode forming part of a capacitive measuring element is provided. In addition to the capacitive measuring element an optical measuring element is provided, comprising a light source arranged on one side of the measuring gap and a photoelectric element arranged on the other side of the measuring gap. With a view to generating a homogeneous field of illumination in the measuring gap, an aperture or a light guide in the form of a truncated cone is provided between the light source and the measuring gap.
A disadvantage of this known device can be seen in the fact that, in addition to the measuring gap, a lot of space is taken up for the light source and for means for guiding the beam of light. In addition, these means and the light source may have to be separably attached to one another or to a support stand, resulting overall in a solution that saves little space and is not very cost-effective.
SUMMARY OF THE INVENTION
The invention as described below now achieves the object of creating a device of the stated type that takes up little space, can be manufactured easily and is inexpensive.
This is achieved by at least one of the elements that generate a beam path in the region of the test material being of planar construction. Such an element may advantageously be a diffuse radiator of planar construction which acts as a light source. In the region of the elements, electrodes should furthermore be provided that are transmitting with respect to the beams pertaining to the beam path, namely transparent in the case of light beams in particular, and that are preferably applied to the element in the form of a layer. Assigned to the element that acts as beam source or light source is an element that acts as detector and receives beams from the radiator, in which connection said beams may be occluded by the test material or reflected on the test material.
The advantages obtained by means of the invention can be seen in particular in the fact that sensors operating optically and capacitively at the same time can be constructed very simply, cheaply and in space-saving manner. Hence the bulk and the cross-section or diameter of the test material, for example, can be registered simultaneously. The low space requirement allows further sensors that register various properties in respect of a test material to be provided additionally in a predetermined space. For example, in addition to sensors for registering the irregularity of bulk and diameter of the test material, further sensors for registering extraneous substances or the surface structure of the test material may accordingly be provided. Or the same property may be registered by two or more sensors having different characteristics, for example different spectral sensitivities. If the device according to the invention is constructed for textile yarns, then it may be part of a yarn clearer which has reduced external dimensions and can consequently be easily installed at selected points in a textile machine, something which, as is generally known, is not always possible, since little space is usually available on a textile machine for additional apparatus, or at least not at those places where registration of the yarn is meaningful for monitoring or measurement of the yarn.
BRIEF DESCRIPTION OF THE DRAWING FIGURES
In the following we have elucidated the invention in more detail on the basis of an example and with reference to the enclosed drawings. Illustrated are:
FIGS. 1 and 2: in each case a simplified representation of a device according to the invention with a test material,
FIGS. 3 and 4: a part of an element of the device, and
FIG. 5: a device with a measuring gap.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 shows a device according to the invention for a test material 1, said device consisting of an element 2 of planar construction, here a radiator or a beam source, with electrical connectors 3 and 4, an electrode 5 with connectors 6 and 7, and of a further element 8, here likewise of planar construction, a beam sink (usually a detector) with connectors which are not visible here. With this construction the electrode 5 is arranged at a distance 9 from the radiator 2, and both register a region 21 of the test material 1.
The electrode 5 is transmitting with respect to the radiation of the element 2, so that a beam path 10, 11 between the elements 2, 8 that emanates from the radiator 2 and is reflected on the test material 1 falls back onto the radiator 2 and, if the radiator 2 is also transmitting, is able to pass through the radiator 2 and strike the detector 8, where incoming beams are converted into an electrical signal, for example in a manner known as such. In the case of a non-transmitting radiator 2 the radiation 10, 11 may also pass through the radiator 2 through a window 12 in the latter and strike the detector 8.
However, it is also possible, as will be shown below, to provide on the side of the test material 1 facing away from the radiator 2 a detector which receives the radiation that is not occluded by the test material 1. It is also possible to split the device into two halves which extend to the left and to the right of the dot-dashed line 13, so that each half 14, 15 radiates a radiation with a definite property differing from the radiation in the other half. For example, each half 14, 15 could emit light of a different wavelength. Similarly it would be possible to arrange the electrode 5 behind the element 2 instead of in front of it.
FIG. 2 shows a device wherein an electrode 16 is arranged on the radiant face 18 of a radiator 17. The electrode 16 may preferably take the form of a layer and be attached to the radiant face 18. The radiant face 18 of the radiator 17 preferably radiates its beams diffusely and in directions such as are represented for a surface element 20 by arrows 19. These directions also include all those in between the individual arrows. It will also be discerned that the test material 22 here takes the form of a tape, for example. Assigned to the element with the radiator 16 and located opposite the electrode 17 is an element 23 which takes the form of a detector for receiving beams, in which connection the actual detector for the beams is provided with the reference symbol 24 and is of planar construction and equipped with an electrode 25.
FIG. 3 shows a part of a device wherein an element 26 is built up from several layers 27, 28. In this case an electrode 29 may also take the form of a layer, arranged between the layers 27, 28. This of course assumes that at least one layer is also transparent to beams. It may also be the case that the electrode 29 is one of the layers necessary for forming the beams and hence performs two functions. This structure is equally suitable for beam sources and for beam sinks (detectors).
FIG. 4 shows another part of a device wherein several elements are arranged behind or above one another. Here it is possible to discern, for example, two radiators 30 and 31, each of which emits beams having definite properties. Such properties are, for example, different wavelengths of the radiation, different frequencies or modulations etc.
FIG. 5 shows a device for a test material 32 with a beam source 33 and a beam sink 34 which are positioned in relation to one another in such a way that a measuring gap 35 is formed for the test material 32 which is preferably moved in its longitudinal direction, so that a relative movement corresponding to an arrow 36 arises between the device or the measuring gap 35 and the test material 32.
The mode of operation of the device according to the invention is as follows:
With a view to registering parameters in respect of an elongated test material 1 the latter is moved, in a manner known as such and therefore not described here in any detail, past a sensor as represented by elements having reference symbols 2, 5, 8, 17 etc. With this device it is intended to register the bulk, capacitively for example, and, optically, the diameter or cross-section of the test material or alternatively the irregularities thereof over the length. However, instead of, or in addition to, the irregularities it is also possible, in the case of yarn for example, for the hairiness, the extraneous-fibre content etc to be registered. Instead of optical waves, other waves or beams may be employed. Registration may be undertaken for the purpose of a measurement or for the purpose of monitoring. For the subsequent part of the specification it will be supposed that this parameter is to be registered, on the one hand, by means of an electric field and, on the other hand, by means of radiation, here in the form of light beams.
For a first registration the test material 1 is therefore illuminated in its region 21 by light beams from the radiator 2 which may pass largely unattenuated through a transparent electrode 5. The light beams are emitted as diffusely as possible, as is evident from FIG. 2. Said light beams may be registered, in the sense of a measurement of transmitted light, by a receiver or beam sink 34 (FIG. 5). Owing to absorption, reflection and scattering, the receiver 34 then receives only a fraction of the radiation emitted by the radiator 2. From the amount of light received it is accordingly possible for a signal to be derived in known manner which represents the curve of the parameter that is being sought.
For a second registration the same region 21 of the test material 1, 32 can be moved through an electric field 37 (FIG. 5) located between electrodes which are present in the transmitter 33 and receiver 34 and which are constructed as represented in FIGS. 1 to 3. Between the electrodes, which preferably have the same structure in the receiver 34 as in the transmitter 31, the changes in the electric field caused by the test material can be measured in known manner, so that a curve of the parameter that is being sought can also be obtained in this way.
If the electrodes are not of transparent construction, the light beams may pass through a window 12 and accordingly impinge on the test material 1. Reflected light beams may similarly pass through the window 12 and the transmitter to reach the detector 8, whereas transmitted light beams may pass through a corresponding window in the electrode of the receiver 34 to reach a detector where their residual intensity is registered. In the case of strongly diffuse radiation, sufficient radiation is always present that is influenced by the test material and passes through the windows.
If use is made of several colours for a registration of transmitted light and/or incident light, then a corresponding number of detectors may also be employed which are each selective in only one colour. In addition, a colour selection may also be effected by means of taps 38, 39 for electrons at various depths of a single detector.
All the transmitters and receivers represented with layers may in addition comprise a transparent layer affording protection against harmful environmental influences such as moisture, oxygen, abrasion etc.
Particularly well suited as radiators of planar construction are, for example, luminous polymers such as, for instance, those produced by Cambridge Display Technology in Cambridge, UK.
By planar construction we understand, in particular, the construction of an element such that the beam-emitting face has a length or width substantially greater than the depth of the element, said depth extending approximately perpendicular to the stated face. In other words, the beam-generating element is characterised in that it comprises no other optical elements which form, deflect, scatter etc the beams. This results in a space-saving arrangement. The face that emits beams is the same size as the measuring field. Accordingly connectors 3, 4 and 6, 7 (FIG. 1) for supplying electrical energy are also located close to the test material, preferably separated only by the spacing of the test material from the radiant face and by a fraction of the depth of the element.
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A device for registering parameters of an elongated test material that takes up little space, can be manufactured easily and is cost-effective includes a light source for illuminating at least one region of the test material. The light source is in the form of a radiator of planar construction which is preferably designed for the emission of diffuse light. The radiator is connected to an electrode that is transparent and that can be applied to the radiator in the form of a layer.
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BACKGROUND OF THE INVENTION
The present invention relates to a method and apparatus for producing tabbed or indexed sheets.
SUMMARY OF THE INVENTION
Tabbed or indexed sheets are used as dividers, for example, in ring binders or in other stationery applications. In the simplest form, the material forming a sheet is cut to define a tab projecting from its leading edge. However, where a number of such sheets are to be used, they each need to have their tab at a different position along the leading edge, and this complicates the manufacture. In addition, where the tab is formed of the sheet material, the tab may not be sufficiently strong to withstand wear and tear. Increasingly, reinforced tabs, for example of polyester sheets are provided. For example, each tab may be formed by a strip of the reinforcing material secured to the leading edge of the sheet. This has the advantage that the tabs are relatively strong, and additionally different colour tabs can be provided to aid the user distinguish between the sheets. The reinforcing material forming the tab may be arranged to leave a space between two facing parts whereby an insertable tab is defined. Furthermore, irrespective of the manner of their formation, each tab may be printed with a letter, a number, or other indexing marks so that a set of the tabbed sheets provides an index.
Because each tab is at a different position along the leading edge of its sheet, may be of a different colour, and may carry an index letter or number, the production of such tabbed or index sheets currently requires the use of large, complex and expensive machinery. Frequently, for speed, a quantity of sheets having one particular configuration are fabricated, and then a quantity of sheets having a different configuration are made, and so on. A collator is then used to form sets each including one sheet of each configuration. For example, in its first configuration, a sheet may have a tab at one end of its leading edge, the tab being printed with the letter "A". A second configuration of sheet may have a tab spaced from the one end of its leading edge by about the width of a tab and printed with the letter "B", and so on.
The present invention seeks to provide a method and apparatus for producing tabbed or indexed sheets which is simpler and more convenient than the known methods.
According to the present invention there is provided a method of producing a tabbed sheet from sheet material, the method comprising the steps of forming at least one aperture in the sheet material, inserting a length of reinforcing material through said aperture and securing the reinforcing material to the opposed faces of the sheet material, and cutting the sheet material to define a leading edge for the sheet from which said reinforcing material protrudes and defines a tab.
In a preferred embodiment, the reinforcing material within said aperture is folded to define a leading edge for said tab which remains uncut for strength.
In a preferred embodiment, said aperture is an elongate slot arranged proximate to and extending substantially parallel to the leading edge of the sheet to be formed. Preferably, the reinforcing material is inserted into the slot and is then folded and crimped to engage one edge of the elongate slot and to be substantially flat along the opposed faces of the sheet material. The reinforcing material may be secured to the opposed faces by any suitable means. In a preferred embodiment, the securing means may be heat sealing, thermoplastics, or thermosetting means. For example, the reinforcing material may be thermoplastics and arranged to adhere to the sheet upon heating.
In an alternative embodiment, each said aperture comprises a substantially elongate slot arranged proximate to and substantially parallel to the leading edge of the sheet to be formed, the aperture further having a cut out portion extending from one edge of the slot. As previously, a length of a reinforcing material is inserted into the aperture and secured to opposed faces of the sheet. The tab is defined such that the reinforcing material extending over the cut out portion defines a sleeve of an insertable tab.
In an embodiment, the method of producing a tabbed sheet is utilized to produce a series of tabbed sheets from a web of sheet material, the method further comprising the steps of feeding the sheet material from the web, and forming a series of spaced apertures along the sheet material such that there is at least one aperture in each sheet to be formed from said web.
Preferably, the method further comprises finally separating a leading sheet from the web, wherein the leading sheet is separated from the web in a cutting operation which both forms a trailing edge for said leading sheet and defines the tabbed leading edge on a following sheet. Advantageously, the apparatus for performing the method includes a separating blade specifically adapted to perform this function.
In an embodiment, the sheet material is fed from the web through a number of operating stations, a respective operation being performed on the sheet material at each said station. In this respect, the sheet material is preferably fed intermittently from the web.
In an embodiment, the material is fed from the web periodically in sheet lengths and is controlled such that when the web is stationary, a respective sheet length is arranged in each said operating station.
In a preferred embodiment, a number of substantially aligned holes are punched adjacent the trailing edge of the sheet length arranged in one of said operating stations. Preferably, at an operating station preceding said one station a reinforcing strip is applied to the trailing edge of the sheet length arranged therein adjacent to said trailing edge.
Preferably, the method further comprises printing a substantially aligned series of index marks adjacent the leading edge of the respective sheet length at a further one of said operating stations. The aligned index marks may comprise a series of consecutive letters from the alphabet, or a series of consecutive numbers. In the subsequent cutting operating at which a tabbed leading edge is defined, all but one of said index marks is arranged to be cut away.
In a preferred embodiment, punch means are provided at one said operating station for providing a number of substantially aligned holes adjacent the trailing edge of the sheet length arranged in said one operating station. Preferably, at an operating station preceding said one station, means are provided for applying a reinforcing strip to the sheet length arranged therein, for example, adjacent to the trailing edge thereof.
The invention additionally extends to apparatus for producing a tabbed sheet from sheet material, the apparatus comprising means for forming at least one aperture in the sheet material, means for inserting a length of reinforcing material through said aperture, and subsequent cutting means for cutting the sheet material to define a leading edge for the sheet from which said reinforcing material protrudes and defines a tab.
Typically, the apparatus further comprises feeding means for feeding the sheet material from the web, and subsequent cutting means for separating a leading sheet from the web, said cutting means being arranged both to form a trailing edge for said leading sheet and to define a tabbed leading edge on a following sheet.
The apparatus may also further comprise applicator means for applying a series of index marks substantially transversely of the sheet material, and preferably cutting means for cutting the sheet material to define a substantially transversely extending leading edge of a sheet and to remove all but a selected one of said applied index marks, said selected one of the marks being in the region of the tab.
The invention will now be further described in specific embodiments by way of example only, and with reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows schematically a side elevation of apparatus of the present invention for producing a series of tabbed sheets;
FIG. 2 shows schematically a plan view of a web of sheet material illustrating successive steps of a method of the invention for producing a series of tabbed sheets;
FIG. 3 is a plan view of a web showing successive steps in the formation of a tab by a method of the invention, and
FIG. 4 shows a plan view of a web of sheet material showing successive steps in the formation of an insertable tab by a method of the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 shows schematically a side elevation of apparatus of the present invention for producing a series of tabbed sheets from a web 4 of a sheet material. The sheet material, which may be of any suitable material such as paper, card or board, is provided on a reel 2 to be fed through the apparatus. In this respect, feed rollers (not shown) can be provided to draw the material from the reel 2. As we shall see, it is preferred for the material to be drawn from the reel 2 periodically so that it comes to rest successively in a number of operating stations. Preferably, means are provided to index the drawing of the web 4 such that it is accurately fed to the operating stations in turn. For example, the feed rollers may be driven by a stepper motor (not shown) used to drive or control the drive of operating means of said operating stations.
In the apparatus shown in FIG. 1, the web 4 is to form a plurality of individual sheets each having their leading and trailing edges extending substantially transversely to the direction of feed of the web 4. The web is fed first through an operating station which includes a punch 6 arranged to cut a slot in the web 4. The punch 6 is controlled relative to the indexing of the web 4 such that an individual slot 12 is punched in each sheet of the web, each individual slot being proximate to and substantially parallel to the leading edge of the respective sheet. As we shall see below, the transverse position of the slot 12 in each sheet can be adjusted as required.
The web 4 is fed next to an operating station at which there is at least one reel 8 of reinforcing material 10. In the preferred embodiment, the reinforcing material is an elongate strip of a plastics or thermoplastics material such as "MYLAR" (registered trade mark). In an embodiment, the reel 8 is arranged to extend over the transverse extent of the web 4 and to carry a number of strips of reinforcing material, each of a different colour. When the web 4 is at rest with one sheet in the operating station, a length of the reinforcing material 10 is inserted through the earlier formed slot 12. The insertion can be achieved simply by unwinding the reinforcing material 10 from the reel 8. A predetermined length of the reinforcing material 10 is unwound, and then a predetermined length, extending through the slot 12, is severed by way of a retractable knife indicated at 14.
Subsequent movement of the web 4 in its direction of feed tends to cause the length of reinforcing material 10 in the slot 12 to be folded over opposite to the direction of movement of the web 4. If required, pinch rollers (not shown) may be provided to flatten the reinforcing material 10 against opposed faces of the respective sheet. Such pinch rollers may be arranged to crimp the fold at the leading edge of the reinforcing material 10 to give a sharp leading edge thereto.
At the next operating station, the web 4 brings the folded reinforcing material 10 to rest between the jaws 16 of a hydraulically operated heating and clamping arrangement. Each jaw 16 is heated and is operable to move towards the other jaw to clamp the folded reinforcing material therebetween. Where the reinforcing material is thermoplastics, the heat of the jaws 16 causes the reinforcing material to adhere to the opposed faces of the respective sheet. The jaws 16 are then retracted.
Further feeding of the web 4 brings the sheet with the reinforcing material adhered to an operating station having a punch 18 with appropriate die 20. The punch 18 and die 20 are arranged to sever the material substantially transversely of the web 4 to define a trailing edge of a first leading sheet 22 and also to define a leading edge of the following sheet.
The effect of the operations undertaken by the apparatus of FIG. 1 can best be understood with reference to FIGS. 2 and 3. FIG. 2 shows a plan view of the web 4 as it is moved successively through seven operating stations, whereas FIG. 3 shows a length of the web specifically illustrating the production of a tab on a sheet formed therefrom.
In the embodiment shown in FIG. 2, the material undergoes a number of operations which are not provided for by the apparatus of FIG. 1. In this respect, the web 4 of FIG. 2 is fed first to an operating station 1 at which a reinforcing strip 24 of a suitable material is adhered to the web to extend transversely thereof. As can be seen, this reinforcing strip 24 is elongate and is arranged to extend proximate to and substantially parallel to what will become the trailing edge 30 of a respective sheet. The web 4 is then indexed forwardly, as indicated by the arrow, and movement thereof is ceased when the sheet which was originally in station 1 is correctly aligned in operating station 2. In station 2, a punch (not shown) punches holes 26 through the reinforcing strip 24 and through the web 4. In this manner, reinforced holes aligned along the trailing edge of each sheet are provided.
The web is again indexed forwardly so that the sheet from operating station 2 is now correctly positioned in operating station 3. In this station 3, a print head (not illustrated) is applied to the web 4 to print an aligned series of index marks 28 transversely of the sheet. Clearly, any required index marks may be applied by printing, or by other means, at this station 3. The index marks 28 may comprise all of the letters of the alphabet, or simply a selection thereof, or a series of numbers, or the like. Once the required index marks 28 have been applied, the web 4 is moved forwardly so that the printed sheet is correctly aligned in operating station 4. It is operating station 4 which includes the slot punch 6 of FIG. 1, and as can be seen in FIG. 2, the punch 6 is operated to provide the slot 12 adjacent to one of the index marks 28. In the embodiment illustrated in FIG. 2, the slot punch 6 is movable transversely relative to the web 4 and is controlled to be indexed together with the web 4. Thus, after each operation, the slot punch 6 is moved transversely relative to the web 4 so that it is aligned alongside the next index mark 28. As is therefore immediately apparent from FIG. 2, as the web 4 is fed through the operating stations, slots 12 are formed against successive index marks 28.
After a slot 12 has been formed, the web 4 is indexed forwardly to position the slotted sheet in operating station 5 at which the reinforcing material 10 is inserted through the slot 12. As indicated, where there is only a single reel 8 of reinforcing material 10, the reel may be indexed to move transversely of the web 4 so that it offers a length of reinforcing material 10 to each successive slot 12 arriving. Alternatively, a number of reels 8 carrying the reinforcing material may be arranged transversely of the web and operated in their turn so that reinforcing material 10 is presented to the slot provided.
It is at operating station 6 that the reinforcing material 10 is heat clamped to the opposing faces of the sheet by way of the jaws 16 or other heat clamping means. In this respect, each heat clamp may extend over the full transverse extent of the web 4. Alternatively, it would be possible to index the heat clamps 16 transversely of the web if required.
The web then moves forward to position the sheet with secured reinforcing material in operating station 7 which incorporates the punch 18 and die 20 of FIG. 1. The punch and die are indexable transversely of the web 4 to provide the correct cut for the sheet being formed. In this respect, the punch 18 and die 20 co-operate to cut the web 4 substantially transversely to define the trailing edge 30 of a sheet 22, previously formed, which is thereby separated from the web 4. In the same cutting operation, the punch 18 and die 20 also define a leading edge 32 of the sheet positioned in station 7, from which leading edge 32 a tab 34, formed from the reinforcing material 10, protrudes.
FIG. 3 shows three successive stages in the definition of the tab 34. In FIG. 3, there is shown part of the web 4 having a sheet defined therein in which a slot 12 has been punched adjacent to its leading edge 32. In the next position of this sheet, the reinforcing material 10 is shown as having been inserted through the slot 12 and adhered to the opposed faces of the sheet. The final stage shows the formation of the tab 34. In this respect, the punch 18 and die 20 are controlled to remove the material 36 from the web 4. The leading edge of this removed material is substantially linear and it is this leading edge of the cut which defines the trailing edge 30 of the preceding sheet. The trailing edge of the removed material 36 is substantially linear but is gapped, representing a gap in the punch, die combination. Thus a cut is produced which is substantially linear and extends substantially transversely of the web to define the leading edge 32. However, in the region of the slot 12 and reinforcing material 10 the punch and die are shaped to form longitudinally extending, shaped side surfaces of the reinforcing material 10, and to join the cut at the leading edge 32 with the slot 12. Thus, the fold at the leading edge of the reinforcing material 10 is released and forms the leading edge of a tab 34 so formed. It will thus be appreciated from FIG. 3 that the tab 34 has a folded leading edge and therefore a very strong resistance to use. This is quite distinct from many prior art tabs which are formed by cutting and which have a cut leading edge which is subject to fraying and the like.
FIG. 4 shows a view similar to FIG. 3 showing the formation of an insertable tab. In this respect, the elongate slot 12 is replaced by an aperture 12' which has a leading edge substantially parallel to the leading edge 32 of the sheet to be formed but has a rectangular cut out portion 38 provided on the trailing edge of the slot. As previously, a length of reinforcing material 10 is inserted through the slot and folded over to contact the opposed faces of the sheet. The reinforcing material 10 is secured to the sheet, for example by heat clamping, but in this case it is ensured, for example by suitable shaping of the clamps 16, that the parts of the reinforcing material 10 which face each other across the cut out 38 are not adhered. Thereafter, the leading edge 32 of the sheet is released by the punch and die to define a protruding tab 34 as previously. However, it will be immediately appreciated from FIG. 4 that the non-adhered facing parts of the material 10 define a sleeve in which index cards, for example, may be inserted.
It will be immediately appreciated from FIG. 2 that the method of the invention enables a series of tabbed sheets to be produced directly from a web without the need for any collating to put the resultant sheets into sets. In this respect, successive sheets can be arranged to have their tab in the succeeding position along the transverse extent thereof and for the tab to carry the next appropriate index mark. It is simply necessary to place a collecting tray after station 7 to receive the sets so formed.
In the embodiments described the sheets are produced to have differently positioned tabs and different index marks. However, it will be appreciated that the index marks can be omitted if required.
Other modifications and variations to the method and apparatus as described above may be made within the scope of this application.
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Tabbed or indexed sheets typically for use in ring binders or other stationery applications are produced from a web of sheet material by means of forming an aperture in the sheet material and inserting through the aperture a length of reinforcing material. The length of reinforcing material is secured to the opposed faces of the sheet material and the individual sheet separated from the remainder of the web of sheet material by cutting to form a trailing edge and a leading edge for the sheet. In cutting the sheet material to form the leading edge of the sheet, a tab or indexed portion of the reinforcing material is obtained at the leading edge.
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BACKGROUND
[0001] 1. Field of Invention
[0002] The present invention relates to a small sealed container and an applicator. More specifically, the present invention relates to a small slender container designed to be used with an applicator such as a cotton swab.
[0003] 2. Description of Related Art
[0004] Small containers in the general form of an elongated tube may be used to distribute and/or apply small quantities of products such as creams, lotions, and make-ups. The small container's contents are generally difficult to extract, particularly if the viscosity of the content is high. Therefore, either the remaining contents are disposed of or some form of applicator or extractor must be used to extract the contents.
[0005] Often, an applicator is required to retrieve and accurately apply the content of the container to the desired location. The applicator is generally a separate component that is inserted into the container to retrieve the content and then applied to the desired location. Some applicators are incorporated into the cap of the container such that when the cap is removed, the applicator is exposed and can be used to retrieve and apply the content of the container. Other applicators are completely separate from the container such that it is not a part of the container.
[0006] U.S. Pat. No. 5,702,035, Slender Tubular Container with Opening and Closing Means, is one of applicant's patented containers and is one example of a container with applicator for liquids. A more effective design is required for high viscosity contents.
SUMMARY OF THE INVENTION
[0007] The present invention is a small slender container and an applicator that may be used to store small quantity of substance, such as creams, lotions, and make-ups in a sealed environment and easily and sanitarily dispenses its content for application as desired. The content of the slender container may be permanently sealed with an opening means or may be sealed with a high viscosity substance such as silicone. The container and applicator comprises of a small slender container with a sealed first end and a second end with a high viscosity substance sealed within the container and an applicator that is inserted into the container to simultaneously extract and inject the content into the applicator. The applicator may then be used to apply the contents to the desired location. After application, the sealed compartment and the applicator are disposed of.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] [0008]FIG. 1 shows the preferred embodiment of the container and applicator.
[0009] [0009]FIG. 2 shows another embodiment of the container and applicator.
[0010] [0010]FIG. 3 shows another embodiment of the container and applicator.
[0011] [0011]FIG. 4 shows another embodiment of the container and applicator.
[0012] [0012]FIG. 5 shows another embodiment of the container and applicator.
[0013] [0013]FIG. 6 shows another embodiment of the container and applicator.
[0014] [0014]FIG. 7 a shows another embodiment of the container and applicator.
[0015] [0015]FIG. 7 b shows another embodiment of the container and applicator.
[0016] [0016]FIG. 8 shows another embodiment of the container and applicator.
[0017] [0017]FIG. 9 shows another embodiment of the container and applicator.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0018] [0018]FIG. 1 shows the preferred embodiment of the container and applicator. The preferred embodiment of the container and applicator comprises an elongated housing 1 with a first sealed end and a second open end. A substance 2 such as cream, lotion, make-up, or other liquid is contained within the elongated housing 1 near the first sealed end. If the substance 2 is evaporative, a high viscosity sealer 3 such as silicone may be used to separate the substance 2 from the second open end to prevent evaporation. An applicator 4 is affixed to the first end of a hollow tube 5 . When the second end of the hollow tube 5 with the applicator 4 is inserted into the elongated housing 1 , the contents of the elongated housing 1 will be forced into the applicator 4 through the hollow tube 5 with the applicator 4 due to the displacement of the content in the elongated housing 1 by the inserted hollow tube 5 .
[0019] [0019]FIG. 2 shows another embodiment of the container and applicator. In this embodiment, the container and applicator comprises an elongated housing 1 with a first sealed end and a second open end. A substance 2 such as cream, lotion, make-up, or other liquid is contained within the elongated housing 1 near the first sealed end separated from the first sealed end with a high viscosity substance 6 such as silicone. If the substance 2 is evaporative, another high viscosity sealer 3 such as silicone may be used to separate the substance 2 from the second open end to prevent evaporation. An applicator 4 is affixed to the first end of a hollow tube 5 . When the second end of the hollow tube 5 with the applicator 4 is inserted into the elongated housing 1 , the contents of the elongated housing 1 will be forced into the applicator 4 through the hollow tube 5 with the applicator 4 due to the displacement of the content in the elongated housing 1 by the inserted hollow tube 5 . The high viscosity substance 6 near the first sealed end is the last to enter the hollow tube 5 and is designed to force the remaining content of the elongated housing 1 out of the inserted hollow tube 5 and into the applicator 4 .
[0020] [0020]FIG. 3 shows another embodiment of the container and applicator. In this embodiment, the container and applicator comprises an elongated housing 1 with a first sealed end and a second sealed end with an opening means 7 near the second sealed end. A substance 2 such as cream, lotion, make-up, or other liquid is contained within the elongated housing 1 near the first sealed end. An applicator 4 is affixed to the first end of a hollow tube 5 . When the second end of the hollow tube 5 with the applicator 4 is inserted into the elongated housing 1 after the elongated housing 1 is opened through the opening means 7 near the second sealed end of the elongated housing 1 , the contents of the elongated housing 1 will be forced into the applicator 4 through the hollow tube 5 with the applicator 4 due to the displacement of the content in the elongated housing 1 by the inserted hollow tube 5 .
[0021] [0021]FIG. 4 shows another embodiment of the container and applicator. In this embodiment, the container and applicator comprises an elongated housing 1 with a first sealed end and a second sealed end with an opening means 7 near the second sealed end. A substance 2 such as cream, lotion, make-up, or other liquid is contained within the elongated housing 1 near the first sealed end. If the substance 2 has low viscosity, a high viscosity sealer 3 such as silicone may be used to separate the substance 2 from the second sealed end to retain the substance 2 near the first sealed end. An applicator 4 is affixed to the first end of a hollow tube 5 . When the second end of the hollow tube 5 with the applicator 4 is inserted into the elongated housing 1 after the elongated housing 1 is opened through the opening means 7 near the second sealed end of the elongated housing 1 , the contents of the elongated housing 1 will be forced into the applicator 4 through the hollow tube 5 with the applicator 4 due to the displacement of the content in the elongated housing 1 by the inserted hollow tube 5 .
[0022] [0022]FIG. 5 shows another embodiment of the container and applicator. In this embodiment, the container and applicator comprises an elongated housing 1 with a first sealed end and a second end with an opening means 8 such as a screw-on cap. A substance 2 such as cream, lotion, make-up, or other liquid is contained within the elongated housing 1 near the first sealed end. An applicator 4 is affixed to the first end of a hollow tube 5 . When the second end of the hollow tube 5 with the applicator 4 is inserted into the elongated housing 1 after the elongated housing 1 is opened through the opening means 8 at the second end of the elongated housing 1 , the contents of the elongated housing 1 will be forced into the applicator 4 through the hollow tube 5 with the applicator 4 due to the displacement of the content in the elongated housing 1 by the inserted hollow tube 5 .
[0023] [0023]FIG. 6 shows another embodiment of the container and applicator. In this embodiment, the container and applicator comprises an elongated housing 1 with a first sealed end and a second open end. A substance 2 such as cream, lotion, make-up, or other liquid is contained within the elongated housing 1 near the first sealed end. If the substance 2 is evaporative, a high viscosity sealer 3 such as silicone may be used to separate the substance 2 from the second open end to prevent evaporation. A plug 9 with a hole through its center is placed immediately next to the substance 2 or the high viscosity sealer 3 , if one is utilized. An applicator 4 is affixed to the first end of a hollow tube 5 . When the second end of the hollow tube 5 with the applicator 4 is inserted into the elongated housing 1 , the hollow tube 5 will force the plug 9 to apply pressure and scrub the contents of the elongated housing 1 from the inside walls of the elongated housing 1 to fully force all the contents into the applicator 4 through the hollow tube 5 with the applicator 4 due to the displacement of the content by the inserted hollow tube 5 .
[0024] [0024]FIG. 7 a shows another embodiment of the container and applicator. In this embodiment, the container and applicator comprises an elongated housing 1 with a first sealed end and a second sealed end with an opening means 7 between the first sealed end and the second sealed end. A substance 2 such as cream, lotion, make-up, or other liquid is contained within the elongated housing 1 near the first sealed end separated from the opening means 7 with a high viscosity substance 3 such as silicone. A substance 11 such as cream, lotion, make-up, or other liquid is contained within the elongated housing 1 near the second sealed end separated from the opening means 7 with a high viscosity substance 10 such as silicone. An applicator 4 is affixed to the first end of a hollow tube 5 . When the second end of the hollow tube 5 with the applicator 4 is inserted into either end of the elongated housing 1 after the elongated housing 1 is opened through the opening means 7 , the contents of the elongated housing 1 will be forced into the applicator 4 through the hollow tube 5 with the applicator 4 due to the displacement of the content in the elongated housing 1 by the inserted hollow tube 5 . The substance 2 in elongated housing 1 near the first sealed end may be the same as or a different substance than the substance 11 near the second sealed end.
[0025] [0025]FIG. 7 b shows another embodiment of the container and applicator. In this embodiment, the container and applicator comprises an elongated housing 1 with a first sealed end and a second sealed end with an opening means 7 between the first sealed end and the second sealed end. A substance 2 such as cream, lotion, make-up, or other liquid is contained within the elongated housing 1 near the first sealed end separated from substance 11 near the second sealed end with a high viscosity substance 3 such as silicone with an opening means 7 at the location of the high viscosity substance 3 . An applicator 4 is affixed to the first end of a hollow tube 5 . When the second end of the hollow tube 5 with the applicator 4 is inserted into either end of the elongated housing 1 after the elongated housing 1 is opened through the opening means 7 , the contents of the elongated housing 1 will be forced into the applicator 4 through the hollow tube 5 with the applicator 4 due to the displacement of the content in the elongated housing 1 by the inserted hollow tube 5 . The substance 2 in elongated housing 1 near the first sealed end may be the same as or a different substance than the substance 11 near the second sealed end.
[0026] [0026]FIG. 8 shows another embodiment of the container and applicator. In this embodiment, the container and applicator comprises an elongated housing 1 with a first sealed end and a second open end. One or more small holes 14 are located on the elongated housing 1 near the second open end. An elongated member 12 with at least one sealed end is inserted into the elongated housing 1 and rests on the first sealed end. An opening means 7 on the elongated housing 1 is located at a predetermined location along the position of the elongated member 12 . A substance 2 such as cream, lotion, make-up, or other liquid is contained within the elongated housing 1 near the sealed end of the elongated member 12 . If the substance 2 is evaporative, a high viscosity sealer 13 such as silicone may be used to separate the substance 2 from the second open end to prevent evaporation. An applicator 4 may be affixed to the second open end of the elongated housing 1 . When the elongated housing 1 is opened through the opening means 7 , the elongated member 12 is exposed and can be depressed to extract the content of the elongated housing 1 into the applicator 4 .
[0027] [0027]FIG. 9 shows another embodiment of the container and applicator. In this embodiment, the container and applicator comprises an elongated housing 1 with a first open end and a second open end. One or more small holes 14 are located on the elongated housing 1 near the second open end. An elongated member 12 is inserted into the elongated housing 1 and positioned near the first open end. An opening means 7 on the elongated housing 1 is located at a predetermined location along the position of the elongated member 12 . A stopper 15 is attached to the end of the elongated member 12 near the second open end. A substance 2 such as cream, lotion, make-up, or other liquid is contained within the elongated housing 1 near the stopped 15 at the end of the elongated member 12 . If the substance 2 is evaporative, a high viscosity sealer 13 such as silicone or a rubber stopper may be used to separate the substance 2 from the second open end to prevent evaporation. An applicator 4 may be affixed to the second open end of the elongated housing 1 . When the elongated housing 1 is opened through the opening means 7 , the elongated member 12 is exposed and can be depressed to extract the content of the elongated housing 1 into the applicator 4 through the one or more holes 14 near the end of the second open end.
[0028] Although the description above contains many specificities, these should not be construed as limiting the scope of the invention but as merely providing illustrations of some of the presently preferred embodiments of this invention. Thus the scope of the invention should be determined by the appended claims and their legal equivalents, rather than by the examples given.
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A small slender container and an applicator that may be used to store small quantity of substance, such as creams, lotions, and make-ups in a sealed environment and easily and sanitarily dispenses its content for application as desired is disclosed. The content of the slender container may be permanently sealed with an opening means or may be sealed with a high viscosity substance such as silicone. The container and applicator comprises of a small slender container with a sealed first end and a second end with a high viscosity substance sealed within the container and an applicator that is inserted into the container to simultaneously extract and inject the content into the applicator. The applicator may then be used to apply the contents to the desired location. After application, the sealed compartment and the applicator are disposed of.
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REFERENCE TO RELATED APPLICATION
This is a continuation-in-part of application Ser. No. 08/413,796 filed Mar. 30, 1995, now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to the field of spray guns for the spray application of liquid coatings. More specifically, the invention primarily relates to improvements in spray guns of the type known as high volume, low pressure (hereafter, "HVLP") including a novel fluid nozzle assembly with integral pressure reduction and air volume control capabilities, an improved trigger fulcrum assembly, an improved construction based upon the use of components made of aluminum or of an aluminum alloy in place of components that have conventionally been made of stainless steel, and an exterior nozzle configuration which provides improved atomization.
2. Description of the prior Art Compressed air spray guns are adjustable and are capable of producing finely atomized particles by using high pressure atomizing air or they can produce large atomized particles by using an appropriate cap and nozzle and employing HVLP air for the atomizing air at the gun cap. When guns are adjusted to high cap pressures, the paint is atomized into very small particles which results in smooth high gloss paint coatings such as are observed on automobiles. When many of the atomized particles are very small and light they can be blown past the target into the surrounding air by the high velocity of the surrounding atomizing air or merely drift into the surrounding ambient air. Transfer efficiencies, as a consequence, are poor and air pollution can also occur. The cost effectiveness of high pressure air atomizing has dropped drastically as the cost of paint has risen.
HVLP atomizer guns were developed which expanded the low adjustment end of the standard conventional spray guns. These guns use baffles to reduce the incoming high pressure from air compressor lines in order to supply reduced cap air pressures and also use specially designed air caps and fluid nozzles to enhance this form of atomization. U.S. Pat. No. 5,209,405 (Robinson et al.), the disclosure of which is hereby incorporated herein by reference, describes a separate removable baffle which acts as a pressure reduction means for atomizing air and pattern control air in combination. Yet other gun designs use some form of pressure reduction within a part of the gun body before the high pressure air reaches the spray head portion of the apparatus. This type of configuration is seen in U.S. Pat. No. 5,064,119 (Melette), where a variable adjustment of the atomizing air is accomplished by adjustment of an air valve stem located in the gun body air passage. The HVLP method of atomization produces a large distribution of medium and relatively large atomized particles which, partly due to the low velocity of the atomizing air exiting the spray cap assembly, will strike and attach themselves to the target being coated. This results in more of the atomized paint reaching and attaching to the target surface with higher transfer efficiencies, lower air pollution, and more efficient paint usage, but with somewhat coarser surface finishes. This type of gun has proven to be useful where high gloss surface finishes are not required.
To keep the weight of the guns light so as to reduce operator fatigue, gun bodies are fabricated of aluminum but, because corrosive materials may be sprayed, it has been necessary to fabricate the fluid chambers of stainless steel, which increases the weight of these guns. This is exemplified in U.S. Pat. No. 4,537,357 (Culbertson et al.). This spray gun clearly claims a separate fluid section assembled at the front end of the device. U.S. Pat. No. 5,090,623 (Burns et al.) shows a corrosion resistant insert pressed into the gun body as well. Some gun bodies are fabricated from plastic to achieve weight reduction but they are not highly regarded due to their inability to withstand rough handling. Trigger pull is another important factor which can cause operator fatigue. There are minimal spring forces in spray guns which are required to return the fluid needle and the atomizing air valves to their closed position regardless of friction caused by packing seals and dried paint. Accordingly, most spray guns require high trigger force which can cause operator hand, wrist and finger fatigue. U.S. Pat. No. 5,236,129 (Grime et al.) makes claims to exceptionally light trigger forces based on the action of added internally designed pilot valves.
Because air supplying equipment is used to provide air to all air atomizing guns and because the cost of operating this equipment must be factored into the total cost of painting, it is important to obtain efficient ratios of paint atomization to the amount of air used in order to achieve overall cost efficiency.
SUMMARY OF THE INVENTION
According to this invention an improved HVLP spray gun which operates from an air supply source is provided. The HVLP gun has a fluid nozzle including an integral laterally extending portion including pressure reduction orifices which are calibrated, relative to a fluid passage in the nozzle, so that the spray gun operates as an HVLP spray gun. Specifically, the pressure reduction orifices reduce the pressure of the atomizing air to a level of 10 PSI or less within the air cap chamber of the spray cap assembly of the gun. It is preferred that the laterally extending portion include a plurality of calibrated pressure reduction orifices to effect the required pressure reduction while allowing for the required high air volume needed to atomize the fluid stream exiting from the fluid nozzle. According to a further embodiment of this invention, the fluid nozzle includes a second laterally extending portion including a surface against which atomization air impinges after exiting the calibrated pressure reduction orifices. The second outwardly extending portion includes a plurality of longitudinally extending air distribution holes, preferably positioned radially outwardly from the location of the calibrated pressure reduction orifices so that atomization air, after passing through the pressure reduction orifices is directed radially outwardly in an expansion chamber between the first and second laterally extending portions of the fluid nozzle where the low velocity air is pressure equalized before exiting through the air distribution holes. After passing through the distribution holes, the evenly distributed high volume of low pressure air is directed within the air cap inwardly toward a fluid atomizing annulus created by a concentric hole in the air cap and an outer cylindrical concentric fluid nozzle surface from which the fluid to be atomized will exit. Confusion that a gun user normally feels about the use of most spray guns where there are multiple variables of separate spray caps, separate nozzles, and separate air pressure reduction baffles, all of which must be used in the proper combination in order to achieve desired atomization of paint, is eliminated by the HVLP spray gun of the present invention.
It is preferred that the spray gun body be fabricated completely of aluminum. To make the surface of the aluminum sufficiently hard so that it will not become dented or scarred during handling, the gun body is first machined and then hard coat anodized. This process creates a deep oxide surface which is extremely hard and resistive to surface damage. Teflon material is then vacuumized into the depressions in the hexagonal oxide surface, thereby creating uniquely protective interior and external surfaces of the gun. The following advantages are the result of this unusual surface treatment of the spray gun: 1. The aluminum oxide surface is extremely hard and resists damage and blemishes caused by rough handling. 2. The impregnation of inert teflon into all oxide surfaces helps the surfaces to shed all fluid materials, thereby making the gun surface very easy to clean. 3. The oxide anodized base with the teflon impregnation creates an internal surface in the fluid passages which is impervious to waterborne paints and solvents, and to corrosive and abrasive fluids. 4. The surface treatment of this improved spray gun eliminates the need to use stainless steel inserts in order to withstand waterborne and abrasive fluids thereby reducing the weight of this spray gun embodiment. 5. Elimination of separately machined stainless steel inserts and the assembly of these inserts into the aluminum body as seen in most spray guns reduces the manufacturing cost of the spray gun according to the invention.
In a second embodiment of the invention, the force required to pull the gun trigger is reduced. In most conventional spray guns, the fulcrum of the trigger is located well above the horizontal air passage near the top of the gun body barrel with considerable distance to the spring loaded needle connection point. The trigger fulcrum of this invention is located below the air passage section of the body, creating a lever advantage by placing the trigger pivot point close to the spring loaded fluid needle and air valve assembly contact point, which reduces the needle opening finger force on the trigger. It is preferred to further reduce the trigger pull force, and make it easier to operate a spray gun according to the invention, by providing roller bearings which are supported on and extend outwardly from the needle, perpendicular to its longitudinal axis. The rollers are engaged by a rear concave radial surface of the trigger contact area. As the trigger is pulled back, the rear curved surface of the trigger which makes contact with the rollers causes the rollers to rotate as the needle is moved backward against its spring force, thereby reducing the friction between the needle and trigger.
In yet another embodiment of the present invention, there is a double taper provided on the front outer surface of a fluid exit tube of a fluid nozzle. Atomization air exits from an annulus contained within a hole in the front of an air cap which contains the fluid exiting tube concentrically at its center. Because the atomization air which causes the atomization of the fluid exiting the fluid tube moves generally horizontally along the outer front surface of the fluid tube, the taper on the front of the outer edge of the fluid tube causes a reduction of pressure at its tapered edge and consequently draws the atomizing air inwardly into the exiting fluid stream surface where the tapered edge on the fluid tube meets the fluid stream. Because the atomizing air is driven into the emerging fluid stream exactly at the point the fluid stream exits the fluid tube, atomization occurs very close to the front surface of the gun cap. This results in improved atomization as well as a reduction in the air volume required to cause the atomization.
It is an object of this invention to provide an HVLP spray gun fluid nozzle with a fluid outlet and a laterally extending portion including pressure reduction orifices which are calibrated to the fluid outlet and operable to throttle high pressure air for atomizing a fluid stream exiting the nozzle under HVLP conditions.
Accordingly, it is an object of this invention to provide an improved air atomizing spray gun which is lighter than most competitive types and which can be operated with less trigger pull, thereby reducing operator fatigue.
It is another object of the invention to provide a spray gun whose interior and exterior surfaces are impervious to all types of destructive fluids, and are easily cleanable.
Other objects and advantages will be apparent to those skilled in the art from the following description of preferred embodiments thereof.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a vertical sectional view showing a spray gun according to the instant invention.
FIG. 2 is an enlarged view in vertical section showing the front end of the spray gun of FIG. 1.
FIG. 3 is a view in horizontal section showing a fluid nozzle according to the invention which is a part of the spray gun of FIGS. 1 and 2.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
An HVLP fluid spray gun according to the invention is indicated generally at 10 in FIG. 1. The gun 10 includes a spray gun body 12 having a handle 14 with a fitting 16 at the base of the handle for connection to a source of air. At the forward end of the gun, there is a spray head assembly indicated generally at 18 which includes an air cap retaining ring 20 and an air cap 22 which provides atomizing air through a passage 24 and pattern air through a passage 26. A fluid nozzle 28 is also a part of the spray head assembly 18. Fluid to be atomized is prevented from flowing through a passage 30 in the fluid nozzle 28 when the front portion of a needle 32 is in the position shown so that a tapered tip thereof closes the passage 30. When the needle 32 is withdrawn to the right from the position shown, fluid is free to flow through the passage 30 in the front end of the fluid nozzle 28.
A supply air passage or chamber 36 extends through the handle 14. In the position shown, an air valve 40 prevents the flow of air from the supply air passage 36. The air valve 40 is carried by a needle actuating assembly indicated generally at 42, which is moveable to the rear of the gun 10, i.e., to the right in FIG. 1, when the lower end of a trigger 44, which is pinned to the body 12 as indicated at 46, is moved toward the handle 14, causing a concave rear portion of the trigger 44 to contact a roller bearing 48 which is pinned to the needle 32 and to the needle actuating assembly 42 as indicated at 50, and move the needle 32 and the assembly 42 to the right, opening the passage 30 of the fluid nozzle 28 and the air valve 40, and compressing a spring 52. When the pressure on the trigger 44 is released, the spring 52 causes the needle 32 and the needle actuating assembly 42 to return to the position shown. So long as the lower part of the trigger 44 is held in a position closer to the handle 14 than that shown, the air valve 40 is open, and the needle 32 no longer prevents the flow of fluid through the passage 30 from the interior of the fluid nozzle 28.
When the trigger 44 is moved toward the handle 14, pressurized air which enters the air passage 36 can flow through the air valve 40 into a first chamber 54, from which fan or pattern air can flow into a second chamber 56 and then into the passage 26 and through air pattern holes 58, compressing the normally circular atomized fluid stream emitted from the fluid outlet passage 30 of the nozzle 28, into a narrow straight line pattern. Fan air volume, which controls the size of the narrow atomized fluid pattern, can be adjusted by moving a fan adjusting needle 60 in or out of the second chamber 56 by rotating the needle 60 clockwise or counterclockwise.
Atomizing air exits the first chamber 54 through apertures 62 located before the fan air adjustment needle 60 lowers the air pressure in the fan air cavity 56 and, consequently, the pressure of atomizing air is unaffected by the fan air adjustment. The atomizing air flows into and through a third chamber 64, then into and through fluid nozzle pressure reduction orifices 66 (see, also, FIGS. 2 and 3), into a fourth, pressure equalizing chamber 68, through air distribution holes 70, into the atomizing air passage 24, sometimes referred to hereinafter as a fifth chamber, and then through an atomizing air annulus 72 where it atomizes exiting fluid from the fluid outlet passage 30 of the fluid nozzle 28. Atomizing air also flows from the passage 24 through holes 73.
FIG. 2 shows the spray head assembly 18 of the fluid spray gun 10, including the air cap 22, the fluid nozzle 28 and the air cap retaining ring 20 mounted on the front portion of the gun body 12. When the gun is in operation, fluid under pressure enters a gun body fluid inlet 74 from which it flows into a cavity 76 of the fluid nozzle 28, which is threadably engaged with the body 12, as indicated at 78. Since the needle 32 is withdrawn to the right during operation of the gun 10, the fluid which enters the cavity 76 flows through the opening or fluid outlet passage 30 of the nozzle 28 and is atomized by air which flows through the apertures 62, and through the third chamber 64, the fluid nozzle pressure reduction orifices 66, the fourth, pressure equalizing, chamber 68, the distribution holes 70, and into the atomizing air passage or fifth chamber 24, and then through the atomizing annulus 72 to atomize fluid leaving nozzle 28. Atomizing air leaving the annulus 72 flows along a first tapered portion 79 of the nozzle 28 and past a tapered forward end 80 of the nozzle 28. The tapered forward end 80 is more severely tapered than the first tapered portion 79. There is a pressure reduction as a consequence of atomization air flowing past the intersection 81 of the first tapered portion 79 and the tapered end 80. Air moves inwardly as a consequence of the reduced pressure, causing it to impinge upon and cause effective atomization of the fluid leaving the opening 30 of the fluid nozzle 28.
The pressure reduction orifices 66 extend through a first, laterally extending portion of the nozzle 28. The orifices 66 are calibrated to reduce the pressure of atomization air as it passes through the orifices 66 so that air causes atomization of a fluid stream exiting the fluid outlet passage 30 under HVLP conditions. Excellent results have been achieved, in the case where the fluid outlet passage 30 had a diameter of 0.042 inch (1.10 mm), with three pressure reduction orifices 66, evenly spaced around the nozzle 28, each having a diameter of 0.055 inch (1.40 mm). It is preferred that there be at least three pressure reduction orifices and that the be evenly spaced around the nozzle 28. A differently sized fluid outlet passage 30 will require a different arrangement or size of pressure reduction orifices in order that the nozzle will produce HVLP atomization of an exiting fluid. In any case, the present invention integrates these calibrated pressure reduction orifices with a given fluid outlet passage in a single nozzle, thereby eliminating the need for operators to mix and match fluid nozzles with air pressure reduction baffles according to the prior art.
Air passing through the pressure reduction orifices 66, into the fourth chamber 68, is directed onto a solid portion of a second, laterally extending portion of the nozzle 28. As a consequence, the atomization air flows radially outwardly in the fourth, pressure equalization chamber 68, before passing through the distribution holes. Excellent results have been achieved in the specific embodiment described in the preceding paragraph where there are 12 air distribution holes, equally spaced around the second laterally extending portion of the nozzle 28, each having a diameter of 0.090 inch (2.29 mm).
The gun body 10 is formed from one piece of aluminum which is machined prior to being hard coat anodized. After the hard coat anodizing, the body is subjected to a teflon impregnation process. The anodizing is sufficiently deep in the aluminum that it produces a hard, porous aluminum oxide surface; the teflon impregnation fills the pores, reducing porosity and making it resistant to damage by corrosive fluids. Because of the hardness of the anodized aluminum surface, it is also resistant to damage by abusive handling. All of the surfaces of the fluid spray gun 10, interior and exterior, are preferably subjected to hard coat anodizing and then to teflon impregnation, but the anodizing and teflon impregnation are particularly important on the surfaces which enclose the body fluid inlet 74, the surfaces which enclose the cavity 76 and the passage 30 of the fluid nozzle 28, the needle 32 and the surfaces which enclose a cavity 82 in the body 12 through which a fluid to be atomized must flow between the cavity 74 and the cavity 76. All of these surfaces come into contact with the fluid being atomized. Because they are hard coat anodized and teflon impregnated there is no need for stainless steel in the components where steel was previously considered to be necessary, particularly in the fluid inlet cavity 74. The teflon surface sheds all types of paints and fluids that are used in fluid air guns, offering a lubricous surface which is easy to maintain and clean. Nimet Industries, Inc., 2424 North Foundation Drive, South Bend, Ind. 46628 does hard coat anodizing or hard coat anodizing and teflon impregnation on a custom basis; the machined aluminum or aluminum alloy parts for a fluid spray gun according to the invention which require hard coat anodizing and teflon impregnation can be shipped to the indicated company for the required processing.
It will be apparent to those skilled in the art that various changes and modifications can be made to the preferred embodiments of the invention that have been described without departing from the spirit and scope of the invention as defined in the attached claims. It will also be apparent that the invention is in various improvements to a fluid spray gun of the type that is operated from a source of high pressure air and uses a high volume low pressure flow of air or a high pressure flow from a cap that is releasably attached to and is part of a spray head assembly at the forward end of a gun body for fluid atomization and for pattern shaping of a fluid discharged from a nozzle that, except for a protruding tip, is inside the air-directing cap, and is releasably attached to the gun body, and that the spray gun is one having:
(a) a fluid-inlet for receiving, from a source, fluid to be sprayed, and to deliver the fluid to the interior of the nozzle,
(b) a supply-air passage for receiving high pressure air from a source,
(c) a first chamber in the gun body operably associated to receive high pressure air from the first-air chamber,
(d) a second chamber in the spray head assembly operably associated to receive pattern shaping air from the first chamber,
(e) a needle that is resiliently urged into the interior of the nozzle to prevent the flow of fluid therefrom,
(f) a valve that is resiliently urged toward a closed position where it prevents the flow of high pressure air from the supply-air passage to the first chamber, and
(g) a trigger pinned to the gun body and operably associated with an actuator to withdraw the needle from the interior of the nozzle and to open the valve so that it does not prevent the flow of high pressure air from the supply-air passage to the first chamber.
It will also be apparent that one of the improvements is a longitudinally extending nozzle member which extends through an opening in the cap and has exterior walls spaced from the walls of the cap which surround the opening and form therewith a passage for the flow of air from the supply air chamber to the first chamber, the exterior of said nozzle member having first and second spaced, laterally extending portions. The improved gun further comprises a third chamber, a fourth chamber and means for delivering high pressure air from the first chamber to the third chamber. The first, laterally extending portion of the nozzle separates the third chamber from the fourth chamber and has at least one pressure reduction orifice through which air can flow from the third chamber to the fourth chamber. The second laterally extending portion of the nozzle separates the fourth chamber from a fifth camber which is between the nozzle and the walls of the cap. At least one air distribution orifice is provided in the second laterally extending portion of the nozzle, through which air can flow from the fourth chamber to the fifth chamber. The at least one pressure reduction orifice is calibrated to reduce the pressure of air passing therethrough to that required for atomization of a fluid stream flowing out of the nozzle under HVLP conditions. The nozzle shown in the drawings and described with reference thereto has an exterior surface which is a surface of revolution around the axis of the nozzle. Such an exterior surface is preferred, at least for the portion of the nozzle which cooperates with the cap to form the air annulus through which air flows from the fifth chamber 24.
According to others of the improvements, all of the components of the gun are composed of aluminum or of an aluminum alloy; all of the surfaces of the components of the gun are hard coat anodized; and all of the hard coat anodized surfaces of the components of the gun are impregnated with teflon.
The invention is also an improvement to such a spray gun where the body additionally has a structurally integral, downwardly extending handle at its rear end, is one where the trigger is pinned to the body adjacent the lower surface thereof below the first chamber and forward of the gun handle.
According to another improvement, there are bearing shafts that are structurally integral with the needle and extend therefrom in opposite directions in a plane that is perpendicular to the axis of the needle, there is a bearing with a rolling bearing surface mounted on each of said bearing shafts, and the trigger has a concave contact surface on which the bearing surfaces of the bearings roll as the needle is withdrawn from and returned to its position where it prevents the flow of fluid from the nozzle.
The invention is also a longitudinally extending fluid nozzle for a spray gun which has a fluid inlet end that is threaded for engagement with the fluid cavity of a spray gun body, a fluid outlet end, an interior passage extending from the inlet end through the outlet end, and an exterior surface between the inlet end and the outlet end having a central portion that is a surface of revolution about an axis of the nozzle. The surface of revolution has first and second radially enlarged flanges separated from one another longitudinally of the nozzle, the first of the flanges being nearer the inlet end of the nozzle and having a smaller diameter than the second of the flanges which is nearer the outlet end. There are a plurality of bores extending through both of the flanges, the axes of the bores in each flange being substantially equidistant from the axis of the nozzle, and the axes of the bores through the second of the flanges being farther from the axis of the nozzle than are the axes of the bores through the first of the flanges. The bores in the first flange constitute pressure reduction orifices which are calibrated to reduce the pressure of air passing therethrough to that required for atomization, under HVLP conditions, of a fluid stream flowing, out of the nozzle. A preferred nozzle as described in the previous sentence is one wherein the exterior surface of the nozzle, adjacent the outlet end, is a surface of revolution which has such a uniform taper such that the exterior diameter of the nozzle is substantially equal to the interior diameter thereof at the discharge end.
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An improved HVLP spray gun which operates from an air supply source and an improved nozzle therefor are disclosed. The HVLP gun has a fluid nozzle including a first, integral, laterally extending portion including pressure reduction orifices which are calibrated, relative to a fluid passage in the nozzle, so that the spray gun operates as an HVLP spray gun. The fluid nozzle includes a second laterally extending portion including a surface, against which atomization air impinges after exiting the calibrated pressure reduction orifices, and a plurality of longitudinally extending air distribution holes, wherein atomization air, after passing through the calibrated pressure reduction orifices, is directed radially outwardly in an expansion chamber where the low velocity air is pressure equalized before exiting through the air distribution holes and being directed within the air cap inwardly toward a fluid atomizing annulus. An improved air driven HVLP paint spray gun which is especially lightweight and can be used to spray all types of coating materials including corrosive waterborne paints is also disclosed. A spray gun having a reduced trigger force needed to activate the gun is also disclosed. It is preferred that the leading edge of the fluid tip is doubly tapered so as to introduce the pressurized air directly onto the exiting fluid stream, which produces finer atomization with lower air volume consumption.
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This application is a continuation of application Ser. No. 07/172,239 filed on Mar. 23, 1988, now abandoned.
BACKGROUND OF THE INVENTION
The α-(1-methylethyl)-3,4-dimethoxybenzeneacetonitrile is an intermediate useful in the preparation of a drug having coronodilator activity, internationally known as verapamil (INN), described in U.S. Pat. No. 3,261,859.
The synthesis of the α-(1-methylethyl)-3,4-dimethoxybenzeneacetonitrile has been described in many patents such a U.S. Pat. Nos. 3,415,866, 3,997,608 and 4,593,042, Canadian Patent 986946, Unexamined Japanese Patent Publication No. 78092732, European Publication No. 0165322 and Hungarian Patent HUT 032064.
The primary method, described in the Canadian and Hungarian Patents, in U.S. Pat. No. 4,593,042 and in the Unexamined Japanese Publication, consists in the alkylation of the homoveratronitrile by means of an isopropyl halide, in the presence of many kinds of alkaline agents and in different solvents. In U.S. Pat. Nos. 3,415,866 and 3,997,608, homoveratronitrile is reacted with acetone in the presence of sodium ethoxide and the resulting isopropylidene derivative is catalytically hydrogenated. Finally, in the above mentioned European Publication, the nitrile is obtained by reacting the α-(1-methylethyl)-benzylchloride with sodium cyanide.
DESCRIPTION OF THE INVENTION
An object of the present invention is a new method for the synthesis of the α-(1-methylethyl)-3,4-dimethoxybenzeneacetonitrile of formula (I): ##STR3## starting from the isobutyryl-3,4-dimethoxybenzene of formula (II): ##STR4## which undergoes the Darzens condensation with an alkyl ester of an α-haloacetic acid, in the presence of an alkoxide of an alkali metal or of sodium amide or sodium hydride, to give an α,β-epoxyester of formula (III): ##STR5## wherein R represents a straight or branched alkyl radical, containing from 1 to 6 carbon atoms, which, by alkaline hydrolysis, gives the alkali salt of the epoxyacid of formula (IV): ##STR6## wherein Me + corresponds to a cation of an alkali metal, preferably sodium or potassium, which, by decarboxylation, gives the α-(1-methylethyl)-3,4-dimethoxybenzeneacetaldehyde of formula (V): ##STR7## which, by treatment with hydroxylamine, gives the corresponding oxime of formula (VI): ##STR8## which is dehydrated, for instance in the presence of acetic anhydride and optionally of potassium acetate, to give the desired α-(1-methylethyl)-3,4-dimethoxybenzeneacetonitrile of formula I.
The process object of the present invention can be carried out without isolating and characterizing the various intermediates of the foregoing formulae; however, if it is desired, the various steps of this process can also be carried out separately, by isolating and characterizing the relevant intermediates.
The intermediates of formulae III, V and VI are new and therefore they constitute a further object of the present invention.
The process object of the present invention consists in reacting a molar equivalent of isobutyryl-3,4-dimethoxybenzene of formula (II): ##STR9## with from about 0.5 to about 5 molar equivalents of an α-haloester of formula (VII):
X--CH.sub.2 --COOR
wherein X represents a halogen atom, preferably a chlorine atom and R represents an alkyl radical, straight or branched, containing from 1 to 6 carbon atoms, preferably methyl, ethyl or 2-butyl, in the presence of from about 0.5 to about 5 molar equivalents of a base selected from an alkoxide of an alkali metal of formula (VIII):
R.sub.1 O.sup.- Me.sup.+
wherein Me + represents the cation of an alkali metal, preferably sodium or potassium, and R 1 represents an alkyl radical, straight or branched, containing from 1 to 6 carbon atoms, sodium amide or sodium hydride. The preferably used bases are sodium methoxide, potassium tert-butoxide, sodium 2-butoxide and potassium 2-butoxide. The reaction takes place in a period of time comprised from about 1 to about 24 hours at a temperature comprised from about -25° C. to the boiling temperature of the reaction mixture. The reaction can be carried out with or without solvents. Suitable solvents are the aromatic hydrocarbons, preferably toluene, and the alcohols, straight or branched, containing from 1 to 6 carbon atoms, or their mixtures.
The glycidic ester of formula (III): ##STR10## which forms during the reaction, wherein R has the above meaning, generally is not isolated but it is transformed into the alkali salt of the epoxyacid of formula (IV): ##STR11## wherein Me + corresponds to a cation of an alkali metal, preferably sodium or potassium, by means of an alkaline hydrolysis carried out by treating the solution containing the epoxyester of formula III with an alkali or an alkaline-earth base, preferably sodium or potassium hydroxide, for a period of time comprised from about 1 to about 12 hours at a temperature comprised from about 0° C. to the boiling temperature of the reaction mixture.
The salt of the epoxyacid of formula IV is then decarboxylated at a temperature comprised from about 20° C. to the boiling temperature of the reaction mixture for a period of time comprised from about 1 to about 16 hours. In this way the α-(1-methylethyl)-3,4-dimethoxybenzeneacetaldehyde of formula (V): ##STR12## is obtained. By treating the aldehyde of formula V with a molar equivalent of hydroxylamine hydrochloride, at a temperature comprised from about 0° C. to the boiling temperature of the reaction mixture for a period of time comprised from about 0.5 to about 16 hours, the corresponding oxime of formula (VI): ##STR13## is obtained.
The desired nitrile of formula I is obtained by dehydrating the oxime of formula VI.
According to a preferred method, a molar equivalent of oxime of formula VI, optionally dissolved in a solvent selected among acetic acid, toluene, 2-butanol, acetonitrile and dimethylformamide, preferably in acetic acid, is reacted with from about 1 to about 4 molar equivalents of acetic anhydride optionally in the presence of from about 0.1 to about 2 molar equivalents of sodium acetate at a temperature comprised from about 20° C. to the boiling temperature of the reaction mixture for a period of time comprised from about 1 to about 48 hours, giving the α-(1-methylethyl)-3,4-dimethoxybenzeneacetonitrile of formula (I): ##STR14## pure enough to be used without any further purification for the synthesis of the verapamil. However the nitrile can further be purified by distillation under vacuum or by crystallization.
In a preferred aspect of the invention, the α-(1-methylethyl)-3,4-dimethoxybenzeneacetaldehyde of formula V is not isolated from the reaction medium because, as it forms by decarboxylation of the salt of the epoxyacid of formula IV, it is reacted with hydroxylamine hydrochloride, thus directly transforming itself into the oxime of formula VI which is extracted from the reaction medium by means of an organic solvent, preferably toluene.
The 1 H-NMR spectra of the products of formulae III, V and VI, which are to be new and that therefore constitute a further object of the present invention, have been carried out in CDCl 3 with a Bruker CXP 300 spectrometer, by using tetramethylsilane as reference substance. The symbols used have the following meaning: d=doublet; m=multiplet; q=quartet; s=singlet; t=triplet.
The examples below reported constitute an explanation of the present invention but are not to be considered as a limitation thereof.
EXAMPLE 1
3-(3,4-Dimethoxyphenyl)-3-(1-methylethyl)-oxiranecarboxylic acid, 2-butyl ester
31.2 Grams (0.15 moles) of isobutyryl-3,4-dimethoxybenzene are diluted with 150 ml of toluene, the solution is cooled to +5° C. and added with 42 g (0.375 moles) of potassium tert-butoxide. 53 Ml (0.375 moles) of 2-butyl chloroacetate are added in one hour to the reaction mixture while keeping it under stirring at the temperature of +10° C. for another 30 minutes. Then the reaction mixture is added with 200 ml of water and the two layers are separated. The aqueous phase is extracted with 50 ml of toluene and then is discarded, while the organic phases are collected together, washed three times with 100 ml of water, dehydrated on anhydrous sodium sulphate and lastly filtered on decolourizing earth. The filtrate is evaporated to dryness under vacuum to completely eliminate the solvent. The obtained oily residue is dissolved in 110 ml of hexane and left to crystallize at low temperature. The obtained precipitate is filtered and washed on the filter with cold hexane. The product is crystallized again from hexane thus obtaining 24 g of the 2-butyl ester of the 3-(3,4-dimethoxyphenyl)-3-(1-methylethyl) oxiranecarboxylic acid with a yield of 49.6%.
This product has m.p.=36° C.÷38° C. and its 1 H-NMR spectrum presents characteristic resonance peaks to the following δ (expressed as p.p.m.): 0.6÷0.76 (m, 4H); 1 (m, 7H); 1.24÷1.40 (m, 3H); 1.97 (m, 1H); 3.66 (s, 1H); 3.86 (d, 6H); 4.63 (m, 1H); 6.82 (m, 3H).
EXAMPLE 2
α-(1-Methylethyl)-3,4-dimethoxybenzeneacetaldheyde
62.46 Grams (0.30 moles) of isobutyryl-3,4-dimethoxybenzene are dissolved in 300 ml of toluene, then the solution is cooled to +5° C. and added with 84 g (0.75 moles) of potassium tert-butoxide under nitrogen atmosphere. 104.6 Ml (0.75 moles) of 2-butyl chloroacetate are added to the reaction mixture during one hour while keeping the temperature between +5° C. and +10° C. 200 Ml of water are added after 4 hours stirring at room temperature, the aqueous phase is discarded while the organic phase is washed four times with 100 ml of water. The organic layer is then added in about one hour with a solution containing 51.3 g of 90% potassium hydroxide (0.80 moles) in 210 ml of methanol and the whole is kept under stirring for 3 hours at a temperature of about 30° C. After 210 ml of water are added, the phases are separated and the organic layer is extracted again with 50 ml of water and then is discarded. The aqueous phases are collected together and acidified to pH 4 by means of 32% (w/w) aqueous hydrochloric acid and the reaction mixture is heated to about 65° C. for 2 hours under stirring. After cooling to room temperature, the reaction mixture is brought to pH 9 by means of a 30% (w/w) aqueous solution of sodium hydroxide and is extracted first with 200 ml and then with 50 ml of toluene. The organic phases are collected together, washed with 100 ml of water, dried over anhydrous sodium sulphate, filtered and evaporated to dryness under vacuum.
The obtained oily residue is purified by treating it with n-hexane, obtaining 51 g of pure aldehyde, having m.p.=52° C.÷54° C., with a yield of 76.5% of the theoretical.
1 H-NMR Spectrum: characteristic resonance peaks are observed at the following δ (expressed as p.p.m.): 0.8 (d, 3H); 1.0 (d, 3H); 2.4 (m, 1H); 3.1 (q, 1H); 3.9 (s, 6H); 6.6 (d, 1H); 6.7 (q, 1H); 6.9 (d, 1H); 9.7 (d, 1H).
EXAMPLE 3
α-(1-Methylethyl)-3,4-dimethoxybenzeneacetaldoxime
44.44 Grams (0.02 moles) of α-(1-methylethyl)-3,4-dimethoxybenzeneacetaldehyde prepared in example 2 are dissolved in 180 ml of methanol, then 17.64 g (0.21 moles) of sodium bicarbonate are added and, finally, 14.60 g (0.21 moles) of hydroxylamine hydrochloride are added portionwise in 30 minutes. After stirring for an additional 30 minutes, 150 ml of toluene and 150 ml of water are added and the layers are separated. The aqueous phase is discarded. The toluene phases are collected together, washed with 50 ml of water, dried over anhydrous sodium sulphate, filtered and evaporated to dryness under vacuum. The oily residue is purified by treatment with heptane obtaining 43.40 g of oxime with a yield of 91.4%. An oxime sample crystallized three times from tetrachloroethylene, shows m.p.=89° C.÷91° C. and a 1 H-NMR spectrum showing characteristic resonance peaks at the following δ (expressed as p.p.m.): 0.8 (d, 3H); 1.01 (d, 3H); 2.07 (m, 1H); 3.04 (t, 1H); 3.87 (2s, 6H); 6.76 (m, 3H); 7.54 (d, 1H).
EXAMPLE 4
α-(1-Methylethyl)-3,4-dimethoxybenzeneacetaldoxime
A suspension containing 37.4 g (0.33 moles) of potassium 2-butoxide in 50 ml of toluene is added with 20.8 g (0.10 moles) of isobutyryl-3,4-dimethoxybenzene and then 51 ml (0.36 moles) of 2-butyl chloroacetate are added in about one hour while keeping the temperature between 20° C. and 30° C.
After another hour of stirring at room temperature, a solution of 25.5 g of 90% potassium hydroxide (0.41 moles) in 105 ml of methanol is added and then the reaction mixture is kept 3 hours under stirring at room temperature. The reaction mixture is then added with 150 ml of water and the two layers are separated. The aqueous phase is twice washed with 50 ml of toluene while the organic phases are collected together, extracted with 50 ml of water and lastly discarded. The aqueous phases are collected together, added with 15 ml of acetic acid, heated to 65° C. and added with 6.95 g (0.10 moles) of hydroxylamine hydrochloride dissolved in 20 ml of water, in 30 minutes. After 1 hour at 65° C., the pH is brought to 4 by means of concentrated aqueous hydrochloric acid and the reaction mixture is kept under stirring for another hour. After cooling to room temperature, the reaction mixture is brought to pH 9 by means of a 30% (w/w) aqueous solution of sodium hydroxide and extracted three times with 50 ml of toluene each time. The toluene extracts containing the oxime are collected together, washed with 50 ml of water, dried over anhydrous sodium sulphate, filtered and evaporated to dryness under vacuum. By treating the oily residue with heptane, 21.6 g of oxime are obtained with a yield of 91% of the theoretical.
EXAMPLE 5
α-(1-Methylethyl)-3,4-dimethoxybenzeneacetonitrile
69.2 Grams (0.29 moles) of α-(1-methylethyl)-3,4-dimethoxybeneacetaldoxime are dissolved in 150 ml of glacial acetic acid and then are added with 38.8 ml (0.41 moles) of acetic anhydride.
An exothermic reaction takes place and, after the temperature has lowered to the room value, 24 g (0.29 moles) of anhydrous sodium acetate are added and the reaction mixture is heated at a temperature comprised between 80° C. and 85° C. for 5 hours. The reaction mixture is then evaporated under vacuum, the residue is treated with 200 ml of toluene and 150 ml of water and the resulting mixture is brought to pH 9 by means of a 30% (w/w) aqueous solution of sodium hydroxide. The layers are separated, the aqueous phase is twice extracted with 50 ml of toluene and then is discarded, the toluene phases are collected together, washed with 50 ml of water, dehydrated over anhydrous sodium sulphate and evaporated to dryness under vacuum obtaining an oily residue which is purified by distillation under vacuum; b.p. 2 mmHg 147° C.÷148° C.
57.2 Grams of pure nitrile, having m.p.=53° C.÷55° C., are obtained, with a yield of 90% of the theoretical.
EXAMPLE 6
α-(1-Methylethyl)-3,4-dimethoxybenzeneacetonitrile
26 Grams (0.125 moles) of isobutyryl-3,4-dimethoxybenzene are put into 100 ml of toluene and then 35 g (0.31 moles) of potassium tert-butoxide are added. After cooling to -10° C., the reaction mixture is added with 33.3 ml (0.31 moles) of ethyl chloroacetate in about two hours. Subsequently the temperature is raised to the value of the room temperature and after another two hours the reaction mixture is added with a solution containing 22 g (0.35 moles) of 90% potassium hydroxide in 100 ml of methanol and is kept under stirring for 6 hours. The reaction mixture is then added with 10 ml of acetic acid, and subsequently with 8.68 g (0.125 moles) of hydroxylamine hydrochloride dissolved in 20 ml of water. The reaction mixture is heated to 60° C. for one hour, then it is acidified to pH 4 by means of concentrated aqueous hydrochloric acid, kept another hour at 60° C. and finally added with water until complete dissolution of the undissolved salts. The layers are separated, the aqueous phase is extracted three times with 50 ml of toluene and then is discarded. The organic phase, together with the toluene extracts, is washed with water, dried over anhydrous sodium sulphate and evaporated to dryness. The oily residue is dissolved in 80 ml of glacial acetic acid and added, under nitrogen atmosphere, with 19.5 ml (0.20 moles) of acetic anhydride. After about 30 minutes the reaction mixture is added with 10 g (0.122 moles) of anhydrous sodium acetate and is heated to 75° C. for 6 hours. The acetic acid is evaporated under vacuum and the residue is treated with a mixture of 100 ml of water and 100 ml of toluene. The mixture is brought to pH 9 by means of a 30% (w/w) aqueous solution of sodium hydroxide, then the layers are separated and the aqueous phase is twice extracted with 75 ml of toluene and then is discarded.
The organic phase is added with the toluene extracts and then is twice washed with 100 ml of water, dried over anhydrous sodium sulphate, filtered and evaporated to dryness under vacuum. The obtained oily residue is distilled under vacuum obtaining 22.3 g of pure nitrile with a yield of 81.4% of the theoretical.
EXAMPLE 7
α-(1-Methylethyl)-3,4-dimethoxybenzeneacetonitrile
24.3 Grams (0.45 moles) of sodium methoxide are added portionwise, in a period of time of one hour, to a mixture of 20.82 g (0.10 moles) of isobutyryl-3,4-dimethoxybenzene and of 48 ml (0.45 moles) of ethyl chloroacetate, while keeping the temperature at about 65° C. The reaction mixture is kept at this temperature for another 2 hours, then it is cooled to room temperature and it is diluted with 50 ml of toluene and 100 ml of water. The layers are separated, the aqueous phase is discarded while the organic phase is washed with 50 ml of water and then is added with a solution containing 30.8 g (0.49 moles) of 90% potassium hydroxide in 150 ml of methanol. After stirring 3 hours at 30° C., the reaction mixture is cooled to 10° C. and diluted with 50 ml of water. The layers are separated, the organic phase is discarded while the aqueous phase is added with 5 ml of acetic acid, heated to 60° C. and added in 30 minutes with 6.25 g (0.09 moles) of hydroxylamine hydrochloride dissolved in 15 ml of water and then with concentrated aqueous hydrochloric acid till pH 6.5. After one hour at 65° C., the pH is brought to 4 with concentrated aqueous hydrochloric acid and the reaction mixture is heated for an additional 2 hours. After cooling to room temperature, the reaction mixture is diluted with 50 ml of toluene, the layers are separated and the aqueous phase is extracted three times with 20 ml of toluene and then is discarded. The organic phase is collected together with the three toluene extracts and then it is washed with 50 ml of water, dried over anhydrous sodium sulphate, filtered and evaporated under vacuum. The oily residue is dissolved in 40 ml of glacial acetic acid and the solution is added portionwise with 9.75 ml (0.10 moles) of acetic anhydride and, after 30 minutes, with 6.5 g (0.08 moles) of anhydrous sodium acetate. The reaction mixture is heated to 80° C. for 6 hours and then the solvent is eliminated under vacuum. The oily residue is treated with 75 ml of water and 75 ml of toluene and the mixture is brought to pH 9.0 by means of a 30% (w/w) aqueous solution of sodium hydroxide. The layers are separated, the aqueous phase is twice extracted with 25 ml of toluene and is then discarded. The organic phase is collected together with the toluene extracts, washed with 50 ml of water, dried over anhydrous sodium sulphate, filtered and evaporated under vacuum.
The obtained oily residue is distilled under vacuum at 2 mm of mercury giving 14.4 g of pure nitrile with a yield of 65.6% of the theoretical.
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New process for the synthesis of the α-(1-m.ethylethyl)-3,4-dimethoxyacetonitrile of formula (I): ##STR1## which is known as an intermediate in the synthesis of the drug internationally known as verapamil. The process starts from the isobutyryl-3,4-dimethoxybenzene of formula (II): ##STR2## which, by means of the Darzens condensation, gives an epoxyester which, by alkaline hydrolysis and subsequent decarboxylation, gives the α-(1-methylethyl)-3,4-dimethoxybenzeneacetaldehyde. This product is reacted with hydroxylamine to obtain the corresponding oxime that, by dehydration, gives the nitrile of formula I.
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REFERENCE TO RELATED APPLICATIONS
This is a continuation-in-part of application Ser. No. 09/388,494, filed Sep. 2, 1999, now abandoned entitled “Atomizing Apparatus & Process”, which was a divisional application of parent patent application Ser. No. 08/751,970, filed Nov. 19, 1996, now U.S. Pat No. 5,993,509, issued Nov 30, 1999. The aforementioned application(s) are hereby incorporated herein by reference.
FIELD OF THE INVENTION
This invention relates to a method and apparatus for atomizing a liquid stream of metal or metal alloy. This invention relates to producing powders as well as to spray deposition process.
DESCRIPTION OF RELATED ART
For both powder production and spray deposition process, there are traditionally two kinds of atomization devices for atomizing a liquid stream of metal or metal alloys coming out of the liquid delivery nozzle into a spray of droplets. One is the “Free Fall” type of design, in which the stream of metal or metal alloy is atomized at a certain distance away from the exit of the liquid delivery nozzle. The other design is the “Confined” type of design, in which the stream of metal or metal alloy is atomized at the exit of the liquid delivery nozzle. The Confined type of atomization device gives more efficient and uniform transfer of energy from atomization gas to the stream of metal or metal alloy, due to the shorter distance between the atomization gas and the stream of metal or metal alloy and prefilming of the molten metal or metal alloy over the end of the liquid delivery nozzle. However, since the impingement point of the atomization gas is close to the exit of the liquid delivery nozzle, the molten metal or metal alloy is easier to freeze-up inside the liquid delivery nozzle, which blocks further atomization. The Free-Fall type atomization device doesn't have the freeze-up problem; however, the atomization efficiency is reduced compared to the Confined type of atomization device, resulting in coarser atomized powder and coarser microstructures due to a lower cooling rate.
During atomizing, a backpressure is created by the impingement of the atomization gas jets around the atomization zone below the exit of the liquid deliver nozzle. The backpressure has two effects. One effect is generating backsplash during atomization, in which molten metal or metal alloy is backsplashed upwards away from the atomization zone. The backsplashed molten metal or metal alloy may either deposit back onto the atomization device and block further atomization, or become coarse and irregular shaped powders, which may not be desired. Another effect is influencing the atomization rate, or the flow rate of the metal or metal alloy stream coming out of the liquid delivery nozzle. In the extreme, a complete blockage of the metal or metal alloy stream from coming out of the liquid delivery nozzle is likely to happen due to the backpressure. The present invention provides a method of atomizing and an atomizing apparatus to control the backpressure.
During atomizing, the intensities and directions of the atomization gas jets affect the atomization characteristics, such as atomization efficiency, atomization rate, the cooling rate of atomized droplets, trajectories and velocities of atomized droplets, shapes and sizes of atomized droplets, the spatial flux distribution of atomized droplets, etc. The intensities of the atomization gas jets are manipulated through controlling the pressure and/or flow rate of the atomization gas. However, the directions of the atomization gas jets are fixed by the design of the atomization device. In U.S. Pat. No. 4,779,802, and U.S. Pat. No. 4,905,899, the atomization device is scanned to control the directions of the atomization gas jets. The present invention provides a method of atomizing and an atomizing apparatus to control both the intensities and directions of the atomization gas jets.
SUMMARY OF THE INVENTION
One aspect of the present invention is to control the created backpressure, which, in turn, controls the backsplash and the atomization rate, or the flow rate of the metal or metal alloy stream coming out of the liquid delivery nozzle. Another aspect of the present invention is to control the atomization characteristics by controlling the intensities and directions of the atomization gas jets, which, in turn, controls the droplet characteristics, such as the variations of size, shape, temperature, heat content and microstructure of droplets, etc., and/or powder characteristics, such as powder size distribution, the powder shape distribution, the microstructure variations of powders, etc., and/or spray-deposit characteristics, such as the morphology, macrostructures and microstructures of the deposit, etc.
According to one aspect of the present invention there is provided a method of atomizing a liquid stream of metal or metal alloy consisting of the steps of:
teeming a stream of molten metal or metal alloy into an atomization device,
atomizing the stream with atomization gas to form droplets of metal or metal alloy, and
directing controlling fluid at an atomization gas jets or at atomization zone to control the backpressure and, if desired, the intensities and directions of the atomization gas jets.
Preferably the atomization gas issues from first jets, and the controlling fluid issues from second jets directed at the atomization gas jets or at the atomization zone. The intensity, flow rate and pressure of the secondary jets are preset to control or are in-situ adjusted to in-situ control the backpressure and/or the intensities and directions of the atomization gas jets. The method may be for the production of powder to control the powder characteristics. Alternatively, the method may be for the production of spray deposits to control the deposit characteristics. Alternatively, the secondary jets may be so arranged, through which solid particles or whiskers of the same or different composition (either metallic or non-metallic) of the metal to be atomized are introduced into the controlling fluid which acts as a transport vehicle for the particles or whiskers to be co-deposited with the atomized droplets to form spray-deposited composite materials. Alternatively, the particles or whiskers are introduced from above the secondary jets, which also gives a mixture of the particles or whiskers with the spray to form spray-deposited composite materials. Suitably, the controlling fluid is an inert gas, such as Argon, Helium and Nitrogen, or air. Alternatively, the controlling fluid may be cryogenic liquefied gas which changes to a gaseous phase upon heating by the metal or metal alloy stream. The atomization gas is suitably an inert gas, such as Argon, Helium and Nitrogen, or Air. The selection of gases is made in accordance with the compatibility with the liquid metal or metal alloy to be atomized.
According to another aspect of the invention there is provided an atomizing apparatus consisting of an atomization device for receiving a stream of molten metal or metal alloy to be atomized, means for directing atomization gas at the liquid stream to atomize the stream, and means for directing controlling fluid at atomization gas jets or at an atomization zone to control the backpressure and/or the atomization characteristics. In the preferred arrangement, the means for directing the atomization gas consists of primary jets and the means for directing the controlling fluid consists of secondary jets directed at the atomization gas jets or at the atomization zone. The intensity, flow rate and pressure of the secondary jets are preset to control or are in-situ adjusted to in-situ control the backpressure and/or the intensities and directions of the atomization gas jets. Suitably, the controlling fluid is an inert gas, such as Argon, Helium and Nitrogen, or air. Alternatively, the controlling fluid may be cryogenic liquefied gas which changes to a gaseous phase upon heating by the metal or metal alloy stream. The atomization gas is suitably an inert gas, such as Argon, Helium and Nitrogen, or air. The selection of gases is made in accordance with the compatibility with the liquid metal or metal alloy to be atomized.
Alternatively, the apparatus may be used to produce spray deposits on a suitable collector.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a schematic sectional side elevation of a gas atomizing apparatus according to the invention.
FIG. 2 is a schematic side elevation of apparatus for producing powders including the atomizing apparatus according to the invention together with an alternative base arrangement.
FIG. 3 is a Process Map of P u vs. P 1 for R=15 mm for water atomization.
FIG. 4 is a Process Map of P u vs. P 1 for R=20 mm for water atomization.
FIG. 5 is a Process Map of P u vs. P 1 for R=25 mm for water atomization.
FIG. 6 shows the atomization phenomena for region A in the Process Map of P u vs. P 1 .
FIG. 7 shows the atomization phenomena for region B in the Process Map of P u vs. P 1 .
FIG. 8 shows the atomization phenomena for region C in the Process Map of P u vs. P 1 .
FIG. 9 shows the atomization phenomena for region D in the Process Map of P u vs. P 1 .
FIGS. 10 ( a ) through 10 ( i ) show the distributions of the powder sizes for each set of process parameters with the application of controlling fluid technique.
FIG. 11 shows the mass distribution of powders produced with the application of controlling fluid technique.
FIGS. 12 ( a ) through 12 ( g ) show the variations of the intensities and directions of the atomization gas jets as the pressure of the controlling fluid varies.
DETAILED DESCRIPTION OF THE INVENTION
In FIG. 1, an atomizing apparatus for gas atomizing liquid metal or alloy is shown consisting of a refractory or refractory lined crucible or tundish ( 1 ) for containing liquid metal or metal alloy ( 2 ). The crucible ( 1 ) has a liquid delivery nozzle ( 3 ) to provide a liquid metal or metal alloy stream ( 4 ) of a desired diameter. The liquid metal or metal alloy stream ( 4 ) teems into a central opening in a primary gas atomization device ( 5 ) which causes a number of atomization gas jets ( 6 ) to be directed at the liquid metal or metal alloy stream ( 4 ) so as to atomize the stream into a spray of atomized droplets ( 7 ). The primary atomization gas jets ( 6 ) preferably spray Nitrogen, Argon or Helium, but air may also be used. The atomizing assembly also consists of a secondary controlling fluid jets device ( 8 ), disposed upstream of the primary atomization gas jets ( 6 ), containing a number of controlling fluid jets ( 9 ) which apply Nitrogen, Argon, Helium, air, or cryogenic liquefied gas to the atomization gas jets ( 6 ) or to the atomization zone ( 10 ). The pressure and flow rate of the controlling fluid applied at the secondary controlling fluid jets device ( 8 ) is controlled to manipulate the backpressure and the atomization characteristics. The controlling can be made in-situ during atomizing.
The atomization characteristics, such as mass flux distribution, droplet size distribution and droplet velocity, can be detected by the sensors, such as Phase-Doppler Anemometry (PDA) ( 11 ), and be fed back to the central process unit, such as computer ( 12 ). The central process unit ( 12 ) then sends a command after calculation to actuate the position driver of primary gas atomization device ( 13 ) and/or position driver of secondary controlling fluid jets device ( 14 ) to in-situ control the relative positions among the primary atomization device ( 5 ), the secondary controlling fluid jets device ( 8 ), and/or the liquid delivery nozzle ( 3 ).
FIG. 2 shows the apparatus of FIG. 1 as applied to powder production apparatus. In this figure, the crucible/tundish metal dispensing system ( 15 ) with liquid metal ( 16 ), the gas atomization device ( 17 ) and the controlling fluid jets device ( 18 ) are positioned on a spray chamber ( 21 ). Atomization gas is supplied to the gas atomization device ( 17 ) via an inlet pipe ( 19 ), and controlling fluid is supplied to the controlling fluid jets device ( 18 ) via a separate inlet pipe ( 20 ). At the base of the spray chamber is a powder collection vessel ( 22 ), the chamber additionally containing a gas exhaust pipe ( 23 ). The flow rate of the controlling fluid applied at the secondary controlling fluid jets device ( 18 ) is controlled by activating the controlling fluid control valve ( 25 ) via a current to pneumatic pressure (P/I) converter ( 24 ). The controlling can be made in-situ during atomizing. The atomization characteristics, such as mass flux distribution, droplet size distribution, and droplet velocity, can be detected by the sensors, such as Phase-Doppler Anemometry (PDA) ( 26 ) and be fed back to the central process unit, such as computer ( 27 ). The central process unit ( 27 ) then sends a command after calculation to actuate the position driver of primary gas atomization device ( 28 ) and/or position driver of secondary controlling fluid jets device ( 31 ) to in-situ control the relative positions among the atomization device ( 5 ), the secondary controlling fluid jets device ( 8 ), and/or the liquid delivery nozzle ( 3 ). The horizontal and vertical movements of the primary atomization device ( 5 ) are controlled by one set of the horizontal actuator ( 29 ) and vertical actuator ( 30 ), respectively. The horizontal and vertical movements of the secondary controlling fluid jets device ( 8 ) are controlled by another set of the horizontal actuator ( 32 ) and vertical actuator ( 33 ), respectively.
During atomizing, the backpressure is controlled by the controlling fluid jets device, which controls the extent of the backsplash and the atomization rate, or the flow rate of the metal or metal alloy stream coming out of the liquid delivery nozzle. In addition, the intensities and directions of the atomization gas jets are controlled by the controlling fluid jets device, which controls the atomization characteristics. Consequently, the droplet characteristics, such as the variations of size, shape, temperature, heat content and microstructure of droplets, etc., and powder characteristics, such as powder size distribution, the powder shape distribution, the microstructure variations of powders, etc., are controlled. The pressure and/or flow rate of the controlling fluid are in-situ adjustable during atomizing to in-situ control the backpressure and/or the intensities and directions of the atomization gas jets.
EXAMPLE OF THE USE OF NITROGEN GAS AS THE CONTROLLING FLUID IN THE ATOMIZATION OF WATER
The example below illustrates the principles of selecting the process parameters by illustrating the conditions used for the atomization of water employing the controlling fluid technique. P u is the nitrogen gas pressure used for the controlling fluid jets device, P 1 is the nitrogen gas pressure used for the gas atomization device, and R is the vertical distance between the controlling fluid jets device and gas atomization device.
The principles of selection of R is discussed below for this example. When R>25 mm, the controlling fluid jets device was too far from the gas atomization device, so that when the controlling fluid became large enough to suppress the backpressure, the water was atomized by the controlling fluid also, which rendered the controlling fluid jets device meaningless. When R<5 mm. As a result, the R needed to be limited between 5 mm and 25 mm in this example.
The principles of selection of P u and P 1 is discussed below for this example. FIGS. 3, 4 , and 5 show the Process Maps of P u vs. P 1 for R=15, 20, and 25 mm, respectively. In the figures, each map is divided into Regions A, B, C, and D. The effects of the controlling fluid jets device on the atomization characteristics of water for each Region are shown schematically in FIGS. 6 to 9 , separately. In Region A, the controlling fluid jets are not able to suppress the backpressure completely. In Regions B and C, the backpressure is suppressed by the controlling fluid jets device; however, the water stream between the controlling fluid jets device and gas atomization device in Region C is more turbulent than that in Region B. Region D is the transition region between Region A and Regions B or C. In summary, Regions B and C are the regions suitable for water atomization in this example.
EXAMPLE OF THE USE OF NITROGEN GAS AS THE CONTROLLING FLUID
IN THE PRODUCTION OF Pb—Sn POWDERS
The example below illustrates the conditions used for the production of Pb-50 wt % Sn powders. Table 1 lists the process parameters used for the production of powders. P u is the nitrogen gas pressure used for the controlling fluid jets device, P 1 is the nitrogen gas pressure used for the gas atomization device, and R is the vertical distance between the controlling fluid jets device and gas atomization device.
TABLE 1
P 1
P u
R
Experimental No.
(Mpa)
(Mpa)
(mm)
A035
0.40
0.20
25
A036
0.30
0.30
25
A037
0.20
0.20
15
A038
0.30
0.20
20
A039
0.20
0.30
20
A040
0.40
0.40
20
A042
0.30
0.40
15
A043
0.40
0.30
15
A044
0.20
0.40
25
Table 2 lists the first and second peak values of the distribution of powder sizes. For the condition of P u =0, P 1 =0.30 MPa and R=20 mm, the backsplash created due to the backpressure was so severe that nearly no atomization took place, which resulted in no powder being produced. However, when the controlling fluid jets device was switched on and P u was set to be 0.20 MPa, the backpressure was so controlled that backsplash was eliminated and the powder was produced as illustrated by the A038 production. Using controlling fluid to control the backpressure is demonstrated.
TABLE 2
First Peak
Second Peak
Second Peak/
Experimental No.
μm
μm
First Peak
A035
177-250
53-74
0.36
A036
250-420
53-74
0.24
A037
250-420
88-105
0.31
A038
250-420
53-74
0.18
A039
250-420
53-74
0.17
A040
250-420
53-74
0.17
A042
177-250
53-74
0.34
A043
177-250
53-74
0.75
A044
250-420
53-74
0.29
FIG. 10 shows the distributions of the powder sizes for each set of process parameters. It is shown that the first and second peak values of the distribution of powder sizes are controllable by varying the pressure and position of the controlling fluid jets. FIG. 11 shows the mass distribution of powders are controllable by varying the pressure and position of the controlling fluid jets. Using controlling fluid to control the atomization characteristics is demonstrated.
FIG. 12 shows the variations of the intensities and directions of the atomization gas jets as P u varies. It is shown that the intensity of the atomization gas jets for P u =0.14 MPa is relatively small compared to that for P u =0.40 MPa, which gives a more scattered spray for the former. In addition, the direction of the atomization gas jets for P u =0.14 MPa is also different from that for P u =0.40 MPa, and the former has a larger included angle for the spray cone. Using controlling fluid to control the intensities and directions of the atomization gas jets is demonstrated.
A further application of the use of controlling fluid is in the production of spray deposits. In the production of spray deposits, liquid metal or metal alloy is atomized into a spray of droplets, which consists of a mixture of fully liquid, semi-solid/semi-liquid and solid particles. The resulting spray of metal droplets is directed onto an appropriate collector, where a preform is continuously deposited by these droplets. The process is essentially a rapid solidification technique with an integrated gas-atomizing/spray depositing operation. Deposits with different morphologies, such as tubes, billets, flat products, coated articles, etc., can be produced by manipulating the movement and shape of the collector, and by, in many situations, moving the spray itself. Such products can either be used directly or can be further processed normally by hot or cold working with or without the collector.
During atomizing, the backpressure is controlled by the controlling fluid jets device, which controls the extent of the backsplash and the atomization rate, or the flow rate of the metal or metal alloy stream coming out of the liquid delivery nozzle. In addition, the intensities and directions of the atomization gas jets are controlled by the controlling fluid jets device, which controls the atomization characteristics. Consequently, the droplet characteristics, such as the variations of size, shape, temperature, heat content and microstructure of droplets, etc., and spray-deposit characteristics, such as the morphology, macrostructures and microstructures of the deposit, etc., are controlled. The pressure and/or flow rate of the controlling fluid are in-situ adjustable during atomizing to in-situ control the backpressure and/or the intensities and directions of the atomization gas jets. Alternatively, the secondary controlling fluid jets may be so arranged, through which solid particles or whiskers of the same or different composition (either metallic or non-metallic) of the metal to be atomized are introduced into the controlling fluid which acts as a transport vehicle for the particles or whiskers to be co-deposited with the atomized droplets to form spray-deposited composite materials. Alternatively, the particles or whiskers are introduced from above the controlling fluid jets, which also gives a mixture of the particles or whiskers with the spray to form spray-deposited composite materials.
EXAMPLE OF THE USE OF NITROGEN GAS AS THE CONTROLLING FLUID IN THE PRODUCTION OF SPRAY-DEPOSITED PB-50%SN ALLOY PREFORMS
The example below illustrates the conditions used for the production of Pb-50%Sn spray-deposited preforms. Table 3 lists the atomization process parameters used to produce Pb-50% Sn powder employing the controlling fluid technique.
Example
Example
Process Parameter
Symbol
A
B
Metal Dispensing Temperature (° C.)
T spray
266
266
Metal Flow Rate (Kg/sec)
J melt
0.18
0.18
Atomization gas pressure (MPa)
P 1
0.30
0.30
Controlling fluid pressure
P u
0.00
0.20
Vertical distance between the
R
20
20
controlling fluid jets device
and gas atomization device (mm)
Spray Height (mm)
Z
600
600
Results
Process
Process
Failed
Succeeded
In Example A, only atomization gas was used in the conventional manner of production of spray-deposited preforms. However, since the backsplash created due to the backpressure was so severe that nearly no atomization took place, which resulted in no preform being produced. In Example B, controlling fluid of Nitrogen was introduced by the controlling fluid jets device above the main atomization gas jets. Otherwise, the atomizing was carried out under identical conditions to Example A. The backpressure was so controlled by the controlling fluid jets device that backsplash was eliminated and a spray-deposited preform was produced. Using controlling fluid to control the backpressure in the spray deposition process was demonstrated.
Accordingly, it is to be understood that the embodiments of the invention herein described are merely illustrative of the application of the principles of the invention. Reference herein to details of the illustrated embodiments is not intended to limit the scope of the claims, which themselves recite those features regarded as essential to the invention.
Reference Number of Elements In The Drawings
1
crucible or tundish
2
liquid metal or metal alloy
3
liquid delivery nozzle
4
liquid metal or metal alloy stream
5
primary gas atomization device
6
primary atomization gas jets
7
a spray of atomized droplets
8
a secondary controlling fluid jets
device
9
controlling fluid jets
10
atomization zone
11
sensors, such as Phase-Doppler
Anemometry (PDA)
12
central process unit, such as
computer
13
position driver of primary gas
atomization device
14
position driver of secondary
controlling fluid jets device
15
crucible/tundish metal dispensing
system
16
liquid metal
17
the gas atomization device
18
the secondary controlling fluid
jets device
19
inlet pipe
20
separate inlet pipe
21
a spray chamber
22
a powder collection vessel
23
a gas exhaust pipe
24
a current to pneumatic
pressure(P/I) converter
25
controlling fluid control valve
26
sensors, such as Phase-Doppler
Anemometry (PDA)
27
central process unit, such as
computer
28
position driver of primary gas
atomization device
29
horizontal actuator of primary
gas atomization device
30
vertical actuator of primary gas
atomization device
31
position driver of secondary
controlling fluid jets device
32
horizontal actuator of secondary
controlling fluid jets device
33
vertical actuator of secondary
controlling fluid jets device
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An atomizing apparatus for the production of powders or spray deposits, having an atomization device for receiving a liquid stream of molten metal or metal alloy to be atomized; at least two primary atomization gas jets for directing an atomization gas at an angle into the liquid stream in an atomization zone at an impinging point of the atomization jets to break the stream into atomized droplets; and at least two secondary jets for direction a controlling fluid at a pressure, flow rate and direction, the jets being aimed at the atomization gas jet or into the atomization zone, wherein said secondary jets control a backpressure generated by the primary atomization gas jets. The apparatus also includes means for in-situ controlling at least one of the relative positions among the primary atomization jets, the secondary jets, and the liquid delivery nozzle.
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CROSS-REFERENCE TO RELATED APPLICATION
This application is a continuation of U.S. patent application Ser. No. 11/358,790, filed Feb. 21, 2006, now U.S. Pat. No. 7,211,080, which is a continuation of U.S. patent application Ser. No. 10/436,910, filed May 13, 2003, now abandoned, which in turn is a continuation of U.S. patent application Ser. No. 09/374,563, filed Aug. 13, 1999, now U.S. Pat. No. 6,626,901, which in turn is a continuation-in-part of U.S. patent application Ser. No. 09/035,691, filed Mar. 5, 1998, now abandoned, which is based upon U.S. provisional patent application Ser. No. 60/038,589, filed Mar. 5, 1997, both of which are incorporated herein by reference.
FIELD OF THE INVENTION
The present invention relates generally to instruments and methods for sealing and joining or cutting tissue. The instruments of the present invention are especially intended for use during either conventional open surgery or endoscopic or laparoscopic surgery.
BACKGROUND OF THE INVENTION
Hemostasis, or blood clotting, can be obtained by the activation of a naturally occurring biological pathway known as the coagulation cascade. The pathway can be activated by tissue injury. This injury can come from mechanical, chemical or thermal sources. This natural biological pathway results in the conversion of freely flowing blood to a blood clot. Several biological elements are involved in the coagulation cascade, including tissue proteins, mainly fibrin and thrombin. Cells such as platelets and red and white blood cells are also involved.
During surgery, hemostasis can also be achieved by direct denaturization of the proteins found in the blood. Denaturization of a protein means that its characteristic three dimensional structure is altered without actually breaking up the protein. This direct denaturization is a purely physico-chemical process in which the denatured proteins bond together, forming an amorphous mass of protein which is comparable to a naturally occurring clot. How does denaturing a protein cause it to stick together with neighboring proteins? Proteins generally have a complex three-dimensional structure. A protein is actually a chain of smaller molecules called peptides, which peptides may have side-chains which contain a molecular group which can attract a molecular group on another side chain. The main protein chain is looped and folded on itself in a complex way which results in the three-dimensional structure characteristic of the protein. This looping and folding occurs because of an intra-molecular attraction between side-chains of the peptides. This attraction between side-chains is generally of the “hydrogen bond” or electrostatic type. The attraction which holds the peptides together along the main chain is a covalent bond. When a protein is denatured, it loses its normal three-dimensional structure. As a result of this unfolding of the protein molecule, the side-chains on the peptides, instead of facing “inward” to fold up the protein chain are now able to bond to side chains from proteins which are neighbors. This inter-molecular bonding results in the formation of a lump of denatured protein. This process is not dependent on the activation of the biological cascades of the natural clotting mechanism, but it is a purely physico-chemical process. For hemostasis, the tissue proteins which must be denatured are chiefly those in blood such as hemoglobin and albumin but also include structural proteins such as those found in the wall of blood vessels or in other anatomical structures.
One of the best ways to denature a protein is to heat it up to a temperature high enough to cause the intra-molecular hydrogen bonds to break, but which is not high enough to break the much stronger peptide-peptide covalent bonds along the main chain. A prime example of this process is the heating up of the clear part of an egg until it turns white. This white color means that the original clear protein has been denatured.
Heat which is delivered to tissue proteins may start out as electrical energy, light energy, radiowave energy, or mechanical (vibrational or frictional) energy. As far as the tissue is concerned, it does not matter what the original source of the original energy is, as long as it gets converted in some fashion to heat.
For example, if the source of the energy is a laser, then the light energy is absorbed by molecules in the tissue whose absorption spectrum matches the wavelength of the laser light being used. Once the light energy is absorbed, heat is produced, and the physico-chemical process of protein denaturation is achieved. Any sort of light energy will have this effect, if its wavelength is such that it can be absorbed by the tissue. This is general process is called photocoagulation. The advantage of using a laser is that since its output is monochromatic, one can selectively heat certain tissue elements which have the right absorption spectrum, while sparing other tissue elements for which the laser light is not absorbed. This principle is used commonly in ophthalmology. Another advantage of using a laser is that its coherent and collimated beam can be very tightly focused on very small targets. If one does not care about spatial precision or selective photocoagulation of only certain tissue elements, then it is perfectly possible to coagulate tissue by using a very bright but otherwise ordinary light.
If the source of energy is electrical currents flowing through the tissue, the process is called “electrosurgery”. What happens here is that the current flowing through the tissue heats up the tissue because the tissue has resistance to the flow of electricity (“Ohmic heating”). In the case of ultrasonic coagulation, the rapid vibration of the ultrasonic element induces heating in essentially the same fashion as the production of fire by rubbing sticks together (although the rate of vibration is much much higher and the process is more controllable).
Since it is heat that denatures and coagulates proteins, why go to all the trouble of starting with a laser or an electrosurgery unit? Why not just use a very simple source of heat, such as a resistance wire or, even simpler, a hot piece of metal? In antiquity, “cautery” via a hot piece of iron was used to staunch bleeding wounds. The problem with this approach is not efficacy, it is control and containment of the amount and extent of tissue which is cauterized or injured.
In fact, the development of “electrocautery” in the late 1920's by Professor of Physics William T. Bovie was spurred by the desire (of the pioneering neurosurgeon Dr. Harvey Cushing) to have a more controllable and refined means of producing heat in tissues than possible by using a large piece of heated metal. Electrocautery uses very high frequency alternating electrical current, since it was found that these high frequencies did not cause tetanic (“Galvanic”) stimulation of muscle tissue which occurs when direct current or low frequency current is used. To avoid muscular stimulation, it is necessary to use alternating currents with very high frequencies, about several hundred thousand cycles-per-second. This high frequency falls in the range of the AM radio band, which is the reason why many electrical instruments such as monitors used in the OR will register interference when electrocautery is activated. There are many potential problems stemming from the use of such high frequencies, including difficulty in controlling stray currents which can injure patients and interfere with pacemakers and computer equipment. Electrocautery has been refined over the past fifty years, but it still represents a rather round-about way of getting tissue to heat up.
Numerous instruments are known which coagulate, seal, join, or cut tissue.
For example, there are electrosurgical instruments, both monopolar and bipolar, which use high frequency electrical current that passes through the tissue to be coagulated. The current passing through the tissue causes the tissue to be heated, resulting in coagulation of tissue proteins. In the monopolar variety of these instruments, the current leaves the electrode and after passing through the tissue, returns to the generator by means of a “ground plate” which is attached or connected to a distant part of the patient's body. In a bipolar version of such an electro-surgical instrument, the electric current passes between two electrodes with the tissue being placed or held between the two electrodes as in the “Kleppinger bipolar forceps” used for occlusion of Fallopian tubes.
There are many examples of such monopolar and bipolar instruments commercially available today from companies including Valley Lab, Cabot, Meditron, Wolf, Storz and others worldwide. A new development in this area is the “Tripolar” instrument marketed by Cabot and Circon-ACMI which incorporates a mechanical cutting element in addition to monopolar coagulating electrodes.
With regard to known ultrasonic instruments, a very high frequency (ultrasonic) vibrating element or rod is held in contact with the tissue. The rapid vibrations cause the proteins in the tissue to become coagulated. The ultrasonic instrument also employs a means for grasping the tissue while the proteins are being coagulated.
Olympus markets a heater probe instrument which uses an electrical heating wire contained in a catheter type flexible probe meant to be passed through a flexible endoscope. It is used to coagulate small bleeding vessels found on the inside of the gastrointestinal tract or the bleeding vessels found in peptic or other sorts of gastrointestinal ulcerations. In this instrument, no electrical current passes through the tissues, as is the case for monopolar or bipolar cautery. This instrument would certainly not be suitable for use in laparoscopic or open surgery in which large amounts tissue must be not only coagulated but also divided.
There are a number of relevant patents:
Pignolet, U.S. Pat. No. 702,472, discloses a tissue clamping forceps with jaws wherein one has a resistance for heating the jaw, and a battery to power the heater. The coagulated tissue caused by the heat and pressure is subsequently severed along the edges of the jaws before they are opened;
Downes, U.S. Pat. No. 728,883, teaches an electrothermic instrument is having opposing jaw members and handle means for actuating the jaws. A resistance member is installed in the jaw member, which is closed to direct contact by a plate. This instrument coagulates tissue by heat, not electrical current, applied to the tissue;
Naylor, U.S. Pat. No. 3,613,682, discloses a disposable battery-powered cautery instrument;
Hiltebrandt et al., U.S. Pat. No. 4,031,898, concerns a coagulator with jaw members, one of which contains a resistance coil. This instrument has a timer mechanism for controlling the heating element. The heating element is used directly as a temperature sensor;
Harris, U.S. Pat. No. 4,196,734, teaches a instrument that can effect both electrosurgery and cautery. A thermistor temperature-sensing element monitors a heating loop and regulates the current and thereby the temperature;
Staub, U.S. Pat. No. 4,359,052, relates to a cautery instrument with removable, battery-powered cautery heating tip;
Huffman, U.S. Pat. No. 5,276,306, discloses a pistol-grip, hand-held heating instrument having a trigger mechanism for the battery;
Anderson, U.S. Pat. No. 5,336,221, teaches an optical thermal clamping instrument for welding or fusing tissue, and employing a cutting blade for separating the fused tissue;
Stern et al., U.S. Pat. No. 5,443,463, discloses clamping jaw members that are bifurcated by a cutting blade, having plural electrodes and temperature sensors, and can function as monopolar or bipolar; and
Rydell, et al., U.S. Pat. No. 5,445,638, relates to a bipolar coagulation and cutting instrument.
While each of the above mentioned references is relevant to the invention herein, none teaches or suggests the totality of the invention taught and claimed here.
OBJECTS OF THE INVENTION
It is an object of the present invention to provide a instrument for sealing, cutting, or sealing and cutting tissue.
It is also an object of the present invention to provide a instrument for sealing and joining tissue.
It is another object of the present invention to provide a portable instrument which does not require an external power source.
It is a further object of the present invention to provide a instrument which can be constructed to conform to the requirements of laparoscopic and endoscopic surgery, i.e., to be long and very narrow, in the range of a few millimeters in diameter or even narrower.
It is still another object of the present invention to provide for a method for carrying out surgical procedures using the instrument of the present invention.
It is a still further object of the invention to provide a method and apparatus for optimal heating and optimal pressure to optimize tissue seal strength and to minimize collateral damage to tissue.
These and other objects of the invention will become apparent to one skilled in the art from the following more detailed disclosure of the invention.
SUMMARY OF THE INVENTION
According to the invention, there are three parameters that are independently controlled—the temperature to which tissue is heated, the pressure which is applied, and the time over which the temperature and pressure are maintained. The total heat applied to the tissue is a function of the temperature and the time. A key feature is the combined (simultaneous, partially simultaneous, or sequential) application of pressure and heat to the tissue being coagulated for a specified amount of time, which induces the denatured proteins to bond together, which in turn assists in attaining hemostasis with less heat energy than would be required without the pressure. Also, the total energy applied is minimized by means of the configuration and materials of the parts of the instrument that hold the tissue in opposition during the application of the heat and pressure. Using less heat energy means less collateral damage. In addition, results can be achieved that are at least as good as can be achieved with known electrosurgical and ultrasonic tissue coagulation units, but with a much smaller, lighter power source, such as a battery. Also, a very simple and direct method of heating the tissue is used. Since the basic heating element is so simple, the improved results can be achieved at a fraction of the cost of the more round-about means of heating tissue.
According to one aspect of the present invention instruments and methods for sealing, or coagulating, and cutting tissue during surgery are provided. The instruments incorporate means for controllably heating tissue while simultaneously applying a definite and controllable amount of pressure to the tissue being heated. Because of the combined application of heat and pressure, tissue proteins will become coagulated and blood vessels within the tissue will be sealed shut, achieving hemostasis. Optimal sealing or coagulating tissue means producing a strong and durable seal or coagulation or anastomosis with a minimal amount of collateral tissue damage. In the instruments of the invention optimization is achieved by a combination of the physical configuration of the part of the instrument that holds the tissue during the coagulation process and regulation of the time, temperature, and pressure.
As part of the temperature control, heat can be applied in pulses rather than in a continuous manner. Pulsed heat application allows tissue that is adjacent to the area being coagulated time to recover from the heating process and to remain viable. Also, the application of the pressure may be variable in intensity and may also be applied in a pulsed or discontinuous manner.
It is an aspect of the present invention to provide a method and instrument for the surgical treatment of biological tissue, wherein thermal energy and pressure are applied simultaneously, substantially simultaneously, consecutively, or alternatively, over a time such that tissue proteins are denatured and the tissue will adhere or join to itself or to other tissues, for the purpose coagulating bleeding, sealing tissue, joining tissue and cutting tissue. The minimum amount of heat or thermal energy needed to accomplish these goals is expended, so as to minimize thermal damage to tissue adjacent to the treated site.
The instruments of the invention may also incorporate means for cutting, or severing, the tissue after the tissue has been coagulated, “cutting” including dissecting or tissue division, tissue disruption or separation, plane development, or definition or mobilization of tissue structures in combination with a coagulation or hemostasis or sealing of blood vessels or other tissue structures such as lymphatics or tissue joining. The cutting can be achieved by means of a blade which is passed through the coagulated tissue while the tissue is being held in the jaws of the instrument. Cutting can also be achieved thermally by use of amounts of heat greater than the amount required to coagulate the tissues. Alternatively, cutting can be achieved by other mechanical, ultrasonic, or electronic means, including, but not limited to, shearing action, laser energy, and RF, or a combination of two or more of the above. In the case of using thermal energy to achieve tissue cutting, the instruments and methods minimize the amount of energy required to divide tissues with the least amount of unwanted tissue necrosis.
The heating element may be a resistance wire through which electric current is passed, or the heating element may be another material which generates heat when electrical current is passed through it. The electrical current is applied through the wire either as a continuous current or as a series of pulses of definite duration and frequency. Unlike conventional electrosurgical instruments, the electric current of the instruments of the invention does not pass through the tissue, which can cause problems due to stray electric currents. The electrical elements are electrically insulated from the tissue while being in good thermal contact. In a simple embodiment of the instrument, the total amount of continuous current and hence the total heat energy applied to the tissue, is limited in duration by a simple timer circuit or even by direct visual or other sensory inspection of the treated tissue. In a more sophisticated embodiment, the pulse train configuration and duration is under control of a simple microcontroller, such as, for example, an embedded microprocessor. With microprocessor control, a thermistor heat sensor is incorporated into the part of the instrument that grasps the tissue being coagulated. The microprocessor takes temperature readings from the thermistor and adjusts the pulse train configuration and duration to achieve the optimum temperature to cauterize or seal the tissue while minimizing unwanted collateral thermal damage. The actual value of the optimum temperature can be verified experimentally for this particular instrument.
The temperature of the sealing treatment according to one aspect of the invention is preferably kept in the range required to denaturate tissue proteins (approximately 45° C. to below 100° C.) while avoiding excessive necrosis to the tissue. Keeping the temperature in the range required to achieve protein denaturization without excessive tissue necrosis means that the total heat energy expended in the treatment will be less than if the temperature were not kept in this range. The amount of heat energy expended in the treatment is related to the degree of the heat (the temperature) and the length of time for which the heat is applied. The combined application of pressure with the heat reduces the amount of heat or the degree of temperature that would be required to have the denatured proteins actually stick together. This combined application of pressure also increases the strength with which the denatured proteins actually stick together, for a given amount of heat energy at a given temperature.
The amount of pressure applied is regulated by springs or other elastic elements, or mechanically functional equivalents, which will result in the tissue being held with a predetermined amount of force per unit area, in spite of variations in the size or thickness of the tissue being sealed or coagulated. The pressure may also be regulated by mechanical elements or spacers or by the geometry of the pressure producing elements. As with the temperature value, the exact value for the pressure to be applied can be verified for this instrument with appropriate measurement calibration.
The controlled application of a combination of heat and pressure which is sufficient but not excessive to produce a durable coagulation or seal has the result that only a relatively small amount of heat energy is needed. That only a relatively small amount of heat is needed means that relatively small electrical batteries can be used as the energy source to produce the heat. A instrument of the invention can therefore be free of bulky and heavy external power generators such as are required with conventional electrosurgical, laser or other instruments for coagulating tissue. Because small batteries can be used to power the instrument, the instrument can be made quite compact and light weight, as well as portable and/or disposable. The use of batteries or other sources of low voltage direct current facilitates the avoidance of hazards and inconveniences caused by electrical interference and stray currents, which occur in conventional high-frequency electrosurgical instruments. Laser eye hazards are also thereby avoided.
Since the heating elements and pressure producing elements of the instrument may be inherently simple and inexpensive to manufacture, the part of the instrument that comes in contact with tissue can be made in a disposable manner, if desired, while the more expensive portions of the instrument can be made to be reusable. If the instrument incorporates a simple timer, instead of the microprocessor-thermistor controller, the entire instrument including batteries can be made very inexpensively and to be disposable.
Different embodiments of this instrument employing the same general principle of controlled application of a combination of heat and pressure can be used to join or “weld” adjacent tissues to produce a junction of tissues or an anastomosis of tubular tissues. The joining of tissues is essentially a special case of the controlled coagulation of tissue proteins to achieve hemostasis.
It is a further aspect of the present invention that such heat and pressure effects will be spatially confined by the physical configuration and materials employed in the construction of the instrument. The configurations and construction materials are such that (1) the tissue is held in apposition with enough pressure to effect a strong union of the denatured proteins but not enough pressure to cause necrosis of the tissue, and (2) the heat is concentrated on the tissue being treated by means of the material of the jaws which hold the tissue being treated, such material being a thermal insulator which prevents the heat from being expended on heating adjacent tissues. Such material may also employ a reflective layer or coating to reflect back the treated tissue heat energy that would otherwise be lost to thermal radiation. Such material may also have a geometry or be shaped in such a way to focus the thermal energy on the treated tissue and away from tissue not intended to be treated. For example, the jaws of the instrument may have a concave or parabolic inner surface to focus the thermal energy.
It is a further aspect of the present invention that such effects will be spatially confined by the kind, amount, and duration and temporal distribution of the energy delivery. The energy could originate as heat, light, sound or electricity, chemical, or other forms of energy, as long as this energy is converted to heat to denature tissue proteins. In a preferred embodiment, the energy would be delivered from a simple, low cost thermal heating element which could be powered by a battery contained in the instrument itself. The energy could be delivered in a continuous, or pulsed or intermittent mode, at variable or constant intensity. Pulsed or intermittent delivery of energy can produce a spatial confinement of the energy distribution. Feedback (including optical, thermal, spectroscopic, among others) and a microprocessor could be used to control the thermal effect. In the case of tissue coagulating, sealing or joining, the temperatures produced by the energy source could be the range of from about 45° C. to about 100° C. for a duration long enough to produce denaturation of the proteins in the treated tissue.
The heat or energy delivery source may be a simple electrically resistant wire, straight or curved, a grid or pattern of wires, or a thin-film or coating of electrically resistant material. One or more energy elements may be used. They may target some or all of the tissue treated by the pressure elements. The energy delivery source may be integral with or separate from the pressure elements. Cutting elements may be incorporated into the energy elements. The energy or heat source may move or be fixed. The energy may be delivered in a similar or dissimilar plane compared to the direction of pressure application. The energy or heat source may be constructed in such a way that its shape and size may be varied to conform to different anatomical situations, tissue shapes and thicknesses. For example, an inflatable balloon coated with an electrically resistant material might be employed as the heat source. Another example would be that the heat source might have an expandable fan type configuration which could enlarge (“fan out”) to cover a larger surface or a smaller surface as needed. Another example would be a flexible sheet type configuration that could wrap around the tissue to be treated.
It is a further aspect of the present invention that such effects will be spatially confined by the kind, amount, and duration or temporal distribution of the pressure delivery acting in conjunction with the energy or heat source. The delivery of pressure will usually be from a minimum of two elements of the apparatus rather but may in some cases be from simple abutment or pressing of a single element against tissue, as in the example of the circular cutting wheel or a coring biopsy instrument. Any combination of geometric arrangement between the energy source and the pressure source may be produced, including combined energy-pressure sources and separate energy and pressure sources. A constant requirement is that the energy element deliver energy to at least some of the tissue that is subjected to pressure by the pressure element. The pressure element likewise may be variable in its shape, being able to adjust its shape before or during the application of the energy or pressure to accommodate for different anatomical situations, tissue shapes or thicknesses. Cutting elements or other elements for shaping or forming the tissue may be incorporated with the pressure element. For example, the pressure element may be comprised of a flattened side with an acute up-angled center to produce a combination of cutting effect over the center with compression along the sides. The pressure applied may be constant or variable over time and the relation of the pressure elements to the tissue may be constant or variable during application of the pressure and energy or both. Motion of the appropriately configured pressure elements may be used to effect cutting before, during or after application of the energy or pressure. The variable application may likewise be controlled by feedback from pressure transducers or strain sensors acting with a microprocessor.
It is a further aspect of the invention that a completely separate cutting element could be used in addition to separate energy and pressure elements. It is also an aspect of the invention that mechanical tissue fastening instruments including sutures, staples, clips, bands, screws, plates or tacks could be incorporated into the instrument. In this case the thermal energy and pressure would be used to provide mainly coagulation and sealing and the mechanical elements would provide additional strength to the tissue joint or anastomosis.
The invention can be used in either open, laparoscopic, endoscopic or any form of minimally invasive surgery. Surgical instruments based on this invention could be long and thin, suitable for laparoscopic or minimally invasive approaches.
The parameters of temperature, time, pressure, as well as the any adjustable physical configuration or geometry of the instrument might vary depending on the type, size, and thickness of tissue being treated. These parameters may be experimentally determined before the actual treatment and incorporated into the instrument by means of a “look-up” table in a microprocessor or by means of simple markings and calibrations of adjustable knobs, dials, etc., of the instrument.
For the purpose of thermally joining or anastomosing two hollow tubular structures, e.g., small blood vessels or vas deferens, a preferred embodiment would incorporate two circular or cylindrical elements. Such cylindrical elements would be is designed to fit one into the other, acting as a jug or temporary stent which would hold the two tubular structures together while heat was applied. The tubular structures would be held in such a way to provide either a certain amount of overlap or end-to-end contact. As in previous embodiments, the amount of coaptive pressure which is being applied would be optimized according to the tissue type and thickness. The heat would be provided by a heating element or elements incorporated into the cylindrical jigs or stents and situated to apply the heat to the parts of the two tubular structures which are in overlap or in end-to-end contact. As discussed above, the amounts of heat and pressure applied are the minimum required to produce a secure anastomosis with the least amount of collateral damage.
Another embodiment of this instrument would employ a circular mechanical cutting element, suitable for obtaining “core” biopsies of solid organs such as the liver or a kidney. This circular mechanical cutting element, shaped like a cylinder with sharp edges at one end, would incorporate an electrically resistant element on the outside of the cylinder. This electrically resistant element could be in the form of a thin film of resistance material. As the mechanical cutting of the tissue was done by rotating or pushing the cylindrical cutter into the tissue, hemostasis along the track created by the cutter would be achieved by the heating element on the outside of the cutter. The cylindrical cutter would be constructed out a material, or would incorporate a layer of a material, such that the tissue core sample being removed would be insulated from the thermal effects of the heating element on the outside of the core. This design would allow for retrieval of tissue samples which are not distorted by heat changes and also allow for secure hemostasis along the tract of the biopsy. In this instrument, the lateral pressure exerted by the cylinder wall on the tissues of the track cannot be explicitly controlled; however, there is pressure, and this pressure is part of attaining hemostasis.
In a further embodiment of the invention, a circular cutting wheel would be mechanically rotated to cut tissue, such as skin. This circular cutting wheel would incorporate along its rim, an electrically resistant thin film. This electrically resistant element would provide for hemostasis as the rotating mechanical wheel cuts the tissue.
In a yet further embodiment of the invention, an inflatable elastic balloon could be used to apply heat and pressure to tissue. The exterior surface of the balloon would be coated partly or totally with flexible, optionally stretchable, electrically resistant material that will heat up when electrical current is applied. Here, the pressure exerted on the tissue can be controlled by regulation of the inflation pressure of the balloon.
Another embodiment of the invention comprises a compact electrical cutting and coagulating instrument which allows blood vessels, other vessels in the body, or organ tissue to be divided with electrical energy while at the same time being ligated by heat-induced coagulation. This embodiment comprises a forceps or tweezer-like gripper with two arms which may grasp a vessel or section of organ tissue with gripping areas at the tip of the arms. One arm is fitted with a protruding cutting wire, while the other arm is provided with an anvil surface and, optionally, a recess for receiving the cutting wire. Cutting a vessel or tissue is accomplished by heating the wire and closing the tweezer arms on the vessel or tissue, allowing the hot wire to cut the vessel or tissue. Sealing the vessel or tissue is accomplished when the tweezer arms have closed upon the severed ends of the vessel, whereupon the anvil surface is heated to cause coagulation of the vessel or tissue. The wire may be made of a non-stick composition comprising carbon, and the anvil may comprise non-stick substances such as PTFE or carbon. The cutting wire is heated to a high temperature from an electrical power source, preferably a DC power source, and preferably powered by batteries housed in the body of the instrument or in a portable battery pack. The anvil may be heated by radiant and conductive heat from the cutting wire, with heating wires powered from the electrical power source, or from the cutting wire indirectly.
Optionally a standard clamp can be modified to accept a cartridge containing a heating element and a power supply, or an instrument useful for laparoscopic procedures may be the functional equivalent of the forceps described above.
The instruments of the invention can be used in surgery and are particularly well suited to laparoscopic and endoscopic surgery. Because the method described uses heat energy in the minimum amount and at the lowest temperature consistent with attaining denaturation and sticking together of tissue proteins, instruments which work based on this method will be able to function more efficiently than conventional surgical energy instruments. Therefore these instruments can be portable and even battery powered, which makes them ideally suited for portable or military applications.
There is no instrument or method in the prior art which specifically seeks to obtain surgical coagulation, sealing, joining or cutting by a combination of resistant heat energy and pressure at a time, temperature and pressure which together are sufficient but not excessive to produce protein denaturization, and with a physical configuration and materials of construction which promote the sticking together of the tissues being treated while minimizing losses of heat energy to surrounding tissues beyond the treatment zone.
BRIEF DESCRIPTION OF THE DRAWINGS
Reference is made to the following description taken in connection with the accompanying drawings, in which:
FIG. 1 is a schematic representation of one embodiment of the present invention;
FIG. 1A is a cross-section along line I-I of the embodiment in FIG. 1 with the jaw in closed position;
FIG. 2 is a top, partly cross-sectional view of the lower jaw of the embodiment of FIG. 1 showing the heating and cutting elements;
FIG. 3 is a plan view of another embodiment of the invention;
FIGS. 4 and 5 are cross-sectional views of the embodiment of FIG. 3 ;
FIGS. 6 and 6A are a plan view and a partial, enlarged view, respectively, of a further embodiment of the invention;
FIGS. 7 and 7A are a plan view and a partial cross-sectional view, respectively, of another embodiment of the invention;
FIG. 8 is a partly cross-sectional view of a further embodiment of the invention;
FIG. 9 is a plan view of yet another embodiment of the invention;
FIG. 10 is a top, partly cross-sectional view of the embodiment of FIG. 9 ;
FIG. 11 is a plan view of another embodiment of the invention for heating and cauterizing tissue;
FIG. 12 is a prospective view of a forceps embodying a cutting and/or coagulating element in accordance with the invention;
FIG. 13 is a top view of the embodiment shown in FIG. 12 ;
FIGS. 14 and 15 are each partial views of a forceps arm from the embodiment shown in FIG. 12 ;
FIG. 16 is a cross-sectional view of the distal portions of the forceps arms shown in FIG. 12 ;
FIG. 17 is a graphic representation of the temperature gradient of tissue heated with the embodiment of FIG. 12 ;
FIG. 18 is a graphic representation of the time vs. temperature characteristics of the embodiment of FIG. 12 ;
FIGS. 19 and 20 are prospective views of a clamp embodiment of the invention;
FIG. 21 is a perspective view of an embodiment of the invention specifically adopted for laparoscopic use.
FIG. 22 is a partially cross-sectional view of the distal end of the embodiment shown in FIG. 21 ;
FIG. 23 is a partially cross-sectional schematic detail of an embodiment of the distal end shown in FIG. 22 ; and
FIGS. 24 and 25 are each a schematic, partially cross-sectional view of another embodiment of the invention adapted for laparoscopic use.
DETAILED DESCRIPTION OF THE INVENTION
The invention can perhaps be better appreciated from the drawings. FIG. 1 depicts a schematic representation of the instrument of the invention showing an upper jaw 10 , a lower jaw 12 , an elongated shaft 14 attached to a handle 18 , having a lever 20 for opening and closing the jaws. Upper jaw 10 is attached at hinge 11 to spring support member 13 , and spring 15 is attached to both upper jaw 10 and spring support member 13 to bias upper jaw 10 . Lever 20 is operatively connected through rod 21 to one or both of upper jaw 10 and lower jaw 12 . The end of shaft 14 closest to handle 18 is provided with (1) a pusher 16 which is operatively connected through member 17 and connector 23 to a cutting knife blade 19 housed in lower jaw 12 and (2) a trigger 22 to actuate pusher 16 which in turn actuates cutting blade 19 . The lower end of handle 18 is provided with a rechargeable battery pack 24 , which is operatively connected to heating element actuator 27 and heating wire element 26 in lower jaw 12 .
In FIG. 1A , tissue segment 25 is clamped between jaws 10 , 12 , where it can be cut by blade 19 .
FIG. 2 depicts a top view of lower jaw 12 showing the relative locations of heating wire element 26 and a slot 28 for cutting blade 19 , within jaw 12 . Heating wire element 26 is in a groove of a depth such that the wire is substantially flush with the surface of jaw 12 . Preferably the distal portion 29 of heating wire element 26 is below, or out of, the plane of heating wire element 26 so that only two parallel areas of tissue will be sealed. Heating wire element 26 , which preferably is comprised of nichrome or another suitable electrically resistant metal or alloy, or an electrically resistant thin-film or coating will preferably have a suitable, thermally conductive, electrically resistant, non-stick coating. Examples would include polytetrofluoroethylene (PTFE), e.g., TEFLON®, or other non-stick coatings used in cookware. Moreover, one or both of the facing surfaces of upper jaw 10 and lower jaw 12 may optionally be corrugated, irregular, or grooved.
Both the upper and lower jaws are composed of a material, such as ceramic, which is thermally insulating or thermally reflective. In this way, the heat generated by the heating element is confined to the space between the jaws, and is not allowed to spread or radiate to other tissues that may be in contact with the outside of the jaws. This is beneficial in two ways: first, the heat generated by the heating element is used efficiently to perform the desired sealing or coagulation, and second, surrounding tissues are protected from inadvertent thermal injury.
As would be appreciated by one skilled in the art, the heating, pressure, and/or cutting functions could be mechanically, electromechanically, or electronically synchronized to obtain optimal results according to the invention. Also, the instrument shown in FIGS. 1 , 1 A, and 2 may optionally not have a cutter element. Such a instrument would be intended for situations where only heating and pressure would be necessary to join tissue or to otherwise heat and cauterize tissue to produce coagulation.
In the embodiment of the invention shown in FIGS. 3 and 4 , a cylindrical member 30 is concentrically positioned around a rod 32 , the distal portion of which forms anvil 33 . The distal surface of cylindrical member 30 comprises a circular heating element 34 and a circular cutting element 35 arranged concentrically within heating element 34 . Anvil 33 is configured so that when rod 32 is moved proximally, the proximal circular edge 36 of anvil 33 cooperates with heating element 34 to coagulate or seal tissue.
Use of the embodiment of FIGS. 3 and 4 can be appreciated in FIG. 5 , where, for example, two sections of intestine 38 , 39 are positioned to be joined together. Initially one end of each of sections 38 , 39 is loosely connected with ligatures 40 , 41 about rod 32 . Then, rod 32 is moved distally to cause circular edge 36 of anvil 33 to force portions of intestines 38 , 39 into contact with heating element 34 . Intestine sections 38 , 39 are joined together, and excess tissue is cut off by cutting element 35 . Rod 32 is then pulled further in the proximal direction to remove the excess tissue, cylindrical member 30 , and anvil 33 .
In addition, the instrument shown in FIGS. 3 to 5 to produce circular anastomosis by relying on heat and pressure could additionally incorporate mechanical fastening elements such as staples. Such a instrument is shown in FIGS. 6 and 6A , where a circular stapling instrument 42 comprises a main shaft 43 , a handle 44 , a staple housing 45 , and an anvil 46 . Anvil 46 is fixedly attached to the distal end of anvil shaft 47 , which is movably slidable within staple housing 45 , main shaft 43 , and handle 44 .
The distal surface 48 of staple housing 45 has slots 49 for staples (not shown) and an electrically resistant coating or member 50 . An inner circular member 51 with a cutting edge 52 is arranged circumferentially around anvil shaft 47 , as can be seen more clearly in FIG. 6A . Optionally, slots 49 and coating 50 could be coextensive so as to facilitate direct heating of the staples.
Handle 44 comprises means for operating anvil 46 and heating element 49 and for firing the staples. As would be appreciated by those skilled in the art, a staple firing lever or member 53 can be operatively connected to a cylindrical pushing member within stapling housing 45 that causes the staples to be ejected from slots 49 .
The operation of the circular stapling instrument would be similar to that of instrument shown in FIG. 3 , with the exception that staples would be fired into tissue to be joined. Preferably the staples would be fired subsequent to sealing and concurrently with the cutting. The staples would act in conjunction with the thermal energy to enhance the strength of the tissue seal, joint or bond while the thermal energy would enhance the hemostatic capability of the staples. Staples or other mechanical tissue fasteners could be used in conjunction with thermal energy sealing in configurations other than circular, such as linear or angled.
FIG. 7 depicts an embodiment of the invention that is essentially a tissue-core removal instrument. The tissue-core removal instrument 56 comprises a cylindrical member 58 having a fixedly attached proximally extending handle 60 . Cylindrical member 58 comprises a sharp cutting edge 62 and a heating element 64 arranged on the outer surface 66 of cylindrical member 58 . Optionally, sharp cutting edge 62 could be replaced by a heating element to do the cutting.
Consistent with the description above, a tissue sample is obtained by inserting removal instrument 56 into an organ, with instrument 56 being rotated as it moves forward. The rotation could be either clockwise or counterclockwise, but preferably alternatingly clockwise and counterclockwise, with sufficient pressure to cause edge 62 to cut. Heating element 64 will cauterize or seal tissue adjacent to the tissue sample to be removed, and when a tissue sample of sufficient depth is positioned within cylinder 58 , instrument 56 will be removed. As is conventionally done, removal instrument 56 would preferably contain means for removing a tissue sample, such as an internal piston 59 having a proximally-extending actuator 60 to force the sample to be ejected from the distal end of removal instrument 56 . As would be appreciated by those skilled in the art, a tissue-core removal instrument may optionally have additional cutting means at its distal end to assist in separation of a core tissue sample from the tissue mass.
In FIG. 8 the distal portion 70 of an electrothermal biopsy needle comprises an outer cutting sheath 72 slidably circumferentially arranged around an inner slotted stylus 74 having a slot 76 to capture a tissue sample 78 . The outer sheath 72 has a cutting edge 73 which separates tissue sample 78 from the rest of the tissue mass (not shown) and encloses sample 78 in slot 76 when outer sheath 72 is propelled distally by an actuator (not shown).
Outer sheath 72 preferably has an electrically resistant film 75 coating on its distal portion. Film 75 may have spaced-apart electrical contacts or connectors 77 . In another embodiment of a biopsy needle where stylus 74 has an inner cutting member (not shown), the stylus or the inner cutting member, or both, may have an electrically resistant coating or film.
The aforementioned aspect of the invention could be incorporated into known biopsy instruments. See, for example, U.S. Pat. Nos. 4,600,014 and 5,595,185, both of which are incorporated herein by reference with regard to their descriptions of biopsy instruments.
FIGS. 9 and 10 depict a circular cutting embodiment of the invention in which a disk 80 having a sharp outer edge 82 is attached at its center to a rod 84 which is rotatingly secured to forks 86 of handle 88 . Adjacent edge 82 is a circular heating element 90 , which can be on one or both surfaces of disk 80 . Each heating element 90 is electrically connected to fork 86 , for example, through one or more brushes 91 . Optionally, sharp cutting edge 82 could be replaced by a circumferential heating element to do the cutting.
FIG. 11 represents an embodiment of the invention where a heating and cauterizing instrument 92 comprises a catheter 94 and an inflatable balloon 96 sealingly attached to the distal end of catheter 94 . Catheter 94 comprises at least one lumen 98 , which is in fluid communication with balloon 96 for inflation and deflation. The proximal end of catheter 94 is in fluid communication with a regulated pressure source or inflation source (not shown) for inflating and deflating balloon 96 .
Balloon 96 has an electrically resistant film coating 100 , at least two separate portions of which are connected to wires 102 that extend proximally along or within catheter 94 to a power source 104 . The electrically resistant film coating 100 is intended to cover a substantial portion, if not all, of the outer surface of balloon 96 .
In use, instrument 92 with a deflated balloon 96 is manipulated within a patient's body, e.g., intracorporeally or even percutaneously, to position balloon 96 adjacent to a site to be cauterized. Then, balloon 96 is inflated so that the electrically resistant film coating 100 contacts the area to be cauterized, whereupon film coating 100 is energized with electrical energy from source 104 . After the heat and pressure produce the desired effect, the power is turned off and the balloon is deflated to facilitate removal.
With regard to the embodiments of the invention depicted in FIGS. 3 to 11 , it should be appreciated that the respective heating elements are electrically connected to an appropriate power supply. It is envisioned that in each instance the power supply can be a battery or battery pack, which can be fixedly attached or integral with to the respective instrument. Optionally, the battery or battery pack could be separately mounted or positioned, such as on a clip or belt means for the operator to wear. It is within the scope of the invention that other standard sources of electrical power, such as transformers, may also be used. Other sources of heat such as fuel, e.g., butane, or chemical reactions, may be used.
As mentioned above, one aspect of the invention concerns optimization of (1) thermal energy application, i.e., temperature and time, and (2) pressure, i.e., force and duration, to achieve maximum tissue seal strength and minimal collateral tissue damage. Those skilled in the art will appreciate that useful parameters will vary greatly.
However, in practical application to human tissue a voltage of from about 0.5 volt to about 14 volts, preferably from about 1 volt to about 12 volts, will be applied to a heating element having a resistance sufficient to generate thermal energy to heat tissue to a temperature adequate to cause denaturation of proteins. This temperature is in the range of about 45° C. to about 100° C. The pressure applied would be sufficient to provide coaptation but less than would crush or destroy the tissue itself.
The strength of tissue coagulations, seals, anastomoses or welds can be experimentally measured. For example, the strength of a coagulation produced on the side of a lacerated blood vessel can be measured experimentally by first producing the coagulation and then applying measured amounts of hydrostatic pressure to the inside of the vessel until the coagulation blows off and bleeding recommences. The strength of a tissue weld can be measured by first joining two pieces of tissue together and then placing the joined tissues in a machine which attempts to pull the tissue apart with increasing and measured amounts of force. Collateral thermal damage is also a measurable quantity in that the amount of collateral thermal damage can be readily assessed visually or microscopically. By use of this methodology, a table of optimized parameters could be constructed for any type of tissue. These parameters would be incorporated into the various instruments by means of selecting the voltage, current, and resistance of the heating elements and also the amount of pressure used to press the tissue together during the coagulating/sealing/joining process, as well as the time duration of the process. These parameters can simply be incorporated into the instrument (i.e., simple mechanical timer, fixed preset voltage and current, and spring-loaded pressure instruments, or, we can incorporate more flexible and active controls based on microprocessor regulation of the heating process, guided by a “look-up” table in ROM and by using sophisticated mechanical force/pressure sensors and strain gauges). Also, for certain applications, it may be sufficient to have a skilled operator, visually or by other sensing means, determine the duration of energy application and the amount of pressure required.
The instruments of the present invention may be constructed of any suitable material, such as will be familiar to one skilled in the art, for example, out of a reinforced engineered plastic such as fiberglass reinforced polycarbonate, or machinable or injection-molded ceramics, or high temperature glass or epoxies, or mica. Alternatively they may be constructed out of a suitable alloy steel such as 318 stainless steel, or the like. The heating element may be a simple resistive wire or may be a thin film or coating composed of metallic, organo-metallic, or organic materials which may be conducting or semi-conducting. The actual materials of construction will be a matter of choice depending upon whether the instrument is to be employed repetitively or in a disposable manner. Indeed, in the latter situation it is contemplated that different parts of the instrument may be constructed of metal alloy and/or plastic, in which situation the plastic disposable components can be thrown out after each use and the more expensive metal alloy components reused. If sophisticated and expensive control circuitry is used, this part of the instrument could be made in a reusable manner.
FIG. 12 illustrates an embodiment of a forceps instrument 210 which may be variously described as a pincer or tweezers. Forceps instrument 210 comprises forceps arms 212 and 214 , the proximal ends 216 and 218 , respectively, of which are attached to switch housing 220 . The outer surfaces of forceps arms 212 and 214 contain finger grips 222 to assist the operator in holding and activating forceps instrument 210 . An optional sleeve 221 covers the proximal portion of housing 220 .
Forceps arms 212 and 214 may be formed of a suitable resilient material such as stainless steel, for example, that has the desired combination of stiffness and spring rate. For disposable applications forceps arms 212 and 214 may be formed from a homogeneous plastic material, or a material that is filled with particulate material to increase stiffness or abrasion resistance.
Alternatively, forceps arms 212 and 214 may be formed from a composite material tailored to provide the desired stiffness according to specific functional and ergonomic needs and to provide heat resistance for electrosurgical and thermosurgical applications. The composite material may be any composite construction, e.g., fiber material, glass, carbon fiber, Kevlar, aramid, or metallic particles bound with an epoxy, polyester, or other resin, forming the composite matrix.
Forceps arms 212 and 214 may be manufactured in a unitary construction, via casting, lay-up, compression molding, lamination, or molding of a pre-impregnated fiber cloth in a manner known to one skilled in the art. The forceps arms may also be molded or cut from pre-formed sheet composite material and glued or riveted together. Components may also be filament wound. Alternatively the components may be stainless steel with a flex circuit.
The composite matrix may also have molded into it conductive wires or strips for transmission of electrical energy or transmission of data signals. The carbon in the carbon fiber matrix may also be used to conduct electrical or data signals. The fiber in the matrix, which may be carbon, glass, Kevlar, aramid, or other fiber, may be laminated such that the unidirectional fibers are oriented at an angle to one another to achieve the desired spring rate and stiffness characteristics.
One or both of the distal ends 224 and 226 of forceps arms 212 and 214 , respectively, contain a heater wire 228 , as shown in greater detail in FIGS. 15 and 16 . Each of said distal tips 224 and 226 comprises a non-slip sleeve or “bootie”, such as heater sleeve 230 on distal tip 224 and anvil sleeve 231 on distal tip 226 , which sleeves may be comprised of clear or opaque, deformable, resilient, non-stick material. Suitable materials include polytrafluoro-ethylene (PTFE), available as TEFLON®, graphite, KAPTON, mica, or silicone. Each sleeve 230 , 231 evens out pressure against tissue and insulates the surfaces of forceps arms 212 and 214 electrically and thermally. Sleeves 230 , 231 may also incorporate thermally reflective material as layers or coatings. Useful reflecting materials would include ceramics, thermally reflective metals, or thermally reflective polymers, such as MYLAR(® polymeric compositions. Sleeves 230 , 231 also prevent heat dissipation and focus heat from heater wire 228 on a specific area, while spreading the heat sufficiently to obtain a good seal zone. By insulating and reflecting, i.e., managing, the heat generated by heater wire 228 , sleeves 230 , 231 minimize power consumption to achieve the intended result. Also, the resiliency of sleeves 230 , 231 is intended to lengthen the useful life of heater wire 228 , which becomes fragile when hot.
Switch housing 220 comprises a finger-operated switch 232 , e.g., a multi-directional post-in-tube design, preferably a high current, low voltage switch. When a button 234 is pushed into the plane of forceps arms 212 and 214 , from either direction, switch 232 is activated so that current is provided to heater wire 228 . When button 234 is released, the button returns to its starting position and the flow of current is interrupted. Optionally, housing 220 comprises at least one anti-swivel guide 235 to form a channel to help maintain forceps arms 212 and 214 parallel to one another. In addition, the forceps may be used with a foot-activated switch instead of a finger-activated switch. The same switch housing may be used, but without a finger switch. Instead, the circuit may be completed by depressing a foot switch that is connected via an electrical cable between the battery pack and the forceps power cord.
In a preferred embodiment of the invention switch housing 220 comprises circuitry to control or manage the current supply to heater wire 228 . This circuitry, known generally as an “actuator”, is an important and useful feature. Deterioration of heater wire 228 is prevented by contact of heater wire 228 with the heat sink of the pinched tissue and the opposing forceps arms. The presence of the actuator induces the operator to apply a minimum amount of pressure to the closed forceps distal tips, which insures good sealing/welding of the vessel or organ tissues. In addition there is the important safety aspect that the actuator prevents inadvertent exposure of heating wires to drapes or other flammable materials in the operating room, should the finger-operated switch be inadvertently activated.
As can be seen more clearly seen in FIG. 15 , at least one distal tip of one of the forceps arms, such as distal tip 224 of forceps arm 212 , comprises heater wire 228 on the outer surface of heater sleeve 230 , preferably with a slight gap between distal tip 224 and heater sleeve 230 , which gap could be filled with a fluid such as a gas or liquid. This provides for additional thermal insulation between heater wire 228 and forceps distal tip 224 . Heater wire 228 may comprise any useful electrically resistant, preferably non-stick material such as nichrome or an alloy thereof, graphite, nitinol, stainless steel, platinum, or tungsten, uncoated or coated with a non-stick material such as graphite. In fact, any material may be used such that the heater wire 228 has a lower ohmic resistance than body tissue. This lower resistance allows the resistive element to be exposed but not transfer electricity through the tissue. The length, diameter and material selection are adjusted to optimize sealing and cutting. Although heater wire 228 preferably has a round smooth surface, wire 228 may be other then round and have a textured surface to increase traction. A flat surface would be better for sealing applications, whereas a pointed surface would be better for cutting applications. It is within the scope of the invention that heater wire 228 may be a flex circuit or just a very flat wire. While heater wire 228 is shown in FIG. 12 as being substantially straight, heater wire 228 could instead be curved or arcuate.
Heater wire 228 is connected by solder to broader, flat wire 236 , which is in turn soldered to the distal portion 238 of a copper strip laminated to the inside surface 240 of forceps arm 212 . Flat wire 236 is covered by a polymeric sleeve 242 .
Distal tip 226 of forceps arm 214 comprises sleeve 230 having a thicker inner surface 244 , which inner surface 244 may comprise an integral part of sleeve 230 or a separate component that has been adhered to the inner surface of sleeve 230 . In a preferred embodiment of the invention, said inner surface comprises a separate polymeric member that has been glued or fused with sleeve 230 , optionally with molded ridges on the surface facing heating wire 228 to improve grip/tissue traction.
Heater wire 228 is electrically connected through cord 249 to a power source such as a battery pack 250 . Battery pack 250 can comprise any number of commonly available batteries (such as D cells or AA cells), dependent upon application. Battery pack 250 may optionally comprise sensing circuitry and a vibrating or auditory alarm to indicate a “low battery” situation, to minimize sticking and peeling of tissue when the battery is low and heater wire 228 would not be hot enough to seal or cut. Preferably, there will be a tone from housing 230 or battery pack 250 to indicate the forceps has been activated, with another tone or vibration to indicate that the battery is low. While there could be a cutoff rather than a low battery signal, it is believed that a low battery signal is preferable. It is intended that the battery pack will be capable of being clipped to the operator's uniform or suspended on an IV pole, or otherwise positioned in a convenient location adjacent the treatment area. Preferably the battery pack is connected to instrument 210 with a releasable connection 252 so that battery pack 250 can be readily replaced. The proximal portion of sleeve 221 may comprise a swivel connection 253 with cord 249 .
The preferred power source is a steady DC battery pack. It is within the scope of the invention that the power source could be a wall outlet plug-in transformer of steady DC, pulsed DC, low frequency AC, or even RF. One could also provide for a cutoff ability, for example, in the event of a short circuit or wire break, and/or a temperature feedback, optionally with a control to minimize temperature for sealing and maximizing temperature for cutting. Also, optionally there would be a feedback to power capability to automatically adjust for use under liquid conditions, e.g., saline, versus non-liquid conditions, to reduce the risk of wire burnout.
In the event that the power supply has DC/RF capability, the forceps can also function as an RF instrument. If the distal tips of the forceps arms were closed and then tissue was contacted, the RF/forceps would act like a hemostatic electrode or blade. Optionally a sleeve could be removed and replaced with a Bovie blade. (Also, the instrument could be activated with a dedicated hand switch or a foot switch.)
A primary application of the forceps instrument shown in FIGS. 12 to 16 is to seal and cut tissue such as blood vessels, other corporeal vessels or ducts, corporeal organs, and vascularized tissue. It is also useful for sealing in the lymphatic system. The way in which said forceps works can perhaps be appreciated by referring to FIG. 17 , which comprises a representative graph of the temperature gradient in a vessel or tissue (“tissue”) to which this instrument is applied. At the portion of tissue in direct contact with or immediately adjacent to a heater wire, the temperature of the tissue will be very hot—sufficiently hot to sever the tissue. At the same time, at the areas of tissue immediately adjacent to and roughly parallel to the “cut zone”, the tissue will be heated but not to the same extent as in the cut zone. In these two secondary areas, each referred to as a “seal zone”, tissue will be cauterized and sealed. This tip configuration allows for expedient division and sealing of blood vessels or vascularized tissue with the simple process of closing the forceps arms and momentarily applying heat energy at the forceps tips. This process will divide and seal the tissue. Additionally, when the tissue is gripped under moderate traction, the tissue will often automatically fall away from the jaws of the forceps as the heating element divides and seals the tissue. Heat from the heating element conducts laterally into the adjacent tissue while it is being compressed within the forceps tips. As a result, this tissue is often completely sealed by the time it is divided and falls away from the forceps jaws. This way, the divided tissue will not bleed as it is divided. The surgeon moves to a new area of tissue to be divided hemo-statically, and this simple process is repeated. With this approach to cutting and coagulation, significant time and materials can be saved, reducing the need for applying clips or ligatures, or for the use of other hemostasis products or techniques. Thus, with this particular embodiment of the invention, tissue can be cut and cauterized with one fairly simple repetitive motion.
The time vs. temperature graph shown in FIG. 18 illustrates the principles involved behind the process of sealing and cutting with the forceps device. After tissue is grasped between the forceps tip, the heat is activated by the button 234 at t=0. As the heating element heats up, heat is conducted into the tissue being grasped. As the temperature increases with time, the tissue passes the temperature value necessary for sealing and hemostatis (and eventually approaches the temperature necessary for dividing the tissue). Tissue closer to the heater is hotter than tissue farther away from the heater. Eventually (typically at t=2 to 5 seconds) the tissue immediately adjacent to the heater becomes hot enough that it divides. This division usually occurs after the tissue slightly farther away from the heater has reached a sufficiently elevated temperature for sealing and/or coagulation to occur there. Alternatively a pre-programmed “lock out” interrupts the power supply, so that the tissue remains at the appropriate temperature for the appropriate time, for example, 100° C. for approximately one second, whereupon the tissue is severed and then cools.
In the embodiment of the invention set forth in FIGS. 19 and 20 , a clamp 302 comprises a cartridge 304 that can be removably attached to clamp 302 . Clamp 302 is essentially a common surgical clamp that has been adapted to receive cartridge 304 . Cartridge 304 comprises an elongated member 306 having a switch housing 308 with a switch activator 310 . The distal end of member 306 comprises a heating element 312 that is in electrical connection with switch housing 308 and a power supply (not shown).
The embodiment of the invention shown in FIG. 21 is a modification of the embodiment shown in FIGS. 12 to 16 intended for laparoscopic application. According to this embodiment an elongated member 320 is attached at its proximal end 322 to a handle 324 housing comprising hand grips 326 and 328 attached to grip members 330 and 332 , respectively. The distal end 334 of elongated member 320 comprises gripping arms 336 and 338 , at least one of which has a heating element 340 . Gripping arms 336 and 338 may optionally have sleeves (not shown).
An actuator rod 342 has a proximal end 344 rotatively attached to grip member 330 at fastening point 346 , and the distal end 348 of actuator rod 342 is operatively connected to gripping arms 336 and 338 . Grips 326 and 328 and their respective grip members 330 and 332 are movably connected at pivot point 350 , so that when grip 326 and 328 are squeezed together, proximal end 344 moves proximally and gripping arms 336 and 338 move together. A rotating positioner 352 can rotate to in turn rotate elongated member 320 and gripping arms 336 and 338 .
Grip member 332 preferably contains a finger-activated switch 352 to control the flow of electricity to heater wire 340 .
In FIG. 22 one embodiment of the operative connection between actuator rod 342 and gripping arms 336 and 338 is shown. Distal end 348 of actuator rod 342 is movably connected to a link 360 which is movably connected to member 362 . Gripping arms 336 and 338 rotate in opposite directions about pivot point 364 to close or open upon tissue. When actuator rod 342 moves in the proximal direction, gripping arms 336 and 338 close together. Upper gripping arm 338 comprises heater wire 340 , such as a nichrome wire, which is thermally and electrically insulated from gripping arm 338 by insulator 366 . Here, the distal portion 370 of heater wire 340 is spot welded to the exterior surface 372 of gripping arm 338 . The interior surface 374 of gripping arm 336 is preferably insulated, for example, with a silicone polymeric insulator. Heater wire 340 is operatively connected through wire 376 to a power source (not shown) and/or switch 352 .
A detail of FIG. 22 is shown in FIG. 23 , where the relationship between gripping arms 336 and 338 can be better appreciated, especially for he curved embodiment shown. Member 362 and lower gripping arm 336 are integral and cooperatively arranged with upper gripping arm 338 and member 380 around pivot 364 . The interior surfaces 382 and 374 of gripping arms 338 and 336 , respectively each having polymeric insulation inserts.
As has been shown, the materials and the principles described for the tip design of the forceps can be modified slightly and applied to the clamp and to the laparoscopic grasper. Just as the design can be adjusted to a clamp and to a laparoscopic grasper, it can be applied to virtually any hand-held surgical instrument.
A monopolar RF version of a hook dissector is used in laparoscopic surgery. The embodiments of the invention shown in FIGS. 24 and 25 comprise a surgical dissecting instrument in the form of a hook, and this hook offers safety advantages over the RF version since the heating effect is confined to the tissue caught up in the hook. The heating element, preferably a nichrome wire, is situated on the inner surface of the hook so that tissue is compressed against the heater wire when tissue is “hooked” with the instrument.
The instrument shown in FIG. 24 comprises an elongated member 402 having a proximal end 404 , optionally textured to facilitate gripping, and a distal, hooked end 406 . The interior surface 408 of hooked end 406 comprises a heater wire 410 , which is operatively connected through wire 412 to a power source (not shown). The distal end 414 of heater wire 410 can be spot welded to hooked end 406 , which provides a return path for electricity to the heater wire. Insulative material 416 between heater wire 410 and hooked end 406 thermally and electrically insulates heater wire 410 . Optionally, insulation material 416 comprises a polymeric material in the form of a sleeve.
Elongated member 402 preferably comprises a physiologically acceptable, sterilizable metal such as stainless steel. Non-conductive rigid materials can be used so long as a pathway for electricity from the distal end heater wire 410 is provided.
In FIG. 25 an elongated member 430 has a proximal end 432 , optionally textured, and a distal, hooked end 434 . The lateral interior surface 436 of hooked end 434 comprises a heater wire 438 . Heater wire 438 extends from a spot weld 446 into distal end 434 to a looping point 440 and then proximally. Through spot weld 446 heater wire 438 is in electrical connection with elongated member 430 . Elongated member 430 is connected to one pole of a power source (not shown). The other end of heater wire 438 extending in the proximal direction after looping point 440 extends to wire 442 through an electrically and/or thermally shielded pathway 444 . Wire 442 is connected to the other pole of the power source.
Elongated member 430 comprises a rigid, or substantially rigid, physiologically acceptable, sterilizable material. Useful materials include stainless steel and other conducting metals or alloys. It is within the scope of the invention that the distal portion of elongated member 430 could be comprised of a rigid or substantially rigid non-conducting material such as a suitable polymer, for example, polystyrene or an ABS polymer or copolymer
It is intended that all matter contained in the above description and shown in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense. Also, it is understood that the following claims are intended to cover all of the generic and specific features of the invention herein described and all statements of the scope of the invention which, as a matter of language, might be said to fall therebetween.
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An instrument and method are provided for sealing and joining or hemostatically dividing tissue, which is particularly suitable for laparoscopic and endoscopic surgery. The instrument makes use of the controlled application of a combination of heat and pressure to seal adjacent tissues, to join adjacent tissues, or to anastomose tissues, whereby tissue is heated for an optimal time and at an optimal temperature under optimal pressure to maximize tissue seal strength while minimizing collateral tissue damage. The instrument of the present invention is lightweight and therefore portable, and is particularly useful in field conditions where a source of external power may not be readily available.
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This invention was made with government support under Grant No. N00014-86-K-0766 awarded by the Office of Naval Research. The government has certain rights in the invention.
CROSS-REFERENCE TO RELATED APPLICATIONS
The present invention is cross-referenced to Epstein and Yue U.S. Pat. Nos. 5,137,991, 5,093,439, 4,556,623, 5,135,696, 5,164,465, and 5,159,031, the disclosures of which are expressly incorporated herein by reference.
BACKGROUND OF THE INVENTION
The present invention relates to hydroxylated polyaniline and sulfonated polyaniline electrically-conductive compositions and more particularly to their use in sensing and modulating pH of a medium in association therewith.
Polyaniline is a family of polymers that has been under intensive study recently because the electronic and optical properties of the polymers can be modified through variations of either the number of protons, the number of electrons, or both. The polyaniline polymer can occur in several general forms, including the so-called reduced form (leucoemeraldine base), possessing the general formula: ##STR1## the partially oxidized or so-called emeraldine base form, of the general formula: ##STR2## and the fully oxidized or so-called pernigraniline form, of the general formula: ##STR3##
In practice, polyaniline generally exists as a mixture of the several forms with a general formula of: ##STR4##
When 0≦y≦1, the polyaniline polymers are referred to as poly(paraphenyleneammeimines) in which the oxidation state of the polymer continuously increases with decreasing values of y. The fully reduced poly(paraphenyleneamine) is referred to as leucoemeraldine, having the repeating units indicated above corresponding to a value of y=1. The fully oxidized poly(paraphenyleneimine) is referred to as pernigraniline, of repeat unit shown above corresponding to a value of y=0. The partially oxidized poly(paraphenyleneamineimine), with y in the range of greater than or equal to 0.35 and less than or equal to 0.65, is termed emeraldine, though the name "emeraldine" often is focused on the compositon where y is equal to (or approximately equal to) 0.5. Thus, the terms "leucoemeraldine", "emeraldine", and "pernigraniline" refer to different oxidation states of polyaniline. Each oxidation state can exist in the form of its base or in its protonated (salt) form by treatment of the base with an acid.
The use of the terms "protonated" and "partially protonated" herein includes, but is not limited to, the addition of hydrogen ions to the polymer by, for example, a pretonic acid, such as a mineral acid and/or organic acids. The use of the terms "protonated" and "partially protonated" herein also includes pseudoprotonation, wherein a cadon such as, but not limited to, a metal ion, M + , is introduced into the polymer. For example, "50%" protonadon of emeraldine formally leads to a composition of the formula: ##STR5## which may be written as: ##STR6##
Formally, the degree of protonation may vary from a ratio of [H + ]/[-N=]=0 to a ratio of [H + ]/[-N=]=1. Protonation or partial protonation at the amine (--NH) sites also may occur.
The electrical and optical properties of the polyaniline polymers vary with the different oxidation states and the different forms. For example, the leucoemeraldine base, emeraldine base, and pernigraniline base forms of the polymer are electrically insulating while the emeraldine salt (protonated) form of the polymer is conductive. Protonation of emeraldine base by aqueous 1M HCl to produce the corresponding salt brings about an increase in electrical conductivity by a factor of 10 12 . Deprotonation occurs reversibly in aqueous base or upon exposure to vapors which form aqueous bases, such as, for example, ammonia. The emeraldine salt form also can be achieved by electrochemical oxidation of the leucoemeraldine base polymer or electrochemical reduction of the pernigraniline base polymer in the presence of an electrolyte of the appropriate pH. The rate of the electrochemical reversibility is very rapid. Solid polyaniline can be switched between conducting, protonated, and nonconducting states at a rate of approximately 10 5 Hz for electrolytes in solution and even faster with solid electrolytes. (E. Paul, J. Phys. Chem., 1985, 89, 1441-1447).
The rate of electrochemical reversibility also is controlled by the thickness of the film, thin films exhibiting a faster rate than thick films. Polyaniline, then, can be reversibly switched from an insulating to a conducting form as a function of protonation level (controlled by ion insertion) and oxidation state (controlled by electrochemical potential). Thus, in contrast to, for example polypyrrole, polyaniline can be turned "on" by either an negative or a positive shift of the electrochemical potential, because polyaniline films essentially are insulating at sufficiently negative (approximately 0.00 V vs SCE) or positive (+0.7 V vs SCE) electrochemical potentials. Polyaniline also can then be turned "off" by an opposite shift of the electrochemical potential.
The conductivity of polyaniline is known to span 12 orders of magnitude and to be sensitive to pH and other chemical parameters. It is well-known that the resistance of films of both the emeraldine base and 50% protonated emeraldine hydrochloride polymer decrease by a factor of approximately 3-4 when exposed to water vapor. The resistance increases only very slowly on removing the water vapor under dynamic vacuum. The polyaniline polymer exhibits conductivities of approximately 1 to 200 Siemens per centimeter (S/cm) when approximately half of its nitrogen atoms are protonated. Electrically conductive polyaniline salts, such as fully protonated emeraldine salt [(--C 6 H 4 --NH--C 6 H 4 --NH + )--Cl-] x , have high conductivity (10 -4 to 10 +2 S/cm) and high dielectric constants (20 to 2,000), and have a dielectric loss tangent of from below 10 -3 to approximately 10 1 . Dielectric loss values are obtained in the prior art by, for example, carbon filled polymers, but these losses are not as large nor as readily controlled as those observed for polyaniline.
While the preparation of polyaniline polymers and the protonated derivatives thereof are known in the art, it is novel to prepare sulfonated polyaniline compositions which are capable of being "self-protonated" or "self-doped", as disclosed in the related applications cited above. Use of the terms "self-protonated" and "self-doped" herein includes, but is not limited to, the reorganization of hydrogen ions on the polymer chain. For example, self-doping or self-protonation of a polyaniline base polymer leads to a polyaniline salt polymer and a reorganization of the electronic structure which then forms a polaronic metal. The conductivity of such polaronic metal is independent of external protonation.
BROAD STATEMENT OF THE INVENTION
Broadly, the present invention takes advantage of the ability of self-protonated sulfonated polyaniline (SPAN) to sense and/or modulate pH of a medium in the vicinity of a SPAN electrode. Accordingly, one aspect of the present invention is directed to a method for sensing pH of a medium in the vicinity of a sensing electrode wherein a SPAN electrode and a counter-electrode are placed in a medium and an indicia of said SPAN correlative with the pH of said medium is monitored. Preferably, the SPAN indicia is one or more of electrical potential relative to a reference electrode, conductivity of the SPAN electrode, or color of the SPAN electrode. It is withing the scope of the sensing embodiment of the present invention to control one of the SPAN indicia by varying the pH of the medium. For this SPAN electrode indicia to be effective, nevertheless, the SPAN electrode would be "sensing" the pH of the medium. As another aspect of the present invention, the pH of a medium in the vicinity of a sensing electrode is modulated by placing a SPAN electrode in the medium and applying a voltage to the electrode to controllably emit or absorb protons from said electrode to modulate the pH of the medium in the vicinity of the electrode. As a further aspect of the present invention, the activity/state of a biosensor/catalyst is sensed for the activity/state correlative with pH. This aspect of the present invention comprises associating the biosensor/catalyst with the SPAN electrode in contact with a medium (e.g., the medium containing the biosensor/catalyst and/or the biosensor/catalyst being reacted with the SPAN and/or the biosensor being entrained by the SPAN) and monitoring an indicia of said SPAN correlative with pH which is correlative with the activity/state of one or more of said biosensor/catalyst, a substrate affected by said biosensor/catalyst, or a substrate which affects said biosensor/catalyst. Again, the SPAN indicia is one or more of electrical potential relative to a reference electrode, conductivity, or color. As a further aspect of the present invention, the activity/state of a biosensor/catalyst, where the activity/state is correlative with pH, is controlled by associating the biosensor/catalyst with a SPAN electrode in contact with a medium (e.g., the medium containing the biosensor/catalyst and/or the biosensor/catalyst being reacted with the SPAN and/or the biosensor being entrained by the SPAN), and applying a voltage to said electrode to controllably emit or absorb protons from said electrode to control the activity/state of said biosensor/catalyst. For present purposes, "activity/state" means "activity or state" and "biosensor/catalyst" means "biosensor or catalyst", in conventional fashion.
Additionally, a substituted polyaniline polymer where --OH replaces --SO 3 also is expected to function as does the SPAN electrode, though its E 1/2 (versus pH) does not behave theoretically, as can be seen by reference to FIG. 1. Nonetheless, hydroxylated polyaniline polymers are included within the disclosure of the present invention, even though most of the description will be by reference to SPAN electrodes, which is by way of illustration and not limitation.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 plots potention, E1/2, as a function of pH for the first oxidation wave for a hydroxylated polyaniline electrode versus a Ag/AgCl reference electrode;
FIG. 2 plots potential as a function of pH for the first and second(◯) oxidation waves for a SPAN electrode versus a Ag/AgCl reference electrode;
FIG. 3 plots the reduction potentials of the hydrogen and oxygen half-reactions of equations (IV) and (VI) as function of pH;
FIG. 4 plots the effect of pH on the rate of enzymatic reactions;
FIG. 5 plots pH as a function of potential for a SPAN coated Pt electrode using 0.2 ml of 1M NaCl with a pH of 7.88 as starring solution as described in Example 1;
FIG. 6 plots pH as a function of potential for a SPAN coated Pt electrode using 0.2 ml of 0.3M NaCl with a pH of 3.18 as starting solution as described in Example 2;
FIG. 7 plots pH as a function of potential for a SPAN coated Pt electrode using 0.2 ml of 1M NaCl with a pH of 5.62 as starting solution as described in Example 3; and
FIG. 8 plots pH as a function of potential, scan rate of potential being 10 mv/S, for a SPAN coated Pt electrode using 0.2 ml of 0.3M NaCl with a pH of 3.18 as starting solution as described in Example 4.
DETAILED DESCRIPTION OF THE INVENTION
Self-protonated sulfonated polyaniline (SPAN) compositions useful in practice of the present invention are disclosed in the applications cross-referenced above. Further information can be found in the following publications, the disclosures of which are expressly incorporated herein by reference: MacDiarmid et al, "Polyanilines: Synthesis, Chemistry and Processing", New Aspects of Organic Chemistry II, Proceedings of the Fifth International Kyoto Conference on New Aspects of Organic Chemistry, VCH (Weinheim) and Kodansha (Tokyo), Co-publishers (Spring 1992); Yue et al, "Effect of Sulfonic Acid Group on Polyaniline Backbone" JACS, 113, 2665-2671 (1991); Epstein et al, "Novel Concepts in Electronic Polymers: Polyaniline and its Derivatives", Die Makronwiekulare Chemie, Symposium Volume, Proceedings, International Symposium on Specialty Polymers, Singapore 7-9 November 1990; Epstein et al., "The Chemical Control of Processability, Electromagnetic Response and Other Properties of Polyanilines and Their Applications to Technologies", Proc. Society of Plastics Engineers, Annual Technical Conference, Montreal, Canada, 755-759 (5-9 May 1991); Yue et al, "Synthesis of Sels Doped Conducting Polyaniline", JACS, 112, 2800-2801 (1990); and Yue et al, "Comparison of Different Synthetic Routes for Sulfonation of Polyaniline", Polymer, to be published in 1992), the disclosures of which are expressly incorporated herein by reference.
Such SPAN materials can be represented by formula I (where for the sake of clarity only, the structure shown in formula I is in the non self-protonated form): ##STR7## wherein 0≦y≦1; R 1 , R 2 , R 3 , R 4 , R 5 , and R 6 independently are selected from the group consisting of --H, --SO 3 -, --SO 3 H, --R 7 SO 3 -, --OCH 3 , --CH 3 , --C 2 H 5 , --F, --Cl, --Br, --I, --(NR 7 ) 2 , --NHCOR 7 , --OH, --R 7 OH, --O-, --SR 7 , --OR 7 , --OCR 7 , --NO 2 , --COOH, --COOR 7 , --CHO, and --CN, wherein R 7 is a C 1 -C 8 alkyl, aryl, or aralkyl group.
For the SPAN material, the fraction of rings containing at least one R 1 , R 2 , R 3 , or R 4 group being an --SO 3 -, --SO 3 H, --R 7 SO 3 -, or --R 7 SO 3 H group, can be varied from a few percent (e.g. 20%) to one hundred percent. It is within the contemplated scope of the present invention that the --R 7 SO 3 -and --R 7 SO 3 H substituents can be varied so that the sulfonated polyaniline is soluble in a range of solvents in order to make the sulfonated polyaniline polymer more easily blendable with other polymers and/or more easily cast onto a variety of surfaces. For the hydroxylated polyaniline material, the fraction of rings containing at least one R 1 , R 2 , R 3 , or R 4 group being an --OH group or R 7 OH (wherein R 7 is a C 1 -C 8 alkyl, aryl, or aralkyl group), can be varied similarly. Copolymers, interpolymers, and similar variations of the polyaniline derivatives also can be prepared and used as is necessary, desirable, or convenient.
The solubility of sulfonated polyaniline can be varied by changing the degree of sulfonation (i.e., the sulfonation time and/or temperature in H 2 SO 4 (SO 3 )). It is noted that the oxidation state of the polymer (from leucoemeraldine through emeraldine to pernigraniline) and the degree of sulfonation (x) can be independently varied. Here, x is the fraction Of C 6 rings which have an --SO 3 -or an --SO 3 H group attached thereto.
When x=0, the polymer does not dissolve in either basic or acidic aqueous solutions. Upon increasing the value of x, the polymer becomes soluble in strongly basic, basic, weakly basic, and eventually in acidic aqueous solutions. This progressive improvement in solubility implies that the polymer becomes soluble in neutral media, particularly H 2 O, at the appropriate value of x, yielding a water-soluble conducting polymer. The color of soluble sulfonated polyaniline in acidic solution is green, indicating it is the conducting salt form.
The solubility of polyaniline is increased greatly in basic aqueous solution by the presence Of --SO 3 H group on the phenyl rings. This is in contrast with polyaniline which, when washed with basic solutions, converts to the insoluble base form.
Protonation of the emeraldine base polymer leads to the emeraldine salt polymer and a reorganization of the electronic structure to form a polaronic metal. Since benzenesulfonic acid is a strong acid, i.e. about as strong as hydrochloric acid, the sulfonated polyaniline is capable of self-doping. Hence, the conductivity of the sulfonated polyaniline is independent of external protonation.
Being able to dope itself, the sulfonated polyaniline polymer has enhanced optical and electrical response to electrochemical potential as compared with the parent polyaniline polymer. Since the solid-state diffusion of counterions in and out of a polymer during electrochemical processes often is the rate controlling step of the kinetics, it also limits the speed of both optical and electrical response of polymers. In the self-doped conjugated polymer, the counterions are not necessary from the medium. The positive charge introduced into the conjugated π electron system of the backbone of the polymer is compensated by the protons migrating out of the polymer, or vice versa, leaving behind the opposite charged counterion. Since the hydrogen ion or proton is the smallest and most mobile ion, proton hopping mechanisms lead to relatively fast doping kinetics as compared to those counterions migrating in or out of the polymer. As a consequence, it is possible to achieve sufficient speed with the SPAN electrode to be useful for a variety of technological applications.
Typical cyclic voltammograms of sulfonated polyaniline polymers reveal the two waves, the first oxidation wave varying in its potential as 59 mV/pH and the second oxidation wave varying in its potential as 118 mV/pH. FIG. 2 plots potential of a SPAN electrode versus a Ag/AgCl reference electrode as a function of pH, where the solid dots represent the first oxidation wave and the unfilled dots represent the second oxidation wave. Unique to the self-protonated SPAN electrodes is the ability to control the first oxidation wave.
Typical cyclic voltammograms of the hydroxylated polymers also reveals two oxidation waves, the first varying (on average) at 0.60 mV/pH. FIG. 1 plots potential of an hydroxylated polyaniline electrode versus a Ag/AgCl reference electrode as a function of pH. Unique to hydroxylated polyaniline electrodes is the ability to control the first oxidation wave in the manner shown in FIG. 1.
The SPAN material can be used neat, but preferably is used in a form exhibiting a large surface area. This makes the use of carriers for the SPAN film desirable. Carriers can include, for example, conductive electrodes optionally in screen or other high surface area form, zeolites or similar particulate carriers, or porous substrates such as films. Use of transparent conduction electrodes, such as ITO (indium tin oxide), facilitates optical monitoring of the SPAN and hydroxylated polyaniline electrodes. SPAN also can be entrained in a host polymer. The skilled artisan will appreciate the numerous possibilities that can be envisioned with respect to the form which the SPAN electrode takes for practice of the present invention.
One application is in sensing the pH of a medium into which the SPAN electrode is immersed. Response times in the millisecond range are appropriate for the SPAN electrode, thus making industrial applications even more attractive. This sensing process is non-destructive as no sample is consumed during the pH determination and can be non-intrusive, e.g. by permitting some of the medium to penetrate a membrane area in a wall in a container or other housing for the medium and then contact the SPAN electrode behind the membrane for pH determination.
In general, for an oxidation reaction involving the release of m protons and the transfer of n electrons, the expression for the electrode potential has the form (Bard et al, " Electrochemical Methods, Fundamental & Applications", John Wiley & Sons, New York, New York, 1981): ##EQU1## Hence, the variation of electrode potential with pH is described by the following equation: ##EQU2## With the above considerations in mind, the actual evaluation of oxidation reactions involving the release of m protons can be made. The simplest example is the proton hydrogen half-reaction,
H.sup.+ +e.sup.- →1/2H.sub.2 (IV)
The electrical potential, then, is: ##EQU3## and for the oxygen-water half-reaction:
1/2O.sub.2 +2H.sup.+ +2e.sup.- →H.sub.2 O (VI)
The electrical potential, then, is:
E=1.23+0.059 log{[H.sup.+ ]·P.sub.O2.sup.1/4 } (VII)
The potential for these half-reactions are plotted versus pH in FIG. 3 (Jolly, "The Principles of Inorganic Chemistry", Chapter 7, McGraw-Hill Book Co., New York, New York, 1976). Clearly, this plot shows that if one is able to change the pH of the medium, the reactivity of the system is changed. This is one aspect of application of pH modulation based on the SPAN electrode. Standard reduction potentials for systems of biochemical importance at pH=7 can be found, for example, by reference to Mahler et al, "Biological Chemistry", Chapter 3, Harper & Row Publishers, New York, New York, 1971. All of these values (or reactivities) can be changed by changing the pH of the medium.
Another important aspect of using pH modulation of a SPAN electrode is to control the reactivity of enzymes, which are but one class of biosensors, and sense the condition of the electrode. Almost all enzymes are extremely sensitive to pH, their activity being diminished at either side of a relatively narrow range. These effects are due to a combination of three factors: (1) effects of extremes of pH on protein structure, including alterations on the strength and mode of binding of prosthetic groups; (2) effects on the ionization of the substrate; and (3) effects on its binding to the enzyme and on reactivity in catalysis. (Bender, "Catalysis and Enzyme Action", Chapter 3, McGraw-Hill Book Co., New York, New York, 1973) It is the third class that is of concern here since the first two classes usually can be determined independently of the reaction under kinetic study and corrections made for their effects.
The initial rate of the enzyme reaction proper frequently exhibits three distinct phases as a function of pH as depicted at FIG. 4; a region of pH (at low values) where there is an increase, a region (at high values) where there is a decrease, and an intermediate range (usually around neutrality) where the activity is maximal and leading to a characteristic bell-shaped curve, the location of which, of course, depends upon the individual enzyme or enzyme-like substance. (McGilvery, "Biochemistry--A Functional Approach", Chapter 8, W. B. Saunders Co., Philadelphia, Pa. 1970) By applying the principle shown at FIG. 4, the reactivity of an enzyme can be controlled by the potential modulation of pH for a SPAN electrode in a system.
A possible industrial enzymatic use might be the various sugar producing or reducing enzymes, such as amylase or sucrase. If these enzymes cause protons to be taken up or given up by the media at the same time, then the SPAN electrode would become a specific product detector. The enzyme could be coated onto the electrode or chemically affixed to the SPAN material. For present purposes, an enzyme bound to the SPAN material is "in the vicinity of" for sensing and modulating pH. Also, proton transfer may be direct between the SPAN material and the bound enzyme (though this is presently unknown) and such transfer still is considered within the precepts of the present invention. Further information concerning biosensors can be found in Blum et al, "Biosensor Principles and Applications", Marcel Dekker, Inc., New York, N.Y. (1991), the disclosure of which is expressly incorporated herein by reference.
Regardless of the specific uses, pH modulation with the novel SPAN electrode has certain advantages that make it a potentially useful industrial process. For example, pH change can be easily controlled as micro pH changes are quite within the grasp of the inventive process. Also, the pH change is swift and can go either way, viz up or down. Further, the SPAN electrode provides high charge efficiency, e-/H + . Finally, the SPAN electrodes are easy to fabricate.
Additional applications include food and beverage applications, as well as medical and veterinary medicine applications. For example, sugar detection could be applied to diabetics to control insulin injections. Other in vivo applications that can be envisioned include blood monitoring by pH, enzyme, antibody, or other indicia. Monitoring the brewing and fermenting of beer by pH and enzyme monitoring also is a possible application. In the manner in which biosensors can be utilized, so can inorganic, organic or other catalysts that directly or indirectly take up or emit protons.
The photophysical properties of SPAN in which a color change is experienced in the various oxidation states of the polymer also lead to a number or interesting possible in industrial applications. The voltage required for this change is on the order of 0.5 V and is within the solid state electronic area of application technology. Color generation, or color amplification with respect to voltage, may be useful in signage or other displays, LEDS, television screen manufacture, and the like. Alternatively, a pH indicator or dye could be dispersed in the medium, or otherwise associated with the medium, and pH change sensed or displayed by such indicator in such manner that a flat panel electronic display or flexible high resolution flat panel display can be fabricated. Further, a dye could be associated with the electrode (e.g. by commingling the indicator with SPAN, by the indicator being reacted with SPAN, or by the indicator being reacted with another polymer which then is commingled with SPAN) which dye is color sensitive to potential or conductivity of the electrode, and such dye used to display pH. Dyes or color indicators are well-known to the skilled artisan and can be found by reference to, for example, "Handbook of Chemistry and Physics", pp D-148 and D-149, 66th Edition, The Chemical Rubber Company, Cleveland, Oh. (1985-1986), the disclosure of which is expressly incorporated herein by reference.
Thus, it will be observed that a wide variety of industrial applications are possible using the pH/SPAN interaction disclosed herein as those skilled in the art will appreciate. In this application, all references are expressly incorporated herein by reference.
EXAMPLES
Example 1
About 0.2 mg of SPAN was dissolved into 0.2 nd of 0.1M NH 4 OH and cast onto a 0.25 cm 2 Pt electrode. The SPAN electrode was dried in air. Then, the electrode was dipped into 1M HCl solution for 30 seconds. After the electrode was rinsed with plenty of water, it was further immersed into 20 ml of deionized water for 30 min. After such procedures, the SPAN electrode was ready to be used.
About 0.2 ml of 1M NaCl with pH of 7.88 was placed on the electrode. By step changing the potential of the electrode while the pH change of the solution was monitored by the pH electrode, the relationship between pH and applied potential can be obtained.
The results recorded are displayed at FIG. 5.
Example 2
The procedure reported in Example 1 was repeated, except that 0.3M NaCl with a pH of 3.18 was used as the starting solution. The change of pH as a function of potential is shown at FIG. 6.
Example 3
The procedure reported in Example 1 was repeated, except that 1M NaCl with a pH of 5.62 was used as the starting solution. The change of pH as a function of change of potential is shown at FIG. 7.
Example 4
The procedure reported in Example 2 was repeated, except that the potential was changed continuously instead of stepwise. The change of pH as a function of potential is shown at FIG. 8.
Example 5
About 0.2 mg of SPAN was dissolved into 0.2 ml of a 0.1M NH 4 OH and cast onto a 0.25 cm 2 Pt electrode. The SPAN electrode was dried in air. Then, the electrode was dipped into a 1M HCl solution for 30 seconds. After the electrode was rinsed with plenty of water, it was further immersed into 20 ml of deionized water for 30 min. After such procedures, the SPAN electrode was ready to be used.
Chymotrypsin (an enzyme, 10 mg) was dissolved into 2 ml of 0.5M NaCl, and succinyl-Ala-Ala-Pro-phe-4-nitroanilide (substrate, 10 mg) was dissolved into 0.5M NaCl. Due to the cleavage of phe- and nitroanilide, the ratio, R, of the absorbances at 375 nm (reacted substrate) to 320 nm (unreacted substrate) varies with the oxidation states of SPAN, i.e. the pH of the solution. For sulfonated polyaniline held at 0.30 V, 0.10 V and -0.2 V vs Ag for 20 minutes reaction time, R was determined to be 1.36, 1.26, and 0.94, respectively, indicating that the reactivity of the chymotrypsin enzyme is affected by the change of pH.
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Broadly, the present invention takes advantage of the ability of self-protonated sulfonated polyaniline (SPAN) to sense and/or modulate pH of a medium in the vicinity of a SPAN electrode. Accordingly, one aspect of the present invention is directed to a method for sensing pH of a medium in the vicinity of a sensing electrode wherein a SPAN electrode and a counter-electrode are placed in a medium and an indicia of said SAN correlative with the pH of said medium is monitored. As another aspect of the present invention, the pH of a medium in the vicinity of a sensing electrode is modulated by placing a SPAN electrode in the medium and applying a voltage to the electrode to controllably emit or absorb protons from said electrode to modulate the pH of the medium in the vicinity of the electrode. As a further aspect of the present invention, the activity/state of a biosensor/catalyst is sensed for the activity/state correlative with pH. As a further aspect of the present invention, the activity/state of a biosensor/catalyst, where the activity/state is correlative with pH, is controlled by associating the biosensor/catalyst with a SPAN electrode in contact with a medium containing said biosensor/catalyst, and applying a voltage to said electrode to controllably emit or absorb protons from said electrode to control the activity/state of said biosensor/catalyst.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention concerns personal care compositions providing moisturization both in high and low relative humidity environments.
2. The Related Art
Dry skin is a problem in varying degree to most humans. This condition is particularly evident in winter. Personal care products such as skin creams/lotions, shampoos/conditioners, toilette bars/shower gels and antiperspirant/deodorants are normally formulated with at least one material to address dry skin. Symptoms such as itching flaking and a visually displeasing dermal appearance can all to some extend be modulated.
There are three classes of materials employed against the problem. Occlusives such as petrolatum or silicone oils serve to inhibit loss of natural moisture. They form a barrier between the epidermis and the environment. Another approach is the use of keratolytic agents to enhance rate of dermal exfoliation. Alpha-hydroxy acids are the most common agents for achieving exfoliation.
A third approach to dry skin is topical application of humectants. Hydroxylated monomeric and polymeric organic substances are generally used for this purpose. Glycerin known also as glycerol is one of the most effective humectants.
There are several shortcomings in the performance of known humectants. Even the best such as glycerin requires to be formulated at relatively high levels to achieve good moisturization. Secondly, known humectants perform well in high relative humidity environments; however, hardly any of these substances provide effectiveness at low relative humidity (i.e. less than 20% moisture at 20° C.). Average indoor relative humidity during winter is approximately 13% in areas such as the Northeast U.S. It is quite evident that a real need exists for an improved moisturization technology.
A moisturizer known as Honeyquat 50 with INCl name of Hydroxypropyltrimonium Honey has been reported to be a better humectant than glycerin. See the Arch/Brooks brochure titled “Cosmetic Ingredients & Ideas®”, Issue No. 2, August 2001. Honeyquat 50 is described as being derived from the reaction of pendent hydroxyl groups (on the disaccharide) of a “light” deodorized grade of honey with a chlorohydroxytrimethylammonium derivative. Although this substance has excellent humectancy, moisturization at low relative humidity still remains to be conquered.
Accordingly, the present invention seeks to identify humectants which are operative not only at high but also low relative humidity, for application in personal care products.
SUMMARY OF THE INVENTION
A personal care composition is provided which includes:
(i) from about 0.0000001 to about 10% by weight of a quaternized ammonium trihydroxy dipropyl ether selected from the group consisting of formula (I), (II) and mixtures thereof.
wherein R is the same or different C 1 -C 3 alkyl or hydroxylalkyl group and X − is a cosmetically acceptable organic or inorganic anion; and
(ii) a cosmetically acceptable carrier.
DETAILED DESCRIPTION OF THE INVENTION
Now it has been found that dipropyl ethers substituted with a quaternary ammonium and three hydroxyl groups are excellent moisturizers providing humectancy in both high and low relative humidity environments. These mono-ethers have the structural formula (I) and (II):
wherein R is the same or different C 1 -C 3 alkyl or hydroxylalkyl group and X − is a cosmetically acceptable organic or inorganic anion.
Ordinarily the C 1 -C 3 alkyl constituent on the quaternized ammonium group will be methyl, ethyl, n-propyl, isopropyl or hydroxyethyl and mixtures thereof. Particularly preferred is a trimethyl ammonium group known through INCl nomenclature as a “trimonium” group. Any anion can be used in the quat salt. The anion may be organic or inorganic with proviso that the material is cosmetically acceptable. Typical inorganic anions are halides, sulfates, phosphates, nitrates and borates. Most preferred are the halides, especially chloride. Organic anionic counter ions include methosulfate, toluoyl sulfate, acetate, citrate, tartrate, lactate, gluconate, and benzenesulfonate. Amounts of these dipropyl ethers may range from about 0.0000001 to about 10%, preferably from about 0.00001 to about 8%, more preferably from about 0.0001 to about 5%, still more preferably from about 0.001 to about 3%, even more preferably from about 0.1 to about 1% by weight of the composition.
Synthesis of the preferred dipropyl ethers (V) and (VI) is achieved by any of the synthetic methods described below: 1) reaction of 2,3-dihydroxypropyl trimethylammonium chloride (III) with 1-chloro-2,3-dihydroxypropane (IV) in the presence of aqueous sodium hydroxide (aq. NaOH) (Scheme 1); 2) treatment of 2,3-dihydroxypropyl trimethylammonium chloride (III) with sodium hydride (NaH) in N,N-dimethylformamide (DMF) or 1-methyl-2-pyrrolidinone (NMP), followed by addition of 1-chloro-2,3-dihydroxypropane (IV) (Scheme II); 3) reaction of 2,3-dihydroxypropyl trimethylammonium chloride (III) with 4-chloromethyl-2,2-dimethyl-1,3-dioxolane (VII) in aqueous basic media, followed by acidification (Scheme III); 4) treatment of 2,2-dimethyl-4-hydroxymethyl-1,3-dioxolane (VIII) with sodium hydride in N,N-dimethylformamide or 1-methyl-2-pyrrolidinone, followed by addition of 1,3-dichloro-2-propanol (IX) and final addition of trimethylamine (X) (Scheme IV). The reaction schemes for the synthetic methods described above are shown below.
Thus, the present invention also provide new materials as identified by structures (V) and (VI) and a process of manufacture as reported above. The process in its general form reacts 1-chloro-2,3-dihydroxypropane with 2,3-dihydroxypropyl-1-tri(C 1 -C 3 ) ammonium salt in a relative molar ratio ranging from about 3:1 to about 1:3, preferably about 1:1. The reaction is run in the presence of an alkali material which may be sodium hydroxide, potassium hydroxide, lithium hydroxide, calcium oxide, calcium hydroxide or sodium carbonate. The reaction can be run in protic or aprotic medium. Preferably the medium is protic, especially water. Nonetheless, other useful solvents include diethylether, tetrahydrofuran, ethanol, methanol, N,N-dimethylformamide, 1-methyl-2-pyrrolidinone and any mixtures thereof. Alternatively the reaction may be run neat without any solvent. Process temperatures may range from 5° C. to 200° C., with preference given over the range 20 to 50° C.
Advantageously, compositions of the present invention may also include 2,3-dihydroxypropyl tri(C 1 -C 3 alkyl or hydroxyalkyl) ammonium salts, the alkyl and salt corresponding to R and X of formula (I) and/or (II). Most preferred for the aforementioned non-ether quat is 2,3-dihydroxypropyl trimethyl ammonium chloride. When the dipropyl ether and non-ether quats are formulated together, they may be present in a weight ratio ranging from about 1:1 to about 1:10,000, preferably from about 1:10 to about 1:5,000, more preferably from about 1:100 to about 1:1,000.
By the term personal care composition is meant any substance applied to a human body for improving appearance, cleansing, odor control or general aesthetics. Nonlimiting examples of personal care compositions include leave-on skin lotions and creams, shampoos, hair conditioners, shower gels, toilet bars, antiperspirants, deodorants, dental products, shave creams, depilatories, lipsticks, foundations, mascara, sunless tanners and sunscreen lotions.
Compositions of this invention will also include a cosmetically acceptable carrier. Amounts of the carrier may range from about 1 to about 99.9%, preferably from about 70 to about 95%, optimally from about 80 to about 90% by weight of the composition. Among the useful carriers are water, emollients, fatty acids, fatty alcohols, thickeners and combinations thereof. The carrier may be aqueous, anhydrous or an emulsion. Preferably the compositions are aqueous, especially water and oil emulsions of the W/O or O/W or triplex W/O/W variety. Water when present may be in amounts ranging from about 5 to about 95%, preferably from about 20 to about 70%, optimally from about 35 to about 60% by weight.
Emollient materials may serve as cosmetically acceptable carriers. These may be in the form of silicone oils, natural or synthetic esters and hydrocarbons. Amounts of the emollients may range anywhere from about 0.1 to about 95%, preferably between about 1 and about 50% by weight of the composition.
Silicone oils may be divided into the volatile and nonvolatile variety. The term “volatile” as used herein refers to those materials which have a measurable vapor pressure at ambient temperature. Volatile silicone oils are preferably chosen from cyclic (cyclomethicone) or linear polydimethylsiloxanes containing from 3 to 9, preferably from 4 to 5, silicon atoms.
Nonvolatile silicone oils useful as an emollient material include polyalkyl siloxanes, polyalkylaryl siloxanes and polyether siloxane copolymers. The essentially nonvolatile polyalkyl siloxanes useful herein include, for example, polydimethyl siloxanes with viscosities of from about 5×10 −6 to 0.1 m 2 /s at 25° C. Among the preferred nonvolatile emollients useful in the present compositions are the polydimethyl siloxanes having viscosities from about 1×10 −5 to about 4×10 −4 m 2 /s at 25° C.
Another class of nonvolatile silicones are emulsifying and non-emulsifying silicone elastomers. Representative of this category is Dimethicone/Vinyl Dimethicone Crosspolymer available as Dow Corning 9040, General Electric SFE 839, and Shin-Etsu KSG-18. Silicone waxes such as Silwax WS-L (Dimethicone Copolyol Laurate) may also be useful.
Among the ester emollients are:
a) Alkyl esters of saturated fatty acids having 10 to 24 carbon atoms. Examples thereof include behenyl neopentanoate, isononyl isonanonoate, isopropyl myristate and octyl stearate.
b) Ether-esters such as fatty acid esters of ethoxylated saturated fatty alcohols.
c) Polyhydric alcohol esters. Ethylene glycol mono and di-fatty acid esters, diethylene glycol mono- and di-fatty acid esters, polyethylene glycol (200-6000) mono- and di-fatty acid esters, propylene glycol mono- and di-fatty acid esters, polypropylene glycol 2000 monostearate, ethoxylated propylene glycol monostearate, glyceryl mono- and di-fatty acid esters, polyglycerol poly-fatty esters, ethoxylated glyceryl mono-stearate, 1,3-butylene glycol monostearate, 1,3-butylene glycol distearate, polyoxyethylene polyol fatty acid ester, sorbitan fatty acid esters, and polyoxyethylene sorbitan fatty acid esters are satisfactory polyhydric alcohol esters, Particularly useful are pentaerythritol, trimethylolpropane and neopentyl glycol esters of C 1 -C 30 alcohols.
d) Wax esters such as beeswax, spermaceti wax and tribehenin wax.
e) Sugar ester of fatty acids such as sucrose polybehenate and sucrose polycottonseedate.
Natural ester emollients principally are based upon mono-, di- and tri-glycerides. Representative glycerides include sunflower seed oil, cottonseed oil, borage oil, borage seed oil, primrose oil, castor and hydrogenated castor oils, rice bran oil, soybean oil, olive oil, safflower oil, shea butter, jojoba oil and combinations thereof. Animal derived emollients are represented by lanolin oil and lanolin derivatives. Amounts of the natural esters may range from about 0.1 to about 20% by weight of the compositions.
Hydrocarbons which are suitable cosmetically acceptable carriers include petrolatum, mineral oil, C 11 -C 13 isoparaffins, polybutenes, and especially isohexadecane, available commercially as Permethyl 101A from Presperse Inc.
Fatty acids having from 10 to 30 carbon atoms may also be suitable as cosmetically acceptable carriers. Illustrative of this category are pelargonic, lauric, myristic, palmitic, stearic, isostearic, oleic, linoleic, linolenic, hydroxystearic and behenic acids.
Fatty alcohols having from 10 to 30 carbon atoms are another useful category of cosmetically acceptable carrier. Illustrative of this category are stearyl alcohol, lauryl alcohol, myristyl alcohol, oleyl alcohol and cetyl alcohol.
Thickeners can be utilized as part of the cosmetically acceptable carrier of compositions according to the present invention, Typical thickeners include crosslinked acrylates (e.g. Carbopol 982®), hydrophobically-modified acrylates (e.g. Carbopol 1382®), polyacrylamides (e.g. Sepigel 305®), acryloylmethylpropane sulfonic acid/salt polymers and copolymers (e.g. Aristoflex HMB® and AVC®), cellulosic derivatives and natural gums. Among useful cellulosic derivatives are sodium carboxymethylcellulose, hydroxypropyl methocellulose, hydroxypropyl cellulose, hydroxyethyl cellulose, ethyl cellulose and hydroxymethyl cellulose. Natural gums suitable for the present invention include guar, xanthan, scierotium, carrageenan, pectin and combinations of these gums. Inorganics may also be utilized as thickeners, particularly clays such as bentonites and hectorites, fumed silicas, talc, calcium carbonate and silicates such as magnesium aluminum silicate (Veegum®). Amounts of the thickener may range from 0.0001 to 10%, usually from 0.001 to 1%, optimally from 0.01 to 0.5% by weight of the composition.
Adjunct humectants may be employed in the present invention. These are generally polyhydric alcohol-type materials. Typical polyhydric alcohols include glycerol, propylene glycol, dipropylene glycol, polypropylene glycol, polyethylene glycol, sorbitol, hydroxypropyl sorbitol, hexylene glycol, 1,3-butylene glycol, isoprene glycol, 1,2,6-hexanetriol, ethoxylated glycerol, propoxylated glycerol and mixtures thereof. The amount of adjunct humectant may range anywhere from 0.5 to 50%, preferably between 1 and 15% by weight of the composition.
Personal care compositions of the present invention may be in any form. These forms may include lotions, creams, roll-on formulations, sticks, mousses, aerosol and non-aerosol sprays and fabric (e.g. nonwoven textile)-applied formulations.
Surfactants may also be present in compositions of the present invention. Total concentration of the surfactant when present may range from about 0.1 to about 90%, preferably from about 1 to about 40%, optimally from about 1 to about 20% by weight of the composition, and being highly dependent upon the type of personal care product. The surfactant may be selected from the group consisting of anionic, nonionic, cationic and amphoteric actives. Particularly preferred nonionic surfactants are those with a C 10 -C 20 fatty alcohol or acid hydrophobe condensed with from 2 to 100 moles of ethylene oxide or propylene oxide per mole of hydrophobe; C 2 -C 10 alkyl phenols condensed with from 2 to 20 moles of alkylene oxide; mono- and di-fatty acid esters of ethylene glycol, fatty acid monoglyceride; sorbitan, mono- and di-C 8 -C 20 fatty acids; and polyoxyethylene sorbitan as well as combinations thereof. Alkyl polyglycosides and saccharide fatty amides (e.g. methyl gluconamides) and trialkylamine oxides are also suitable nonionic surfactants.
Preferred anionic surfactants include soap, alkyl ether sulfates and sulfonates, alkyl sulfates and sulfonates, alkylbenzene sulfonates, alkyl and dialkyl sulfosuccinates, C 8 -C 20 acyl isethionates, C 8 -C 20 alkyl ether phosphates, C 8 -C 20 sarcosinates, C 8 -C 20 acyl lactylates, suIfoacetates and combinations thereof.
Useful amphoteric surfactants include cocoamidopropyl betaine, C 12 -C 20 trialkyl betaines, sodium lauroamphoacetate, and sodium laurodiamphoacetate.
Sunscreen agents may also be included in compositions of the present invention. Particularly preferred are such materials as ethylhexyl p-methoxycinnamate, available as Parsol MCX®, Avobenzene, available as Parsol 1789® and benzophenone-3, also known as Oxybenzone. Inorganic sunscreen actives may be employed such as microfine titanium dioxide and zinc oxide. Amounts of the sunscreen agents when present may generally range from 0.1 to 30%, preferably from 2 to 20%, optimally from 4 to 10% by weight of the composition.
Antiperspirants and deodorant compositions of the present invention ordinarily will contain astringent actives. Examples include aluminum chloride, aluminum chlorhydrex, aluminum-zirconium chlorhydrex glycine, aluminum sulfate, zinc sulfate, zirconium and aluminum chlorohydroglycinate, zirconium hydroxychloride, zirconium and aluminum lactate, zinc phenolsulfonate and combinations thereof. Amounts of the astringents may range anywhere from about 0.5 to about 50% by weight of the composition.
Dental products formulated according to the present invention will generally contain a fluoride source to prevent dental caries. Typical anti-caries actives include sodium fluoride, stannous fluoride and sodium monofluoro phosphate. Amounts of these materials will be determined by the amount of fluoride releasable which should range between about 500 to about 8800 ppm of the composition. Other components of dentifrices can include desensitizing agents such as potassium nitrate and strontium nitrate, sweeteners such as sodium saccharine, aspartame, sucralose, and potassium acesulfam. Thickeners, opacifying agents, abrasives and colorants will normally also be present.
Preservatives can desirably be incorporated into the personal care compositions of this invention to protect against the growth of potentially harmful microorganisms. Particularly preferred preservatives are phenoxyethanol, methyl paraben, propyl paraben, imidazoiidinyl urea, dimethyloldimethylhydantoin, ethylenediaminetetraacetic acid salts (EDTA), sodium dehydroacetate, methylchloroisothiazolinone, methylisothiazolinone, iodopropynbutylcarbamate and benzyl alcohol. The preservatives should be selected having regard for the use of the composition and possible incompatibilities between the preservatives and other ingredients. Preservatives are preferably employed in amounts ranging from 0.01% to 2% by weight of the composition.
Compositions of the present invention may include vitamins. Illustrative vitamins are Vitamin A (retinol), Vitamin B 2 , Vitamin B 3 (niacinamide), Vitamin B 6 , Vitamin C, Vitamin E, Folic Acid and Biotin. Derivatives of the vitamins may also be employed. For instance, Vitamin C derivatives include ascorbyl tetraisopalmitate, magnesium ascorbyl phosphate and ascorbyl glycoside. Derivatives of Vitamin E include tocopheryl acetate, tocopheryl palmitate and tocopheryl linoleate. DL-panthenol and derivatives may also be employed. For purposes of this invention, vitamins where present are not considered as unsaturated materials. Total amount of vitamins when present in compositions according to the present invention may range from 0.001 to 10%, preferably from 0.01% to 1%, optimally from 0.1 to 0.5% by weight of the composition.
Another type of useful substance can be that of an enzyme such as amylases, oxidases, proteases, lipases and combinations. Particularly preferred is superoxide dismutase, commercially available as Biocell SOD from the Brooks Company, USA.
Skin lightening compounds may be included in the compositions of the invention. Illustrative substances are placental extract, lactic acid, niacinamide, arbutin, kojic acid, ferulic acid, resorcinol and derivatives including 4-substituted resorcinols and combinations thereof. Amounts of these agents may range from about 0.1 to about 10%, preferably from about 0.5 to about 2% by weight of the composition.
Desquamation promoters may be present. Illustrative are the alpha-hydroxycarboxylic acids and beta-hydroxycarboxylic acids. The term “acid” is meant to include not only the free acid but also salts and C 1 -C 30 alkyl or aryl esters thereof and lactones generated from removal of water to form cyclic or linear lactone structures. Representative acids are glycolic, lactic and malic acids. Salicylic acid is representative of the beta-hydroxycarboxylic acids. Amounts of these materials when present may range from about 0.01 to about 15% by weight of the composition.
A variety of herbal extracts may optionally be included in compositions of this invention. The extracts may either be water soluble or water-insoluble carried in a solvent which respectively is hydrophilic or hydrophobic. Water and ethanol are the preferred extract solvents. Illustrative extracts include those from green tea, chamomile, licorice, aloe vera, grape seed, citrus unshui, willow bark, sage, thyme and rosemary.
Also included may be such materials as lipoic acid, retinoxytrimethylsilane (available from Clariant Corp. under the Silcare 1M-75 trademark), dehydroepiandrosterone (DHEA) and combinations thereof. Ceramides (including Ceramide 1, Ceramide 3, Ceramide 3B and Ceramide 6) as well as pseudoceramides may also be useful. Amounts of these materials may range from about 0.000001 to about 10%, preferably from about 0.0001 to about 1% by weight of the composition.
Colorants, opacifiers and abrasives may also be included in compositions of the present invention. Each of these substances may range from about 0.05 to about 5%, preferably between 0.1 and 3% by weight of the composition.
The compositions of the present invention can also be, optionally, incorporated into an insoluble substrate for application to the skin such as in the form of a treated wipe.
A wide variety of packaging can be employed to store and deliver the personal care compositions. Packaging is often dependent upon the type of personal care end-use. For instance, leave-on skin lotions and creams, shampoos, conditioners and shower gels generally employ plastic containers with an opening at a dispensing end covered by a closure. Typical closures are screw-caps, non-aerosol pumps and flip-top hinged lids. Packaging for antiperspirants, deodorants and depilatories may involve a container with a roll-on ball on a dispensing end. Alternatively these types of personal care products may be delivered in a stick composition formulation in a container with propel-repel mechanism where the stick moves on a platform towards a dispensing orifice. Metallic cans pressurized by a propellant and having a spray nozzle serve as packaging for antiperspirants, shave creams and other personal care products. Toilette bars may have packaging constituted by a cellulosic or plastic wrapper or within a cardboard box or even encompassed by a shrink wrap plastic film.
The term “comprising” is meant not to be limiting to any subsequently stated elements but rather to encompass non-specified elements of major or minor functional importance. In other words the listed steps, elements or options need not be exhaustive. Whenever the words “including” or “having” are used, these terms are meant to be equivalent to “comprising” as defined above.
Except in the operating and comparative examples, or where otherwise explicitly indicated, all numbers in this description indicating amounts of material ought to be understood as modified by the word “about”.
All documents referred to herein, including all patents, patent applications, and printed publications, are hereby incorporated by reference in their entirety in this disclosure.
The following examples will more fully illustrate the embodiments of this invention. All parts, percentages and proportions referred to herein and in the appended claims are by weight unless otherwise illustrated.
Example 1a
This Example reports the synthesis of 1-trimethylammonium-2,5,6-trihydroxydipropyl ether chloride and 1-trimethylammonium-2-hydroxymethyl-4,5-dihydroxypropyl ethyl ether chloride. To a solution of 2,3-dihydroxypropyl trimethylammonium chloride (500 mg, 2.95 mmol) in aqueous sodium hydroxide (2.95 ml, 2.95 mmol) was added 1-chloro-2,3-dihydroxypropane (247 uL, 2.95 mmol). The resultant solution was stirred at room temperature until the pH decreased to <9 The solution was washed with ether and the aqueous layer evaporated under reduced pressure at 50° C. yielding a heterogeneous colorless syrup. Filtration through glass wool affords an isomeric mixture of 1-trimethylammonium-2,5,6-trihydroxydipropyl ether chloride and 1-trimethylammonium-2-hydroxymethyl-4,5-dihydroxypropyl ethyl ether chloride as a homogeneous syrup: m/z (ESI; M + -Cl − ).
Example 1b
This Example reports the synthesis of 1-trimethylammonium-2,5,6-trihydroxydipropyl ether chloride and 1-trimethylammonium-2-hydroxymethyl-4,5-dihydroxypropyl ethyl ether chloride. 2,3-Dihydroxypropyl trimethylammonium chloride (500 mg, 2.95 mmol) is added to a suspension of sodium hydride (2.95 mmol) in N,N-dimethylformamide or 1-methyl-2-pyrrolidone (3-10 ml) and the resulting mixture stirred at room temperature until gas evolution ceases. This mixture is then added to 1-chloro-2,3-dihydroxypropane (247 uL, 2.95 mmol) and the resultant mixture stirred at room temperature until the pH decreases to <9. The solvent is removed under reduced pressure at 50° C. and the residue dissolved in water and washed several times with ether. Removal of the water under reduced pressure at 50° C., followed by filtration through glass wool affords an isomeric mixture of 1-trimethylammonium-2,5,6-trihydroxydipropyl ether chloride and 1 trimethylammonium-2-hydroxymethyl-4,5-dihydroxypropyl ethyl ether chloride as a homogeneous syrup.
Example 1c
This Example reports the synthesis of 1-trimethylammonium-2,5,6-trihydroxydipropyl ether chloride and 1-trimethylammonium-2-hydroxymethyl-4,5-dihydroxypropyl ethyl ether chloride. To a solution of 2,3-dihydroxypropyl trimethylammonium chloride (500 mg, 2.95 mmol) in aqueous sodium hydroxide (2.95 ml, 2.95 mmol) is added 4-chloromethyl-2,2-dimethyl-1,3-dioxolane (418 ul, 2.95 mmol). The resultant solution is stirred at room temperature until the pH decreased to <9 and further washed with ether. Glacial acetic acid (8 ml) is added and the solution stirred room temperature for 16 h. The solution is evaporated under reduced pressure at 50° C. yielding a heterogeneous colorless syrup. Filtration through glass wool affords an isomeric mixture of 1-trimethylammonium-2,5,6-trihydroxydipropyl ether chloride and 1-trimethylammonium-2-hydroxymethyl-4,5-dihydroxypropyl ethyl ether chloride as a homogeneous syrup.
Example 1d
This Example reports the synthesis of 1-trimethylammonium-2,5,6-trihydroxydipropyl ether chloride. 2,2-Dimethyl-4-hydroxymethyl-1,3-dioxolane (367 ul, 2.95 mmol) is added to a suspension of sodium hydride (2.95 mmol) in N,N-dimethylformamide or 1-methyl-2-pyrrolidone (3-10 ml) and the resulting mixture stirred at room temperature until gas evolution ceases. This mixture is then added to 1,3-chloro-2-propanol (281 uL, 2.95 mmol) and the resultant mixture stirred at room temperature until the pH decreases to <9. The solvent is removed under reduced pressure at 50° C. and the residue dissolved in water and washed several times with ether. Removal of the water under reduced pressure at 50° C., followed by filtration through glass wool affords 1-trimethylammonium-2,5,6-trihydroxydipropyl ether chloride as a homogeneous syrup.
Example 2
A representative personal care composition of the present invention in the form of a cosmetic lotion is outlined under Table I.
TABLE I
INGREDIENT
WEIGHT %
PHASE A
Water
Balance
Disodium EDTA
0.05
Methyl Paraben
0.15
Magnesium Aluminum Silicate
0.60
Triethanolamine
1.20
Quaternized Ammonium Trihydroxy
1.00
Dipropylether Salt of Example 1c
PHASE B
Xanthan Gum
0.20
Natrosol ® 250HHR (ethyl cellulose)
0.50
Butylene Glycol
3.00
Glycerin
2.00
PHASE C
Sodium Stearoyl Lactylate
0.10
Glycerol Monostearate
1.50
Stearyl Alcohol
1.50
Isostearyl Palmitate
3.00
Silicone Fluid
1.00
Cholesterol
0.25
Sorbitan Stearate
1.00
Butylated Hydroxy Toluene
0.05
Vitamin E Acetate
0.01
PEG-100 Stearate
2.00
Stearic Acid
3.00
Propyl Paraben
0.10
Parsol MCX ®
2.00
Caprylic/Capric Triglyceride
0.50
Hydroxycaprylic Acid
0.01
C12-15 Alkyl Octanoate
3.00
PHASE D
Vitamin A Palmitate
0.10
Bisabolol
0.01
Vitamin A Acetate
0.01
Fragrance
0.03
Retinol 50C
0.02
Conjugated Linoleic Acid
0.50
Example 3
A water-in-oil topical liquid make-up foundation according to invention is described in Table II below.
TABLE II
INGREDIENT
WEIGHT %
PHASE A
Cyclomethicone
9.25
Oleyl Oleate
2.00
Dimethicone Copolyol
20.00
PHASE B
Talc
3.38
Pigment (Iron Oxides)
10.51
Spheron L-1500 (Silica)
0.50
PHASE C
Synthetic Wax Durachem 0602
0.10
Arachidyl Behenate
0.30
PHASE D
Cyclomethicone
1.00
Trihydroxystearin
0.30
PHASE E
Laureth-7
0.50
Propyl Paraben
0.25
PHASE F
Fragrance
0.05
PHASE G
Water
balance
Quaternized Ammonium Trihydroxy
3.00
Dipropylether Salt of Example 1a
Methyl Paraben
0.12
Propylene Glycol
8.00
Niacinamide
4.00
Glycerin
3.00
Sodium Chloride
2.00
Sodium Dehydroacetate
0.30
Example 4
Illustrated herein is a skin cream incorporating a dipropyl ether salt of the present invention and a non-ether quat.
TABLE III
INGREDIENT
WEIGHT %
Glycerin
6.93
Niacinamide
5.00
2,3-Dihydroxypropyl Trimethyl
5.00
Ammonium Chloride
Permethyl 101A 1
3.00
Sepigel 305 2
2.50
Q2-1403 3
2.00
Linseed Oil
1.33
Arlatone 2121 4
1.00
Cetyl Alcohol CO-1695
0.72
SEFA Cottonate 5
0.67
Tocopherol Acetate
0.50
Panthenol
0.50
Stearyl Alcohol
0.48
Titanium Dioxide
0.40
Quaternized Ammonium Trihydroxy
0.10
Dipropylether Salt of Example 1a
Disodium EDTA
0.10
Glydant Plus 6
0.10
PEG-100 Stearate
0.10
Stearic Acid
0.10
Purified Water
Balance
1 Isohexadecane, Presperse Inc., South Plainfield, NJ
2 Polyacrylamide (and) C13-14 Isoparaffin (and) Laureth-7, Seppic Corporation, Fairfield, NJ
3 dimethicone (and) dimethiconol, Dow Corning Corp. Midland, MI
4 Sorbitan Monostearate and Sucrococoate, ICI Americas Inc., Wilmington, DE
5 Sucrose ester of fatty acid
6 DMDM Hydantoin (and) Iodopropynyl Butylcarbamate, Lonza Inc., Fairlawn, NJ
Example 5
Illustrative of another cosmetic composition incorporating a dipropyl ether salt according to the present invention is the formula of Table IV.
TABLE IV
INGREDIENT
WEIGHT %
Polysilicone-11
29
Cyclomethicone
59
Petrolatum
11
Quaternized Ammonium Trihydroxy
0.2
Dipropylether Salt of Example 1a
Dimethicone Copolyol
0.3
Sunflowerseed Oil
0.5
Example 6
A relatively anhydrous composition incorporating a dipropyl ether salt of the present invention is reported in Table V.
TABLE V
INGREDIENT
WEIGHT %
Cyclomethicone
80.65
Dimethicone
9.60
Squalane
6.00
Isostearic Acid
1.90
Borage Seed Oil
0.90
Quaternized Ammonium Trihydroxy
0.50
Dipropylether Salt of Example 1b
Retinyl Palmitate
0.25
Ceramide 6
0.10
Tocopherol
0.10
Example 7
An aerosol packaged foaming cleanser with a dipropyl ether salt suitable for the present invention is outlined in Table VI.
TABLE VI
INGREDIENT
WEIGHT %
Sunflower Seed Oil
20.00
Maleated Soybean Oil
5.00
Silicone Urethane
1.00
Polyglycero-4 Oleate
1.00
Sodium C14-16 Olefin Sulfonate
15.00
Sodium Lauryl Ether Sulphate (25% active)
15.00
Cocoamidopropylbetaine
15.00
DC 1784 ® (Silicone Emulsion 50%)
5.00
Polyquaternium-11
1.00
Quaternized Ammonium Trihydroxy
1.00
Dipropylether Salt of Example 1b
Water
Balance
Example 8
A disposable, single use personal care towelette product is described according to the present invention. A 70/30 polyester/rayon non-woven towelette is prepared with a weight of 1.8 grams and dimensions of 15 cm by 20 cm. Onto this towelette is impregnated a composition with a dipropyl ether salt as outlined in Table VII below.
TABLE VII
INGREDIENT
WEIGHT %
2,3-Dihydroxy Trimethyl Ammonium
5.00
Chloride
Glycerin
2.00
Hexylene Glycol
2.00
Disodium Capryl Amphodiacetate
1.00
Gluconolactone
0.90
Silicone Microemulsion
0.85
Witch Hazel
0.50
PEG-40 Hydrogenated Castor Oil
0.50
Fragrance (Terpenoid Mixture)
0.20
Quaternized Ammonium Trihydroxy
0.05
Dipropylether Salt of Example 1c
Vitamin E Acetate
0.001
Water
Balance
Example 9
A toilette bar illustrative of the present invention is outlined under Table VIII.
TABLE VIII
INGREDIENT
WEIGHT %
Sodium Soap (85/15 Tallow/Coconut)
77.77
Quaternized Ammonium Trihydroxy Dipropylether
3.50
Salt of Example 1a
Glycerin
2.50
Sodium Chloride
0.77
Titanium Dioxide
0.40
Fragrance
1.50
Disodium EDTA
0.02
Sodium Etidronate
0.02
Fluorescer
0.024
Water
Balance
Example 10
A shampoo composition useful in the context of the present invention is described in Table IX below.
TABLE IX
Ingredient
Weight %
Ammonium Laureth Sulfate
12.00
Ammonium Lauryl Sulfate
2.00
Cocoamidopropyl Betaine
2.00
Sodium Lauroamphoacetate
2.00
2,3-Dihydroxypropyl Trimethyl
1.50
Ammonium Chloride
Ethylene Glycol Distearate
1.50
Cocomonoethanolamide
0.80
Cetyl Alcohol
0.60
Polyquaternium-10
0.50
Quaternized Ammonium Trihydroxy
0.50
Dipropylether Salt of Example 1a
Dimethicone
1.00
Zinc Pyridinethione
1.00
Sodium Citrate
0.40
Citric Acid
0.39
Sodium Xylene Sulfonate
1.00
Fragrance
0.40
Sodium Benzoate
0.25
Kathon CG ®
0.0008
Benzyl Alcohol
0.0225
Water
Balance
Example 11
This Example illustrates an antiperspirant/deodorant formula incorporating the moisturizing actives according to the present invention.
TABLE X
Ingredient
Weight %
Cyclopentacycloxane
44
Dimethicone
20
Aluminum Zirconium Trichlorohydrex Glycinate
15
Quaternized Ammonium Trihydroxy
5.0
Dipropylether Salt of Example 1c
C 18 -C 36 Acid Triglyceride
5.0
Microcrystalline Wax
3.0
Glycerin
3.0
Silica
2.5
Dimethicone Crosspolymer
1.0
Fragrance
0.5
Disodium EDTA
0.4
Butylated Hydroxytoluene
0.3
Citric Acid
0.3
Example 12
A toothpaste according to the present invention can be formulated with the ingredients listed under Table XI.
TABLE XI
Ingredients
Weight %
Zeodent 115 ®
20.00
Glycerin
18.00
Xanthan Gum
7.00
Sodium Carboxymethyl Cellulose
0.50
Sodium Bicarbonate
2.50
Quaternized Ammonium Trihydroxy Dipropylether Salt
2.00
of Example 1a
Sodium Laurylsulfate
1.50
Sodium Fluoride
1.10
Sodium Saccharin
0.40
Titanium Dioxide
1.00
Pluronic F-127 ®
2.00
FD&C Blue No. 1
3.30
Menthol
0.80
Potassium Nitrate
5.00
Water
balance
Example 13
A moisturizing oil-in-water lotion can be formulated with the ingredients listed under Table XII.
TABLE XII
INGREDIENT
WEIGHT %
Water
Balance
Quaternary Ammonium Trihydroxydipropylether Salt of
0.5
Example 1c
Glycerin
5.00
Disodium EDTA
0.1
Methylparaben
0.1
Niacinamide
0.5
Triethanolamine
0.25
D-Panthenol
0.1
Sodium Dehydroacetate
0.1
Benzyl Alcohol
0.25
GLW75CAP-MP (75% aq. TiO2 Dispersion) 1
0.5
Hexamidine Disethionate
0.1
Palmitoyl-Pentapeptide 2
0.0003
N-Acetyl Glucosamine
1.0
Soy Isoflavone
0.5
Isohexadecane
3.0
Isopropyl Isostearate
0.5
Cetyl Alcohol
0.3
Stearyl Alcohol
0.35
Behenyl Alcohol
0.3
PEG-100 Stearate
0.1
Cetearyl Glucoside
0.1
Sodium Acrylate/Sodium Acryloyldimethyl Tuarate
3.0
Copolymer/Isohexadecane/Polysorbate 80
Dimethicone/Dimethiconol
1.0
Polymethylsilsequioxane
0.5
Timiron Splendid Red 3
1.0
1 Available from Kobo products
2 Palmitoyl-lysine-threonine-threonine-lysine-serine available from Sederma
3 Silica and titanium dioxide coated mica red interference pigment available from Rona
Example 14
Illustrated herein is a moisturizing water-in-silicone cream/lotion formulated with the ingredients listed under Table XIII
TABLE XIII
INGREDIENT
WEIGHT %
Water
Balance
Quaternary Ammonium
0.5
Trihydroxydipropylether Salt of Example 1a
Allantoin
0.2
Disodium EDTA
0.1
Ethyl Paraben
0.2
Propyl Paraben
0.1
Caffeine
1.0
BHT
0.1
Dexpanthenol
0.5
Glycerin
10.0
Niacinamide
2.0
Palmitoyl-Pentapeptide 1
0.0003
GLW75CAP-MP (75% aq. TiO2 Dispersion) 2
0.5
Timiron Splendid Red 3
1.0
1 Palmitoyl-lysine-threonine-threonine-lysine-serine available from Sederma
2 GLW75CAP-MP, 75% aqueous titanium dioxide dispersion from Kobo
3 Silica and titanium dioxide coated mica red interference pigment available from Rona
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A personal care composition is provided which includes a trihydroxy and quaternary ammonium substituted dipropyl ether. The substituted dipropyl ether functions as a humectant when applied to human skin to moisturize both in high and low relative humidity environments.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of Korean Patent Application No. 2005-105697, filed on Nov. 4, 2005, 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] Aspects of the present invention relate to a shift register circuit, and more particularly, to a shift register circuit provided in an organic electroluminescent display and sequentially outputting signals different in polarity.
[0004] 2. Description of the Related Art
[0005] In general, an active matrix display such as an organic electroluminescent display is provided with a pixel array matrix in a region where data lines and scan lines intersect with each other.
[0006] Here, the scan lines form horizontal lines (row lines) of a matrix pixel portion, through which predetermined signals are sequentially supplied by a shift register circuit provided in a scan driver.
[0007] Such a shift register is widely classified into a dynamic shift register and a static shift register. The dynamic shift register needs a relatively small number of thin film transistors (TFT) per stage and has a simple structure, but the dynamic shift register has shortcomings that a frequency band for a clock is narrow and power consumption is relatively high.
[0008] On the other hand, the static shift register needs a relatively large number of TFTs per stage, but it has advantages that the frequency band for the clock is wide and power consumption is relatively low.
[0009] For a shift register to be mounted in the active matrix display such as the organic electroluminescent display, it is important to decrease the number of TFTs as long as functions of the shift register are not deteriorated. However, it is more important to secure high reliability and low power consumption in the circuit operation.
[0010] Further, as the organic light emitting display has recently become larger having a large-sized panel, the scan driver to be mounted in the panel should include the shift register, thereby reducing the size, the weight and the production cost of the organic light emitting display. However, the conventional shift register includes a p-type metal oxide semiconductor (PMOS) transistor and an n-type metal oxide semiconductor (NMOS) transistor, so that it is difficult to mount it on the panel. Further, the conventional shift register including the PMOS transistor and the NMOS transistor consumes much power because a predetermined static current flows through the transistor while generating an output signal.
SUMMARY OF THE INVENTION
[0011] Accordingly, an aspect of the present invention is to provide a 2-phase shift register circuit including a plurality of PMOS transistors and capacitors, in which a yield is enhanced, a production coat is reduced, and power consumption is lowered.
[0012] According to an exemplary embodiment of the present invention, a shift register circuit includes n stages SRU 1 through SRUn. Each stage is dependently connected to an initial input signal IN or an output signal of a previous stage and connected to first and second clock signals CLK 1 and CLK 2 , each stage including: a first switching device SW 1 connected between a first power source VDD and an output terminal N 2 ; a second switching device SW 2 connected between the output terminal N 2 and a second power source VSS; a third switching device SW 3 connected between a first node N 1 and the output terminal N 2 and having a gate electrode connected to the gate electrode of the first switching device SW 1 ; a fourth switching device SW 4 connected between the first node N 1 and the second power source VSS and having a gate electrode connected to an output terminal of a conversion part; a fifth switching device SW 5 connected between a first input terminal and the gate electrode of the first switching device SW 1 ; a first capacitor C 1 connected between the output terminal N 2 and the first node N 1 ; and a second capacitor C 2 connected between the first power source VDD and the gate electrode of the first switching device SW 1 .
[0013] Additional aspects and/or advantages of the invention will be set forth in part in the description which follows and, in part, will be obvious from the description, or may be learned by practice of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] These and/or other aspects and advantages of the invention will become apparent and more readily appreciated from the following description of the embodiments, taken in conjunction with the accompanying drawings of which:
[0015] FIG. 1 is a block diagram of a shift register circuit according to an embodiment of the present invention;
[0016] FIG. 2 is a circuit diagram of a stage (SRU) of the shift register circuit of FIG. 1 according to a first embodiment of the present invention;
[0017] FIGS. 3A-3G are timing diagrams showing input/output signal waveforms of the shift register circuit shown in FIG. 1 ;
[0018] FIGS. 4A and 4B are circuit diagrams of stages of the shift register circuit of FIG. 1 according to second and third embodiments of the present invention; and
[0019] FIG. 5 is a table comparatively showing the various interconnections of the stage circuits shown in FIGS. 2, 4A and 4 B.
DETAILED DESCRIPTION OF THE EMBODIMENTS
[0020] Reference will now be made in detail to the present embodiments of the present invention, examples of which are illustrated in the accompanying drawings, wherein like reference numerals refer to the like elements throughout. The embodiments are described below in order to explain the present invention by referring to the figures.
[0021] FIG. 1 is a block diagram of a shift register circuit according to an embodiment of the present invention.
[0022] As shown in FIG. 1 , the shift register circuit includes a plurality of stages (shift register units) SRU 1 through SRU(n). The 1 st stage SRU 1 receives an initial input signal IN, and the output signals of the 1 st through (n−1)th stages are supplied as input signals to the following stages thereof, respectively.
[0023] Further, each stage SRU 1 through SRU(n) includes a first clock terminal CLKa and a second clock terminal CLKb which receive first and second clock signals CLK 1 and CLK 2 having phases inverted from each other. In the odd numbered stages, the first clock terminals CLKa receive the first clock signal CLK 1 , and the second clock terminals CLKb receive the second clock signal 2 . On the other hand, in the even numbered stages, the first clock terminals CLKa receive the second clock signal CLK 2 , and the second clock terminals CLKb receive the first clock signal CLK 1 .
[0024] That is, the stages, which receive the initial input signal IN or the output voltages from the previous terminals and the first and second clock signals CLK 1 and CLK 2 , output predetermined signals through the respective output lines thereof in sequence.
[0025] The shift register circuit according to the embodiment of the present invention employs the odd numbered stages to sequentially shift the signals having an inverted level with respect to the initial input signal, i.e., having an inverted polarity, and outputs the shifted signals P 1 , P 2 , . . . P(n−1), Pn; and employs the even numbered stages to sequentially shift the signals having the same phase with the initial input signal and outputs the shifted signals S 1 , S 2 , . . . S(n−1), Sn.
[0026] Thus, the shift register circuit can either select the signals P 1 , P 2 , . . . P(n−1), Pn sequentially output from the odd numbered stages or the signals S 1 , S 2 , . . . S(n−1), Sn sequentially output from the even numbered stages.
[0027] For example, when the shift register circuit is in general use, the signals S 1 , S 2 , . . . S(n−1), Sn output from the even numbered stages are selected.
[0028] A predetermined capacitor C is, as shown in FIG. 1 , may be provided in an output line of each stage SRU 1 through SRU(n).
[0029] FIG. 2 is a circuit diagram of a stage (SRU) of the shift register circuit of FIG. 1 according to a first embodiment of the present invention, and FIGS. 3A-3G are timing diagrams showing input/output signal waveforms of the shift register circuit shown in FIG. 1 .
[0030] FIG. 2 is a circuit diagram showing the 1 st stage SRU 1 of the shift register circuit shown in FIG. 1 . Here, the first and second clock signals CLK 1 , CLK 2 , respectively, and the initial input signal IN are input to the 1 st stage SRU 1 of the shift register circuit. The CLK 1 and CLK 2 references shown in FIG. 2 represent inputs to CLKa and CLKb, respectively, as shown in FIG. 1 .
[0031] Referring to FIG. 2 , the stage SRU 1 of the shift register circuit shown in FIG. 1 includes a first switching device SW 1 connected between a first power source VDD and an output terminal N 2 ; a second switching device SW 2 connected between the output terminal (OUT) N 2 and a second power source VSS; a third switching device SW 3 connected between a first node N 1 and the output terminal N 2 and having a gate electrode connected to a gate electrode of the first switching device SW 1 ; a fourth switching device SW 4 connected between the first node N 1 and the second power source VSS and having a gate electrode connected to an output terminal N 4 of a conversion part; a fifth switching device SW 5 connected between a first input terminal T 1 and the gate electrode of the first switching device SW 1 ; a first capacitor C 1 connected between the output terminal N 2 and the first node N 1 ; and a second capacitor C 2 connected between the first power source VDD and the gate electrode of the first switching device SW 1 .
[0032] Here, the first power source VDD has a voltage level higher than that of the second power source VSS. Further, the first through fifth switching devices SW 1 through SW 5 may be implemented by PMOS transistors.
[0033] The fifth switching device SW 5 has a first electrode connected to the first input terminal T 1 to receive the initial input signal IN and the gate electrode to receive the first clock signal CLK 1 .
[0034] Further, the fourth switching device SW 4 has a first electrode connected to the first node N 1 , a second electrode connected to the second power source VSS, and the gate electrode connected to an output terminal N 4 of the conversion part.
[0035] The conversion part includes a sixth switching device SW 6 connected between the first power source VDD and a third node N 3 ; a seventh switching device SW 7 connected between the third node N 3 and a second input terminal T 2 ; an eighth switching device SW 8 connected between the output terminal N 4 of the conversion part and a third input terminal T 3 and having a gate electrode connected to the third node N 3 ; and a third capacitor C 3 connected between the third node N 3 and the output terminal N 4 of the conversion part.
[0036] Like the first input terminal T 1 , the gate electrode of the sixth switching device SW 6 receives the initial input signal IN.
[0037] Further, a gate electrode of the seventh switching device SW 7 receives the second clock signal CLK 2 ; the second input terminal T 2 receives the second clock signal CLK 2 ; and the third input terminal T 3 receives the first clock signal CLK 1 .
[0038] That is, the fourth switching device SW 4 is turned on/off by an output signal from terminal N 4 of the conversion part.
[0039] Further, the first capacitor C 1 connected between the output terminal N 2 and the first node N 1 is also connected between the first electrode and the gate electrode of the second switching device SW 2 . Here, the first capacitor C 1 is charged with a voltage corresponding to whether the second switching device SW 2 is turned on or off.
[0040] For example, when the second switching device SW 2 is turned on, the first capacitor C 1 stores a voltage to turn on the second switching device SW 2 . On the other hand, when the second switching device SW 2 is turned off. The first capacitor C 1 stores a voltage to turn off the second switching device SW 2 .
[0041] Likewise, the second capacitor C 2 connected between the first power source VDD and the gate electrode of the first switching device SW 1 is also connected between the first electrode and the gate electrode of the first switching device SW 1 . Here, the second capacitor C 2 is charged with a voltage corresponding to whether the first switching device SW 1 is turned on or off.
[0042] For example, when the first switching device SW 1 is turned on, the second capacitor C 2 stores a voltage to turn on the first switching device SW 1 . On the other hand, when the first switching device SW 1 is turned off, the second capacitor C 2 stores a voltage to turn off the first switching device SW 1 .
[0043] Further, the third capacitor C 3 connected between the third node N 3 and the output terminal N 4 of the conversion part is also connected between the first electrode and the gate electrode of the eighth switching device SW 8 . Here, the third capacitor C 3 is charged with a voltage corresponding to whether the eighth switching device SW 8 is turned on or off.
[0044] For example, when the eighth switching device SW 8 is turned on, the third capacitor C 3 stores a voltage to turn on the eighth switching device SW 8 . On the other hand, when the eighth switching device SW 8 is turned off, the third capacitor C 3 stores a voltage to turn off the eighth switching device SW 8 .
[0045] Referring to FIGS. 2 and 3 , the 1 st stage SRU 1 of the shift register circuit operates as follows.
[0046] In a first period T 1 , the first clock signal CLK 1 has a low level; the second clock signal CLK 2 has a high level; and the initial input signal has a high level.
[0047] In this case, the sixth and seventh switching devices SW 6 and SW 7 are turned off, and the eighth switching device SW 8 is turned on by a voltage previously stored in the capacitor C 3 , thereby turning on the fourth switching device SW 4 having the gate electrode connected to the output terminal N 4 of the conversion part.
[0048] Then, the fifth switching device SW 5 is turned on by the first clock signal CLK 1 , and thus the input signal IN having the high level is input to the gate electrode of the first switching device SW 1 , thereby turning off the first switching device SW 1 .
[0049] Therefore, the second capacitor C 2 is charged with a voltage to turn on the first switching device SW 1 during the first period T 1 , i.e., a voltage corresponding to turning-off the first switching device SW 1 .
[0050] Because the input signal IN has the high level, the third switching device SW 3 is also turned off. Further, the fourth switching device SW 4 turned on as described above allows the second power source VSS to apply a voltage to the gate electrode of the second switching device SW 2 . Then, the output corresponds to the second power source VSS connected to the second electrode of the second switching device SW 2 , i.e., has the low level.
[0051] Thus, the first capacitor C 1 is charged with a voltage to turn on the second switching device SW 2 during the first period T 1 , i.e., a voltage corresponding to turning on the second switching device SW 2 .
[0052] In a second period T 2 , the first clock signal CLK 1 has a high level; the second clock signal CLK 2 has a low level; and the initial input signal has a low level.
[0053] In this case, the sixth and seventh switching devices SW 6 and SW 7 are turned on, and the eighth switching device SW 8 is also turned on as the second clock signal having the low level is applied to the gate electrode of the eighth switching unit SW 8 by the turned on seventh switching device SW 7 .
[0054] Then, the capacitor C 3 is charged with a voltage to turn on the eighth switching device SW 8 during the second period T 2 , i.e., a voltage corresponding to turning-on the eighth switching device SW 8 .
[0055] When the eighth switching device SW 8 is turned on, the first clock signal CLK 1 having the high level is output through the output terminal N 4 of the conversion part, thereby turning off the fourth switching device SW 4 having the gate electrode connected to the output terminal of the conversion part.
[0056] Further, the fifth switching device SW 5 is turned off by the first clock signal CLK 1 , and thus the first and third switching devices SW 1 and SW 3 are turned off by the voltage previously stored in the second capacitor C 2 .
[0057] As the fourth switching transistor SW 4 is turned off, the second switching device SW 2 is turned on by the voltage previously stored in the first capacitor C 1 , so that the output corresponds to the second power source VSS connected to the second electrode of the second switching device SW 2 , i.e., has the low level. As a result, the output in the first period T 1 is maintained in the second period T 2 .
[0058] In a third period T 3 , the first clock signal CLK 1 has a low level; the second clock signal CLK 2 has a high level; and the initial input signal has a low level.
[0059] In this case, the sixth switching device SW 6 is turned on and the seventh switching device SW 7 is turned off. Then, the voltage applied to the gate electrode of the eighth switching device SW 8 is boosted up to be equal to the first power source VDD supplied from the first electrode of the sixth switching device SW 6 . Thus, when the gate voltage of the eighth switching device SW 8 increases up to the first power source VDD, the voltage applied to the first electrode cannot decrease below the first power source VDD, so that the first power source VDD of the high level is output through the output terminal N 4 of the conversion part, thereby turning off the fourth switching device SW 4 having the gate electrode connected to the output terminal of the conversion part.
[0060] Further, the fifth switching device SW 5 is turned on by the first clock signal CLK 1 , and thus the input signals having the low level are applied to the gate electrodes of the first and third switching devices SW 1 and SW 3 , thereby turning on the first and third switching devices SW 1 and SW 3 .
[0061] Then, the second capacitor C 2 is charged with a voltage to turn on the first switching device SW 1 during the third period T 3 , i.e., a voltage corresponding to turning on the switching device SW 1 .
[0062] Thus, when the first and second switching devices SW 1 and SW 3 are turned on, the first power source VDD having the high level is applied to the output terminal and the gate electrode of the second switching device SW 2 .
[0063] On the other hand, the second switching device SW 2 is turned off, so that the first capacitor C 1 is charged with a voltage to turn off the second switching device SW 2 during the third period T 3 , i.e., a voltage corresponding to turning off the second switching device SW 2 , thereby outputting the first power source VDD of the high level.
[0064] In a fourth period T 4 , the first clock signal CLK 1 has a high level; the second clock signal CLK 2 has a low level; and the initial input signal has a high level.
[0065] In this case, the sixth switching device SW 6 is turned off and the seventh switching device SW 7 is turned on. Therefore, the second clock signal CLK 2 having the low level is input to the gate electrode of the eighth switching device SW 8 , so that the eighth switching device SW 8 is turned on, thereby outputting the first clock signal CLK 1 having the high level through the output terminal N 4 of the conversion part.
[0066] Thus, the fourth switching transistor SW 4 having the gate electrode connected to the output terminal of the conversion part is turned off.
[0067] Further, the fifth switching device SW 5 is turned off by the first clock signal CLK 1 , and the first and third switching devices SW 1 and SW 3 are turned on by the voltage previously stored in the second capacitor C 2 , i.e., the voltage previously stored during the third period T 3 and turning on the first switching device SW 1 .
[0068] As the fourth switching device SW 4 is turned off, the second switching device SW 2 is turned off by the voltage previously stored in the first capacitor C 1 and turning off the second switching device SW 2 , thereby outputting the first power source VDD of the high level through the output terminal. As a result, the output in the third period T 3 is maintained in the fourth period T 4 .
[0069] Meanwhile, the foregoing first through fourth periods T 1 through T 4 are repeated in sequence, thereby obtaining output waveforms as shown in FIGS. 3A-3G .
[0070] In each period, each stage of the shift register circuit shown in FIG. 1 is operated so that the output signal has a level inverted with respect to the input signal IN when the first clock signal CLK 1 has the low level, but the level of the output signal in the previous period is maintained when the first clock signal CLK 1 has the high level.
[0071] The remaining stages SRU 2 through SRU(n) are constructed the same as the stage SRU 1 shown in FIG. 2 , however the connections of stages SRU 2 through SRU(n) differ from the connections of stage SRU 1 in the following respects. Each stage SRU 2 through SRU(n) receives an output of a previous stage as an input at the first input terminal T 1 and the gate of switching device SW 6 instead of the input signal IN. Odd numbered stages 3 , 5 , 7 , etc., receive the first clock signal CLK 1 and the second clock signal CLK 2 as shown in FIG. 2 and even numbered stages, 2 , 4 , 6 , etc., receive the second clock signal CLK 2 where the first clock signal CLK 1 is shown in FIG. 2 and receive the first clock signal CLK 1 where the second clock signal CLK 2 is shown in FIG. 2 .
[0072] FIGS. 4A and 4B are circuit diagrams of stages SRU 1 through SRU(n) according to second and third embodiments of the present invention, respectively, in the shift register circuit of FIG. 1 . Here, like elements having like numerals as elements shown in the stage of FIG. 2 have a same function the elements shown in FIG. 2 , and repetitive descriptions will be avoided.
[0073] In the shift register circuit according to the first embodiment shown in FIG. 2 , the sixth and seventh switching devices SW 6 and SW 7 may be turned on at the same time, so that power consumption increases.
[0074] In the state that the sixth and seventh switching devices SW 6 and SW 7 are turned on at the same time, the first clock signal has the high level, so that the fourth switching device SW 4 is turned off, thereby having no effect on the final output.
[0075] The embodiments illustrated in FIGS. 4A and 4B are provided for further reducing the power consumption of the shift register circuit shown in FIG. 1 . The embodiments shown in FIGS. 4A and 4B have the same configuration as the first embodiment and differ in an arrangement of inputs to the circuit of each stage.
[0076] According to the second embodiment as shown in FIG. 4A , a source electrode of the eighth switching device SW 6 is connected to the second clock signal CLK 2 rather than to the first power source VDD as in the first embodiment shown in FIG. 2 . According to the third embodiment as shown in FIG. 4B , a drain electrode of the fourth switching device SW 4 is connected to the first clock signal CLK 1 rather than the second power source VSS as in the first embodiment shown in FIG. 2 .
[0077] Referring to FIG. 4A and FIG. 2 , the operation of the second embodiment is as follows.
[0078] In the first period T 1 , the sixth switching device SW 6 is turned off by the input voltage IN having a high level.
[0079] In the second period T 2 , the sixth switching device SW 6 is turned on by the input voltage IN having a low level. Further, the seventh switching device SW 7 is turned on by the second clock signal CLK 2 having a low level supplied to a gate electrode of the seventh switching device SW 7 in the second period T 2 . Then, the sixth and seventh switching devices SW 6 and SW 7 are turned on, so that a low level voltage is applied to the gate electrode of the eighth switching device SW 8 . In this case, the eighth switching device SW 8 is turned on, so that a high level voltage is applied to the output terminal N 4 of the conversion part.
[0080] According to the second embodiment, even though the sixth and seventh switching devices SW 6 and SW 7 are turned on at the same time in the second period T 2 , the sixth switching device SW 6 receives the second clock signal CLK 2 through the first electrode of the switching device SW 6 , thereby decreasing the power consumption. Comparatively, when the sixth and seventh switching devices SW 6 and SW 7 according to the first embodiment are turned on at the same time, the first power source VDD input to the first electrode of the sixth switching device SW 6 and the second clock signal CLK 2 input to the first electrode of the seventh switching device SW 7 are connected, so that power consumption is relatively high. On the other hand, according to the second embodiment, since the first electrode of the sixth switching device SW 6 receives the second clock signal CLK 2 , the power consumption is relatively low.
[0081] In the third period T 3 , the sixth switching device SW 6 is turned on by the input voltage IN having the low level. As the sixth switching device SW 6 is turned on, the high level voltage is applied to the gate electrode of the eighth switching device SW 8 . Then, the voltage applied to the first electrode of the eighth switching device SW 8 is not dropped to less than the high level, so that the fourth switching device SW 4 is turned off.
[0082] In the fourth period T 4 , the sixth switching device SW 6 is turned off by the input voltage having the high level.
[0083] As described above, the circuit diagram according to the second embodiment of the present invention has a same structure as the circuit diagram of the first embodiment shown in FIG. 2 . However, in operation, the circuit according to the second embodiment of the present invention has advantages that the power consumption is relatively low even though the sixth and seventh switching devices SW 6 and SW 7 are turned on at the same time.
[0084] Referring now to FIG. 4B and FIG. 2 , the operation of the third embodiment is as follows.
[0085] In the first period T 1 , the fourth switching device SW 4 is turned on by an input voltage having a low level and supplied from the output terminal N 4 of the conversion part. At this time, the first clock signal CLK 1 having the low level is applied to the first electrode of the fourth switching device SW 4 . In this case, the low level voltage is applied to the gate electrode of the second switching device SW 2 , so that the second switching device SW 2 is turned on. In the second period T 2 , the third period T 3 and the fourth period T 4 , the conversion part supplies the high level voltage, so that the fourth switching device SW 4 is turned off.
[0086] That is, the shift register circuit according to the third embodiment of the present invention is operated like that of the first embodiment shown in FIG. 2 . Here, the shift register circuit according to the third embodiment employs the odd numbered stages to sequentially shift the signals having an inverted level, i.e., having the opposite polarity to the initial input signal and outputs the shifted signals P 1 , P 2 , . . . . . . , Pn; and employs the even numbered stages to sequentially shift the signals having the same phase with the initial input signal and outputs the shifted signals S 1 , S 2 , . . . . . . , Sn. Thus, in the case where the shift register circuit according to the third embodiment is used as a typical shift register circuit, the output lines of the odd numbered stages can be removed so as to select only the signals S 1 , S 2 , . . . . . . , Sn output through the even numbered stages.
[0087] The stage circuits shown in FIGS. 2, 4A and 4 B may be viewed as a circuit having first through eleventh interface points and connectable in a variety of ways to achieve a same result in an operating shift register circuit. Various combinations of connections of the stage circuit are summarized in FIG. 5 . In FIG. 5 , IN 1 represents an initial input or an output of a previous even numbered stage and IN 2 represents an output of a previous odd numbered stage.
[0088] The embodiments of the present invention provide a shift register circuit, which can improve a production yield thereof and decrease a production cost and a power consumption thereof.
[0089] Although a few embodiments of the present invention have been shown and described, it would be appreciated by those skilled in the art that changes may be made in this embodiment without departing from the principles and spirit of the invention, the scope of which is defined in the claims and their equivalents.
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A shift register circuit comprising a plurality of stages dependently connected to an initial input signal or an output signal of a previous stage and connected to first and second clock signals which are mutually inverted. Each stage includes eight switching devices interconnected together with three capacitors and interfaced through eleven interface points. Some of the interface points are connected to the first and second clock signals according to whether the stage is an even numbered stage or an odd numbered stage. Other ones of the interface points are connectable to the first and second clock signals in alternative ways to reduce power consumption without changing an internal configuration of the stage.
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CROSS REFERENCE TO PROVISIONAL APPLICATION
[0001] This application claims the benefit of provisional application Ser. No. 60/615,367, filed Oct. 1, 2004.
BACKGROUND OF THE INVENTION
[0002] The invention relates to refrigerator cases.
[0003] Refrigerator cases typically have flat panes of glass which form portions of the case, and which can come together leaving a gap defined therebetween. These gaps are needed to allow smooth operation of the refrigerator case, for example during opening and closing.
[0004] In some instances, users and/or regulatory authorities require some form of closing of this gap, either in order to comply with regulations or to improve efficiency by limiting escape of cooled air through the gap.
[0005] It is the object of the invention to provide a solution to this problem.
SUMMARY OF THE INVENTION
[0006] According to the invention, the foregoing objects and advantages have been readily attained.
[0007] According to the invention, a refrigerator case assembly is provided comprising at least two refrigerator case elements positioned next to each other and defining a gap therebetween; and a trim joint comprising a body portion for covering the gap and a mounting member for releasably securing the trim joint relative to the at least two case elements with the body portion covering the gap.
[0008] Still further according to the invention, a trim joint is provided for a refrigerator case, comprising a body portion comprising an elongate member having two ends; and a mounting member positioned at one of the two ends for releasably mounting the body portion to a refrigerator case.
[0009] A method is also provided according to the invention for enhancing efficiency of a refrigerator case, which method comprises the steps of providing at least two refrigerator case elements positioned next to each other and defining a gap therebetween; providing a trim joint comprising a body portion for covering the gap and a mounting member for releasably securing the trim joint relative to the at least two case elements with the body portion covering the gap; and selectively positioning the trim joint so that the body portion covers the gap and the mounting member engages at least one of the refrigerator case elements
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] A detailed description of preferred embodiments of the present invention follows, with reference to the attached drawings, wherein:
[0011] FIGS. 1-3 schematically illustrate a trim joint in accordance with the present invention;
[0012] FIG. 4 schematically illustrates a refrigerator case as an environment of use of the trim joint of the present invention;
[0013] FIG. 5 schematically illustrates a portion of the case of FIG. 4 with a trim joint shown in position with dashed lines; and
[0014] FIG. 6 is a sectional view of a trim joint in position relative to a refrigerator case gap in accordance with the invention.
DETAILED DESCRIPTION
[0015] The invention relates to a trim joint for closing the gap between substantially flat panes of glass or other material which form a refrigerator case.
[0016] FIGS. 1-3 show a trim joint 10 which in this embodiment is a substantially elongate body portion 12 and a securing or mounting member 14 which can advantageously be used to secure trim joint 10 so as to cover a gap between two flat panes of glass on a refrigerator case.
[0017] FIG. 4 schematically illustrates a refrigerator case 50 having a base 52 and two case elements 54 , 56 which define form a wall of the case and define therebetween a gap 58 . As is well known to a person skilled in the art, case elements 54 , 56 , in this instance glass wall members, define along with the other walls of refrigerator case 50 a refrigerated space in which food products or other items can be stored at controlled temperature.
[0018] Case 50 is typically designed so that there is a gap 58 between elements 54 , 56 , since generally at least one of these elements can pivot relative to the rest of case 50 to an open position, and gap 58 avoids frictional resistance to such movement. Unfortunately, gap 58 also allows air flow from inside to outside of the case and this air flow can be undesirable from an efficiency standpoint and also in order to comply with certain government regulations.
[0019] According to the invention, and as will be further discussed below, trim joint 10 according to the invention advantageously can be releasably positioned over the gap 58 as desired.
[0020] FIG. 1 shows trim joint 10 having a body portion 12 which can advantageously have a width selected to cover the expected sizes of gaps. For example, in the preferred embodiment, this member can have a width of about two inches. This width is preferably selected so that trim joint 10 has regions of overlap between side edges of the body portion 12 and edges of case elements 54 , 56 .
[0021] Trim joint 10 preferably has a length sufficient to cover the length of the gap, that is, typically the vertical height of the panes of flat glass which define the gap. In the embodiment illustrated, the trim joint 10 has a length of 30.375 inches.
[0022] According to the invention, a clip member is provided as securing or mounting member 14 , and has a substantially transverse portion 16 and a substantially parallel opposed or clipping portion 18 , which preferably extends back from transverse portion 16 , substantially parallel with body portion 12 , and opposed portion 18 and body portion 12 define a gap into which an edge of case element 54 , 56 is received to releasably mount trim joint 10 relative to gap 58 .
[0023] Opposed portion 18 preferably has an inwardly extending bump 20 which extends toward body portion 12 and is used to clip and secure trim joint 10 relative to refrigerator case elements 54 , 56 which can, for example, be panes of glass. Bump 20 provides a press fit relative to the edge of case elements 54 , 56 to which trim joint 10 is to be secured.
[0024] FIG. 6 shows trim joint 10 positioned over gap 58 by mounting the mounting member 14 along a bottom edge of case elements 54 , 56 . In this position, body portion 12 of trim joint 10 is positioned flat on the glass surfaces, specifically extending along and overlapping the vertical edges of the glass surfaces which define the gap, so that the trim joint seals this gap.
[0025] Trim joint 10 is preferably provided with at least body portion 12 made of substantially transparent material. Since case elements 54 , 56 are typically glass or some other transparent material so that objects within the case can be viewed, it is functionally if not aesthetically preferable for trim joint 10 to also be provided from transparent material in accordance with the invention.
[0026] It should be appreciated that trim joint 10 of the present invention advantageously solves the need for a structure to cover gap 58 , thereby providing for compliance with potential government regulations and also for blocking air flow from inside to outside of case 10 through gap 58 , which enhances efficiency of operation as well.
[0027] It should of course be appreciated that the invention is not limited to the illustration described and shown herein, which is deemed to be merely illustrative of the best modes of carrying out the invention, and which is susceptible to modifications of form, size, and arrangement of parts and details of operation. Rather, the invention is invented to encompass all such modifications which are within its spirit and scope.
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A refrigerator case assembly is provided which includes at least two refrigerator case elements positioned next to each other and defining a gap therebetween; and a trim joint having a body portion for covering the gap and a mounting member for releasably securing the trim joint relative to the at least two case elements with the body portion covering the gap.
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FIELD OF THE INVENTION
This invention pertains to building shutters, and more particularly, to adjustable modular shutter assemblies having a multiple panel.
BACKGROUND OF THE INVENTION
As is well known, there are various decorative building shutters designed to be installed next to building openings, such as windows. Such shutters may be constructed from a variety of materials. While many shutters are constructed as integral units, shutters assembled from modular components provide a degree of flexibility not available with the one-piece units. The length and width of such modular shutter assemblies may be varied to desirably match the size of the opening to which it is to be installed.
An example of such a modular adjustable shutter assembly constructed of plastic is shown in Foltman U.S. Pat. No. 4,251,966. The shutters disclosed in the aforementioned Foltman patent are representative of the general arrangement of components in adjustable modular shutter assemblies. Such shutter assemblies are constructed with a pair of side rails, top and bottom rails, one or more center panels that may take the form of louvers or raised panels. Depending upon its size and style, the shutter may include a center rail or center mullion disposed between adjacent upper panels and lower panels. In such assemblies, the top rail, center panels, center rail and bottom rail are captured and retained in place between the side rails with the top and bottom rails having laterally extending wings that overlie the upper and bottom edges, respectively, of the side rails. The wings may include projections or flanges that extend into the ends of the side rails and braces for maintaining the positional relationships of the components.
The length of such modular shutter assemblies is selected by varying the length of the side rails, and by varying the length of the center panels, e.g., the louver panels, inserted between the side rails. In addition, for longer shutter assemblies, the height of the top and bottom rails as well as the center mullion rail may be increased.
The width of the shutter assemblies is also adjustable by use of center panels having different widths. The widths of the top, bottom, and center rails inserted between the side rails of the shutter assembly are also changed. Thus, the width of a shutter is changed by using panels, top rails, center rails, and bottom rails of different discrete widths. The length of each of these shutter assemblies may be adjusted by varying the length of the side rails and the center panels, e.g., by cutting or trimming the side rails and the center panels to the desired length.
In spite of the degree of flexibility which has been obtained by use of such modular shutter assemblies, such assemblies utilize a single center panel located between and connected to the side rails. A plurality of such panels may be stacked one on top of the other to produce a shutter assemblies of different lengths. While shutter assemblies of varying widths have been produced by using center panels of different widths, the number of different center panels are limited. Furthermore, the ability to vary the appearance and configuration of the shutters is also limited by the use of a single center panel between the side rails.
It would be desirable, therefore, to be able to produce and assemble modular shutter assemblies having varying appearances and varying widths not limited in size by the size of individual center panels themselves. Such structures would provide even additional flexibility in the design construction and appearance of modular shutter assemblies.
SUMMARY OF THE INVENTION
In accordance with the present invention, there is provided a modular shutter assembly having multiple center or louver panels disposed side-by-side between, and captured by, side rails and framed by plural top rails, plural bottom rails, and where desired plural center rails. A multi-panel modular shutter assembly in accordance with the present invention includes modular components, typically formed from a plastic material, e.g., polypropylene or styrene. Such components may be molded or extruded and include a pair of side rails and a plurality of side-by-side interconnected center panels disposed therebetween and framed at opposite ends by a plurality of end rails.
Each of the end rails may be substantially identical. Alternatively, the top end rails and the bottom end rails may be somewhat different in appearance and height. Each of the end rails is normally configured with a pair of detachable or severable wings extending laterally from each side thereof with selected wings being severed to facilitate the use of end rails in the multi-panel modular shutter assembly of the present invention.
When an end rail is used at the end of a center panel which is adjacent to one of the side rails, only one of the severable wings is used. The other wings, remote from the side rail, is severed or detached therefrom. If an end rail is positioned at the end of a center panel which does not abut and connect to either of the side rails, both of the detachable or severable wing portions are severed from the end rail.
Each of the adjacent center panels and end rails are connected together by an elongate stabilizing rail for retaining the adjacent center panels and end rails in position between the side rails.
Thus, in accordance with the present invention, there is provided a multi-panel modular shutter assembly in which a plurality of center panels can be arranged side-by-side between and enclosed by a pair of side rails and framed between top and bottom rails. Typically, the end rails are those designed for use with a single panel shutter assembly and have a pair of detachable or severable wings on each side thereof. Selected ones of the wings are severed for facilitating construction of the shutter assembly. One or more end stabilizing clips can be inserted between adjacent end rails to further stabilize the shutter system of the present invention.
The elongated stabilizing rails utilized in the shutter assembly of the present invention include decorative planar front portions for capturing and covering the exposed edges or runners of each of the center panels and end members and appropriately shaped rear retaining hook portions engagable with the sides or runners of the center panels and end members for retaining the panels in place and facilitating stabilization of the entire assembly.
Numerous other features and advantages of the present invention will become readily apparent from the following detailed description of the invention and an embodiment thereof, from the claims, and from the accompanying drawings in which the details of the invention are fully and completely disclosed as a part of this specification.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a multi-panel shutter assembly incorporating the present invention;
FIG. 2 is a partial enlarged exploded view showing the various components thereof;
FIG. 3 is an enlarged partial front view showing a stabilizing clip; and
FIG. 4 is a sectional view taken along line 4--4 of FIG. 3 showing a stabilizing member thereof.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
While the present invention is susceptible of embodiment in various forms, there is shown in the drawings, and will hereinafter be described, a preferred embodiment of the invention with the understanding that the present disclosure is to be considered as an exemplification of the principles of the invention and is not intended to limit the invention to the specific embodiment illustrated.
As shown in the drawing, the multi-panel modular shutter assembly 10 is comprised of a plurality of modular members including left side rail 12 and right side rail 14. The side rails 12, 14 are substantially identical to each other. For convenience, only left side rail 12 will be described in detail. The side rail 12 has a front wall 16, an outer side wall 18, and an inner side wall 20. Both sidewalls 18, 20 extend rearwardly from the front wall 16. The inner side wall 20 terminates in a rear hooked shaped retaining portion 22. The front wall 16 of side rail 12, also includes a generally planar retaining portion 24 extending inwardly from the inner side wall 20 which defines with the rear retaining portion 22 a mounting channel 25 for receiving and retaining the other components of the shutter assembly 10, including top rails 26 (shown in the drawing as top rails 26a, 26b, and 26c), bottom rails 28 (shown in the drawing as bottom rails 28a, 28b, and 28c), center panels 30 (shown in the drawing as upper center panels 30a, 30b, 30c, and lower center panels 30a', 30b', and 30c'), and center rails 32 (shown in the drawing as center rails 32a, 32b, and 32c).
The mounting channel 25 formed on each of the side rails 12, 14 is designed to slidably receive and retain one of the side runners 34, 36 of a center panel member 30, shown in the drawing in the form of a louver member having a plurality of louvers extending between the runners. As indicated above, in the shutter assembly of the present invention, a plurality of upper center panel members 30a, 30b, 30c are disposed side by side between a plurality of top rails 26a, 26b, 26c and a plurality of center rails 32a, 32b, 32c, respectively. A plurality of lower center panel members 30a', 30b', 30c' are disposed side-by-side between the center rails 31a, 31b, 31c and a plurality of bottom rails 28a, 28b, 28c, respectively.
The runners 34, 36 of the outermost upper center panel members 30a, 30c and of the outermost lower center panel members 30a', 30c' are received in the mounting channels 25 of the side rails 12, 14, as is evident from FIG. 2. The other runners 34, 36 of the center panels are retained in place by elongated T-shaped stabilizing rails 40 disposed therebetween. The stabilizing rails 40 are identical and each includes a forward, planar portion 42 and generally U-shaped hook portion 44 interconnected by a center web 46 together defining a pair of retaining channels 48 on opposite sides of the center web 46. Each of the stabilizing members 40 slidably receives and retains a runner 34 or 36 of a center panel member 30 in one of the channels 48 for stabilizing the assembly of adjacent center panels retained between the side rails 12, 14. The top rails 26 are substantially identical and each has side runner portions 50, 52 and front wall portion 53. The bottom rails 28 are substantially identical to each other and with the top rails (except for some decorative enhancements) and each has substantially identical side runner portions (not shown). The center rails 32 are identical to each other and with the top and bottom rails and each also has substantially the same side runner portions as the top rail runner portions 50, 52. As shown in the aforementioned Foltman patent (as evident from FIG. 2), all of these side runner portions are receivable in the mounting channels 25 of the side rails 12, 14. The side runner portions are also receivable in the channels 48 of the stabilizing rails 40, which are substantially the same in shape and configuration as the channels 25, as shown in FIG. 2. The slidable engagement of the runner portions 34 and 36 of the central panel members 20 is shown in FIG. 4. The side runner portion 50, 52 of top rails 26 and the corresponding substantially identical side rail portions of the bottom rails 28 and the center rails 32 are also receivable in the channels 25 and 48 in the same manner as are the side rails runners 34 and 36 as is evident from the drawing.
The upper end of the shutter assembly 10 is framed by the plurality of top rails 26. The top rails 26 are substantially identical to each other extending laterally outwardly and include severable or detachable wing portions 62, 64 at from either side thereof. The wing portions 62, 64 are designed to cover the exposed ends of the side rails 12, 14, respectively. Each of the wings has a flange 66 which is insertable into the open end of the side rails 12, 14. As is well known, bracing members (not forming part of the present invention and omitted for clarity) may be used. The upper surface of the wings 62, 64 are typically designed to extend over the exposed edges of the side rails 12, 14 for producing a finished looking product.
The wings 62, 64 of the top rails 26 that do not extend over adjacent side rails are removed or severed to allow for positioning of top rails adjacent to each other. The bottom edge of each of the top rails 26 abuts the upper edge of a corresponding upper center panel 30. The adjacent edges of the top rails from which the wings have been removed may be interconnected by an end rail stabilizing clip 70 receivable therebetween. The clip 70 includes a decorative outer portion 76, a transverse web 77, and a lower flange portion 78. The web 77 is positioned in the space between adjacent end rails, with the lower flanged portion 78 passing through a slot 79 formed in the side runner portions 50, 52 of the end rails as is evident from FIG. 3.
The lower end of the shutter assembly 10 is framed by a plurality of bottom rails 28. The bottom rails 28 are similar to the top rails 26 and may be identical thereto. It is recognized that for some shutter assemblies, the appearance and shape of the bottom rails may differ from the top rails as indicated in the drawing.
The bottom rails 28 are substantially identical to each other and include severable or detachable wing portions 72, 74 extending laterally outwardly from either side thereof. The wing portions 72, 74 on each of the bottom rails 28 are substantially identical to the wing portions 62, 64 of the top rails 26 and cover the exposed ends of the side rails 12, 14. The wings 72, 74 have flanges insertable into the exposed bottom ends of the side rails as described above.
The wings that do not extend over adjacent side rails are severed to allow for positioning of bottom rails adjacent to each other. Bottom rail runner portions are received in the channels 25 of the side rails and channels 48 of the stabilizing rails 40. As is the case with the top rails 70, retaining clips can be inserted between the severed edges of the bottom rails.
Thus, there has been disclosed a multi-panel modular shutter assembly in which a plurality of center panels can be assembled side-by-side and retained between a pair of side rails for producing a shutter assembly having a variety of appearances and dimensional variations not without the necessity of producing thinner panels to fulfill these various dimensional configurations. The adjacent edges of the center panels are retained in position by elongated stabilizing rails that include a decorative planar portion that overlies the side edges of each of the adjacent center panels and includes a rear retaining portion that cooperates to define a mounting channel for receiving the runners of the adjacent center panels. A plurality of end panels having severable wing portions frame the assembly to produce a multi-panel modular shutter assembly capable of being configured in a variety of ways not previously possible.
Center panels for the shutter assembly of the present invention can have different shapes and configurations while being disposed side-by-side as well as one above the other in a transverse stacked configuration, and can produce a variety of shutters having different dimensional configurations as well as different appearances.
From the foregoing, it will be observed that numerous modifications and variations can be effected without departing from the true spirit and scope of the novel concept of the present invention. It will be appreciated that the present disclosure is intended as an exemplification of the invention, and is not intended to limit the invention to the specific embodiment illustrated. The disclosure is intended to cover by the appended claims all such modifications as fall within the scope of the claims.
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A multi-panel modular shutter assembly comprised of a plurality of center panels disposed side-by-side between a pair of side rails which include retaining means engagable with the adjacent sides of a center panel for retaining said center panel in place and including a plurality of top and bottom rails for framing said center panels engagable with said side rails and an elongate stabilizing strip disposed between adjacent center panels and end rails for retaining said center panels in place and providing a stable shutter assembly.
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CROSS-REFERENCE TO RELATED APPLICATION
This is a continuation of application Ser. No. 09/496,816, filed Feb. 2, 2000 now U.S. Pat. No. 6,359,204.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention generally relates to improvements in the structure and function of a musical instrument. The present invention more particularly relates to improvements in the structure and function of a harmonica.
2. Background Information
Harmonicas are among the world's oldest and most popular musical instruments. Harmonicas produce musical tones by a player blowing or drawing air into the harmonica to vibrate one or more of the reeds of the harmonica. One form of the harmonica is the ten-hole diatonic harmonica. In a diatonic harmonica, twenty reeds produce nineteen natural tones, with one tone being duplicated. The ten-hole diatonic harmonica typically has ten blow reeds, which sound in response to air blown into the harmonica by positive oral pressure; and ten draw reeds, which sound in response to air drawn in through the harmonica by negative oral pressure. The nineteen tones allow the player to play all the diatonic tones of a middle octave and most of the tones of a lower and a higher octave.
A moderately advanced diatonic harmonica player can produce twelve additional tones by a process known as “bending,” whereby the player modifies the resonant volume in the vocal passage, principally with the tongue, to “bend” or adjust the tone produced to achieve the desired pitch. A “bend” is therefore a procedure involving the adjustment of the player's embouchure wherein a tone is flatted by causing the normally idle lower-pitched reed of the reed pair in a harmonica to vibrate in its opening mode.
A more advanced player can also produce four additional tones by a technique known as “overblowing,” whereby the player more strictly matches the appropriate resonant volume with the tone he or she wishes to produce, typically causing the draw reed of the first, fourth, fifth, and sixth holes to produce tones corresponding to a flatted third of the low octave and a flatted third, fifth, and seventh respectively of the middle octave. Similarly, drawing and a strictly controlled shaping of the resonant passage will produce “overdraw” tones from the blow reeds corresponding to a sharped first, fifth and eighth of the highest octave. On an ordinary diatonic harmonica tuned to the key of C, the overblow tones are Eb-4 of the low octave, Eb-5, F#-5 and Bb-5 of the middle octave, and the overdraw tones are C#-6, G#-6 and C#-7 of the highest octave. Overblow and overdraw tones can be produced from all holes of the diatonic harmonica, but except for those listed, tones can be produced more easily with other techniques. See, e.g., U.S. Pat. No. 5,739,446 to Bahnson.
Therefore, an overblow or overdraw procedure is one in which the tone is sharped by causing the higher pitched reed in a harmonica reed pair to vibrate in its opening mode. Overblow occurs on the first six holes of a standard diatonic harmonica wherein the higher-pitched reed is the draw reed; overdraw occurs on the last four holes of a standard diatonic harmonica wherein the higher-pitched reed is the blow reed.
In all, the most skilled diatonic harmonica player can produce a total of thirty-eight tones from the ten-hole diatonic harmonica, using the normal playing, bending, overblowing, and overdrawing techniques. A problem with any musical instrument, including the diatonic harmonica, is that not all players are highly skilled or even moderately advanced at playing the instrument, and a majority of instrument players are at skill levels far below the advanced level and cannot significantly improve their skills even with much practice.
The technique of “overblowing” is extremely difficult and diatonic harmonica players, even those of great skill, have been known to practice the technique for years before feeling comfortable enough to use the technique in a live performance. The same can be said of the “overdrawing” technique.
Because the seven tones achieved by overblowing or overdrawing are not readily achieved on a ten-hole diatonic harmonica, many less-advanced players resort to a chromatic harmonica, which offers a full chromatic scale of semitones by means of a slide that directs air to reeds pitched a semitone higher than those activated without the slide. However, the chromatic harmonica is not as adaptable as the diatonic harmonica to musical expression such as the type of expression experienced in blues, country, soul, and jazz harmonica music. Although the chromatic scale is easier to play on the chromatic harmonica than on the diatonic, its more limited expression makes it less enjoyable for many, including both listeners and players.
The construction of the diatonic harmonica (See, e.g., FIG. 1) includes a set of ten flexible metallic reeds affixed to a flat reed plate containing rectangular slots through which the reeds vibrate. The typical construction provides an individual reed for each slot. Two such sets of reed plates are typically attached to opposing faces of a comb, thereby creating ten cells, each allowing two notes to be played per cell of the comb: one when blowing and one when drawing.
There are, however, limitations associated with this construction. The usual mechanical connection of reeds on a top surface of the reed plate can create a gap at the reed tip and along the lateral sides or flanks of the reed through which air may leak during play. When the reed vibrates due to a physical influence such as the blowing or drawing action of a musician, these gaps can widen and narrow to permit the reed to vibrate. However, when vibration is initiated, these gaps can also result in one or more unsatisfactory air leaks that can cause the player to blow more forcefully, alter his embouchure, and possibly stop reed vibration from occurring.
This problem is especially acute when attempting to play notes arising from a “bent,” “overblown” and/or “overdrawn” procedure. These notes are characterized by an anomalous physical behavior of two given reeds positioned in a cell of the harmonica. As shown in Bahnson et al., “Acoustic and Physical Dynamics of the Diatonic Harmonica,” Journal of the Acoustical Society of America . Vol. 103(4), pp. 1234-1244, 1998, when one of these maneuvers is performed and achieved, the normally stationary reed can be caused to vibrate while the normally active reed is caused to close. In the case of the overblow procedure, for example, the draw reed operates in an “opening” fashion while the blow reed operates in a “closing” fashion.
As previously discussed, the gap formed between the blow reed and its corresponding slot can create an air leak during this procedure. Consequently, there may be insufficient air pressure to induce vibration in the opening reed. Furthermore, the acoustic impedance of the oral-reed system may be affected so as to prevent vibration, or cause dissonant vibration within the harmonica.
An additional problem associated with conventional harmonica play is the occurrence of aberrant and discordant whistling or squeaking sounds while attempting to play a note. These aberrant sounds can be particularly problematic while attempting an overblow or overdraw procedure. The cause of this phenomenon is the establishment of “edge tones” created by the flow of air through a gap or gaps formed between one or more reeds and the reed plate and subsequent torsional vibration of the reed.
Another problem associated with conventional harmonicas is the difficulty in aligning the reeds within the reed slots of the reed plate during assembly. The clearance between the lateral edges or flanks of the reeds and the corresponding edges of the slot is typically small, in the approximate range of less than 0.002″. Because the reed is often affixed to the reed plate with a single rivet or other similar mechanical fastener, it is possible for the reed to rotate about the rivet thereby causing a nonparallel alignment between the rotated reed and the reed plate. Furthermore, irregularities or burrs introduced during fabrication of the reed or reed plate can adversely affect the free vibration of the reed. This is exacerbated when the reed is not properly aligned in its slot within the harmonica.
An additional problem associated with conventional harmonica construction is that roughened surfaces can be present on the edges and other internal surfaces of a reed slot. Because these slots are typically fabricated by the shearing action of a die, their internal surfaces are typically characterized by burrs, grooves and other irregular projections and recesses. These irregularities introduce non-uniformity into the reed slot of the harmonica and can interrupt the smooth flow of air through the reed passage.
A further problem with conventional harmonicas is that the material properties of the reed usually alter during the life cycle of the instrument thereby affecting the pitch and alignment of the reed. If the instrument is played with greater than usual force or air pressure, for example, the pitch of the reed can be altered. To rectify the pitch, the instrument must be disassembled to adjust the reeds. To lower the pitch of the reed, material is removed from the root of the reed, usually by abrasive means, such as sandpaper. To raise the pitch of the reed, material is removed from the reed tip. To readjust the reed position, the reed is manually or mechanically deflected in a exaggerated fashion in the direction opposite of the dislocation, perhaps resulting in a weakening of the attachment of the reed to the reed plate.
A still further problem associated with conventional harmonica play is that the player must modify his or her oral cavity to achieve certain bends, overblows, or overdraws. Low draw bends typically require excessively large embouchure, necessitating that the jaw be lowered, and the tongue positioned low in the oral cavity. Conversely, overblows, blow bends, and overdraws require relatively small oral volume and that the tongue of the musician to be positioned against the palate with the tip forward against the upper teeth. The volume provided within the comb of the harmonica supplements the volume required within the oral cavity of the musician. Therefore, enlarging the cavity would facilitate draw bends, while reducing the volume of the cavity would facilitate overblows, overdraws and blow bends.
A number of devices have been used to improve the playing of harmonicas. Paris, U.S. Pat. No. 574,625, discloses a siding mouthpiece for transferring a blast of air from one cell chamber to another without moving the lips. Newman, U.S. Pat. No. 1,671,309, discloses a chromatic harmonica having a frontal slide which occludes certain blow holes in the harmonica to allow the player to achieve a chromatic scale, as opposed to a diatonic scale. Other chromatic harmonicas having blow hole-occluding devices include U.S. Pat. Nos. 1,752,988; 2,005,443; 2,339,790; and 2,675,727.
Bahnson, U.S. Pat. No. 5,739,446, discloses a harmonica and method of playing which involves the use of a valve mechanism. A sliding set of louvers is added to one side of each reed plate, which apparently, when activated, block the air leakage from the inactive reed. This mechanism appears to be relatively complicated and expensive to implement. The Bahnson harmonica also appears to require the player to activate the valve at the exact instant that the overblow note is to be played, thus requiring additional motions and interaction with the harmonica by the player, and preventing modulation of frequency as required for certain tremelo effects.
Accordingly, an advance in the art could be realized if a harmonica could be constructed which readily permits the production of bent, overblown, and overdrawn tones, enabling even the player having limited skills to achieve the characteristic expression of the diatonic harmonica and yet realize the full half tone scale capability of the chromatic harmonica. It would also be beneficial to provide a harmonica that permits the overdrawing and overblowing techniques of the invention to be practiced without otherwise requiring any significant changes in playing techniques. Another significant benefit could be realized from a harmonica that is more susceptible to the techniques of bending, overblowing and/or overdrawing.
A harmonica with reeds and associated reed plates that reduce the excessive leakage of airflow from the cells of the harmonica is also needed. What is also needed is a simple construction for use in fabricating and assembling reed plates that also improves harmonica performance and reduces lifetime maintenance and tuning. Another advantage could be realized by providing a harmonica having reed slots with generally uniform and relatively smooth surfaces that improve interaction between reeds and reed slots. What are also needed are improvements in the structure of the comb body, the reed plates and the position of reeds within a conventional harmonica. A harmonica is needed that can achieve draw and blow bends by improving interaction between a reed pair in a cell.
Still another problem that needs to be addressed is that of achieving sufficient loudness from the harmonica. An improvement is needed that can increase the amount of time the reed spends in the slot, thereby increasing the time that the reed receives aerodynamic impetus for vibration. Under circumstances of high-pressure airflow in the harmonica, such as when the player exerts sufficient pressure to cause the tip of reed to vibrate entirely through its respective slot, then a new leakage path is created. A means of reducing the leakage caused by this new path would be advantageous in an improved harmonica.
SUMMARY OF THE INVENTION
The improved harmonica structures of the present invention have met and/or exceeded the above-described needs.
The harmonica structures of the present invention include, in one embodiment, a reed comb having a common bridge with reeds formed integrally with the common bridge. The reed plate has a plurality of reed slots formed therein and is adapted to receive the reeds of the reed comb into corresponding slots formed in the reed plate. The reed plate has a first portion positioned within a first plane and a second portion positioned in a second plane. The second portion of the reed plate has a stepped portion formed therein adapted to receive a reed of the reed comb therein to permit substantial encasement of the reed within the reed slot.
In the harmonica of the present invention, one or more counterbores can be formed in the reed plate adjacent to the tips of the reeds. The counterbore can extend a distance beyond or behind the reed tip and can be provided in a variety of configurations, such as a rectangular shape. In addition, material can be applied to a surface of the reed plate at a location adjacent to the flanks of the reeds to resist leakage of air between the reed plate and the flanks of the reed during harmonica play. The reed plate can include a first stepped portion upon which the roots of the reeds are positioned and a second stepped portion positioned adjacent to the tips of the reeds.
In another aspect of the present invention, the reeds can be formed by direct cutting or forming of the reeds in the reed plate. A reed is formed by cutting along three sides of its perimeter and leaving the fourth or “short” side uncut. This provides a substantially integrally formed reed plate.
In still other aspects of the present invention, a radiused surface can be formed on a portion of the reed or on the surface of the reed slot in which the reed is positioned. A substantially wedge-shaped comb having angled top and bottom surfaces can also be provided. In another aspect of the present invention the height of the comb and the thickness and structure of the reed plates can be adjusted to achieve a variety of acoustical objectives. The width of the cells in the comb can also be adjusted to vary the volume of individual cells. In addition, substantial axial alignment of the roots of a given pair of reeds can be made to provide different acoustical results for the harmonica. The walls of the cells in the comb can also be tapered to alter acoustical effects. A flexible structural member can be used in conjunction with the inside surface of the cells of the comb to close a slot in the reed plate during harmonica play.
The present invention will be more fully understood from the following description of the invention and by reference to the figures and claims appended hereto.
BRIEF DESCRIPTION OF THE DRAWINGS
A full understanding of the invention can be gained from the following detailed description of the invention when read in conjunction with the accompanying drawings in which:
FIG. 1 is an exploded, isometric view of a conventional diatonic harmonica;
FIG. 2 is a sectional view of a set of reeds in a conventional diatonic harmonica;
FIG. 3 is a plan view of a reed attached to a reed plate in a conventional harmonica;
FIG. 4 is a sectional view of a single reed attached to a reed plate in a conventional harmonica;
FIG. 5 is a sectional view taken along 5 — 5 of FIG. 3;
FIG. 6 is a partially schematic sectional view of a reed and reed plate exhibiting air leakage during a closing action of the reed;
FIG. 7 is a partially schematic sectional view of a reed and reed plate exhibiting air leakage during an opening action of the reed;
FIG. 8 is a top plan view of a reed plate of an embodiment of the present invention;
FIG. 9 is a sectional view taken along 9 — 9 of FIG. 8;
FIG. 10 is a sectional view taken along 10 — 10 of FIG. 8;
FIG. 11 is a sectional view taken along 11 — 11 of FIG. 8;
FIG. 12 is an exploded isometric view of a reed comb and reed plate of an embodiment of the present invention;
FIG. 13A is a fragmentary, isometric view of an embodiment of the present invention;
FIG. 13B is a fragmentary, isometric view of an embodiment of the present invention;
FIG. 13C is a fragmentary, isometric view of an embodiment of the present invention;
FIG. 14 is an exploded isometric view of a reed comb and reed plate of an embodiment of the present invention;
FIG. 15 is an isometric view of an integrated reed-bridge reed plate of the present invention;
FIGS. 16-19 are top plan views of reed plate embodiments of the present invention;
FIGS. 20 and 21 are plots of the real component of acoustical admittance versus frequency during harmonica play;
FIG. 22 is a sectional view of a portion of a reed plate and reed embodiment of the present invention;
FIG. 23 is a sectional view of a comb embodiment of the present invention;
FIGS. 24 and 25 are sectional views of comb and reed plate embodiments of the present invention;
FIG. 26 is a partially schematic top plan view of a conventional reed plate;
FIG. 27 is a partially schematic top plan view of a reed plate embodiment of the present invention;
FIG. 28 is a sectional view of a reed embodiment of the present invention;
FIG. 29 is a sectional view of a reed plate embodiment of the present invention;
FIG. 30 is an enlarged sectional view taken at 30 — 30 of FIG. 29; and,
FIG. 31 is a sectional view of a flexible member embodiment of the present invention.
DETAILED DESCRIPTION OF THE EMBODIMENTS
Referring now to FIGS. 1 and 2, a diatonic harmonica 2 is shown including a body or “comb” depicted generally at 10 . The comb 10 is preferably fabricated of a wood, resinous plastic or metal material. The comb 10 is sandwiched between two reed plates 11 , 12 which include a blow reed plate shown generally at 11 and a draw reed plate shown generally at 12 . The plates 11 , 12 are further sandwiched within a housing comprising an upper cover 13 and a mating cover 14 . The plates 11 , 12 are preferably composed of brass or another similar material suitable for use in a harmonica. It can be appreciated that the harmonica 2 can be assembled by use of conventional mechanical fasteners such as screws, bolts and the like.
As shown in FIGS. 1 and 2, the blow reed plate 11 contains a plurality of blow reed slots 30 - 39 , that each accommodate a blow reed such as reed 15 (shown slightly flexed) in each blow reed slot, such as slot 30 . The blow reeds 15 are mounted on the blow reed plate 11 such that when the blow reed plate 11 is positioned next to the comb 10 during assembly, the blow reeds 15 seat inside the cells such as cell 17 formed within the comb 10 . These cells 17 allow air passage into and out of the harmonica 2 by the actions of blowing and drawing, respectively.
Referring again to FIGS. 1 and 2, the draw reed plate 12 has within it a series of draw reed slots, 40 - 49 , each including a draw reed such as draw reed 20 therein. The draw reeds 20 are mounted on the outside of the draw reed plate 12 relative to the comb 10 . The draw reeds 20 naturally vibrate when the harmonica player draws air out of the harmonica. Each blow reed 15 , such as the blow reed 15 in position 30 , has a corresponding draw reed 20 , such as the draw reed 20 in position 40 , positioned substantially opposite the blow reed 15 , such that the matched pair of reeds 15 , 20 share a common cell 17 . During harmonica play, each cell 17 communicates with a blow reed 15 and a draw reed 20 as a matched pair of reeds 15 , 20 .
Referring again to FIGS. 1 and 2, the draw reeds 20 in positions 40 - 49 normally sound only when air is drawn out of the harmonica 2 . This is how the diatonic harmonica 2 is designed to operate during normal play. However, it has been established that during certain procedures, known as “bends,” “overblows,” and “overdraws,” wherein the resonance of the vocal tract is critically altered, both the draw reeds 20 and the blow reeds 15 can be caused to vibrate sympathetically.
Referring again to FIGS. 1 and 2, reeds 15 and 20 are normally attached by a rivet or another suitable mechanical fastener to the reed plates 11 , 12 so that each reed, in its detent or resting position, is in a substantially parallel position with respect to the reed plate but is also substantially outside respective reed slots, 30 and 40 . In normal functioning of the harmonica 2 , the reeds are caused to vibrate by positive or negative air pressure applied to the cells 17 by the player. During a blowing action, the blow reed 15 is caused to close while draw reed 20 is caused to open. The closing action of the blow reed 15 normally results in a sustained oscillation due to the inverse relationship between the air pressure and the aerodynamic resistance across the reed slot 30 . That is, additional instantaneous air pressure causes the reed 15 to close further, thereby decreasing the clearance between the reed 15 and the blow reed plate 11 , and thereby increasing the aerodynamic drag. This, in turn, causes a reduction of airflow that inevitably allows the normal elasticity of the reed 15 to reopen the slot 30 . By contrast, the draw reed 20 is moved to an open position during a blowing operation, thereby decreasing its aerodynamic resistance. As such, the draw reed 20 does not support oscillation, but instead accounts for unwanted loss of air pressure. Likewise, when the player draws through passage 17 , the roles of the reeds are reversed.
Under certain situations, both reeds can be caused to oscillate. This generally occurs when the player is drawing through the first six cells 21 - 26 of the harmonica 2 or blowing through the last four cells 27 - 30 of the harmonica. In each of these situations, the opening reed is tuned to a frequency lower than the closing reed in the shared, corresponding cell, such as cell 17 for the reeds 15 , 20 . Likewise, during a draw bend or blow bend procedure, the vibration of the lower-pitched opening reed increases while the vibration of the closing reed decreases.
Referring now to FIGS. 3 through 5, a reed plate 52 is shown having a reed 54 attached thereto such as by a mechanical fastener or rivet 56 . In a closed position 55 of the reed 54 as it vibrates in position over the slot 58 formed in the reed plate 52 , lateral gaps 60 , 62 are formed between the reed 54 and the reed plate 52 . During harmonica play, these gaps 60 , 62 disadvantageously permit air to escape or enter the slot 58 between the reed 54 and the reed plate 52 .
As shown more particularly in FIGS. 6 and 7, during harmonica play air flow can pass through lateral gaps 60 , 62 during a closing action or by relative motion of the reed 54 in the direction of the slot 58 of the reed plate 52 (as shown in FIG. 6 ). The closing action of the reed 54 is caused by the negative air pressure −AP. In addition, the air flow can pass through lateral gaps 60 , 62 during an opening action or by relative movement of the reed 54 away from the reed plate 52 and the slot 58 (as shown in FIG. 7 ). The opening action of the reed 54 is caused by the positive air pressure +AP.
Referring now to FIGS. 8 through 12, the harmonica of the present invention includes a reed comb 72 having a plurality of integrally formed reeds such as reeds 74 , 76 , 78 extending from a common bridge 80 . The reed comb 72 is adapted to be received and connected by mechanical attachment such as by rivet 82 onto a reed plate 84 having a plurality of reed slots such as reed slot 79 formed therein. The reed plate 84 has a first portion 86 positioned within a first plane 88 and a second portion 90 extending through a second plane 92 . The first plane 88 is substantially parallel to the second plane 92 as shown. The second portion 90 of the reed plate 84 also has a stepped portion 91 on a surface of the first portion 86 of the reed plate 84 . The root 77 of the reed 76 rests on this stepped portion 91 and is mechanically connected as previously discussed to the reed plate 84 by the rivet 82 . A counterbore 96 is formed within the second portion 90 of the reed plate 84 . It is therefore the function of the stepped portion 91 to permit substantial encasement of the reed 76 within the reed slot 79 . The counterbores 96 , 98 can extend distances 100 , 102 , respectively beyond the tips 104 , 106 of the reeds 76 , 74 .
It can be appreciated that the reed plates and reed combs can be fabricated in any of several ways including conventional milling, die stamping, electron discharge machining, laser cutting, electroforming or photo-etching to promote reed dimensions and alignment relative to the common bridge. Furthermore, an integrally formed and single-piece reed comb is relatively easier to assemble to the reed plate than a conventional harmonica design typically wherein ten individual reeds are assembled to a reed plate. In addition, in the harmonica of the present invention, the rotational alignment of the reed with respect to the reed comb is assured by the integral association of the reeds with the common bridge of the reed comb.
This invention therefore features a novel configuration of reeds within the reed slots of a given reed plate. Unlike the stacked arrangement of reeds on top of a conventional reed plate slot, the reeds of this invention are situated partially or substantially within a counterbore. The counterbore proves a small clearance at the tip of the reed near the second portion of the reed plate. However the flanks of the reed are positioned substantially within the slot of the reed plate when the reed moves toward the reed plate slot during play. This structure thereby substantially interrupts the leakage of air characterized by conventional harmonica play. This interruption of airflow also reduces the edge tones responsible for undesirable whistling and squealing while playing a harmonica.
The reeds of the present invention are composed of a material selected from the group of elastic metals including phosphor bronze, beryllium copper, brass, and nickel-titanium alloy. Nickel-titanium alloy is characterized by relatively high elasticity and durability, and is therefore a preferred material for the reeds of the present invention. This alloy also addresses the problems associated with relatively softer materials, namely the problem of detuning of the harmonica due to strain hardening and fatigue.
In addition, a material that is too yielding can result in dislocation of harmonica components such as the reeds.
It should be appreciated that although the embodiment of the present invention depicted in FIGS. 8 through 12 shows a reed plate having material removed near the tip and near the base of the reed, substantially similar properties can be achieved if material is added along the flanks of the reeds. Referring now to FIGS. 13A, 13 B and 13 C, it is shown that material can be removed from the area adjacent to the root 107 of the reed 108 . Material can also be removed from the reed plate in the vicinity of the tip 109 of the reed 108 . As shown in FIG. 13B, material 110 can be positioned adjacent to the reed 108 to resist leakage of air between the reed plate and the flanks of the reed 108 during harmonica play. Material removed from the vicinity of the tip 109 of the reed 108 can form a substantially ramped surface, as shown in FIG. 13 C.
Referring now to FIG. 14, the reed plate 112 of the present invention can include two stepped portions 114 , 116 in conjunction with assembly of a reed comb 118 with the reed plate 112 . The stepped portion 116 extends along substantially the entire length of the reed plate 112 . In the form of the invention shown, a plurality of recesses such as recesses 120 , 122 , 124 are also formed in the reed plate 112 .
Referring now to FIG. 15, in another embodiment of the present invention, the reeds 125 , 126 , 127 are formed integrally with the reed plate 128 of the harmonica by cutting along three sides 129 , 130 , 131 of the perimeter of each reed. This permits each reed to cantilever from the fourth, uncut side 132 of each reed when the reed vibrates during harmonica play.
Referring now to FIGS. 16 through 19, FIG. 16 shows an aspect of the present invention wherein the recess 142 at the tip 144 of the reed 146 positioned in the slot 148 of the reed plate 150 is a substantially circular counterbore. FIG. 17 shows an aspect wherein the recess 152 at the tip 154 of the reed 156 is a rectangular counterbore located primarily forward of the tip 154 of the reed 156 on the reed plate 150 . FIG. 18 shows an aspect wherein the recess 162 at the tip 164 of the reed 166 is a rectangular counterbore located primarily behind the tip 164 of the reed 166 on the reed plate 150 . FIG. 19 shows an aspect wherein the recess 172 at the tip 174 of the reed 176 is a rectangular counterbore located both in front of the tip 174 of the reed 176 a distance L 1 and behind the tip 174 of the reed 176 a distance L 2 .
Referring now to FIGS. 20 and 21, the acoustic performance of reeds in a harmonica can be characterized by their acoustic admittance, defined as the first derivative of acoustic flow with respect to pressure. This is typically a complex quantity, containing a real part and an imaginary part. Vibration theory prescribes that when the real part of the complex admittance is negative, the reed exhibits sustained vibration. When plotted as a function of frequency and pressure, the typical response of a pair of reeds such as those found in a harmonica is shown as a solid-line plotted in FIGS. 20 and 21.
FIG. 20 depicts the admittance of a reed pair wherein the higher-pitched reed is operating as a closing reed and the lower-pitched reed is operating in its opening mode. For example, this admittance is provided when a harmonica player is drawing holes 1 to 6 or blowing holes 7 to 10 of a standard 10-hole diatonic harmonica. The fundamental frequencies of the lower-pitched reed and the higher-pitched reed are shown as f LP and f HP , respectively.
FIG. 21 depicts the admittance of a reed pair wherein the lower-pitched reed is operating as a closing reed and the higher-pitched reed is operating in its opening mode. This admittance characteristic is provided when the player is blowing through holes 1 to 6 or drawing through holes 7 to 10 of the 10-hole diatonic harmonica. The second “dip” seen in FIG. 20 corresponds to the overblow or overdraw note which is distinct from the respective blow and draw notes.
In the context of FIGS. 20 and 21, an object of the present invention is to increase the range (bandwidth) of the unstable frequencies and to increase the range of acoustic admittance for which the reed is unstable. This, in turn, enlarges the range of oral geometries that a player may achieve a desired tone. It can also have the effect of lowering the pressure at which instability occurs. This is shown more particularly by the dashed curves in FIGS. 20 and 21. These acoustic admittance curves of reed pairs are adapted and shown herein for illustrative purposes from Johnston, R. B., “Pitch Control in Harmonica Playing,” Acoust. Aust. 15(3), 69-75 (1987).
Referring now to FIG. 22, in another embodiment of the present invention, a cross-section of a reed 202 of the present invention is shown partially positioned within its respective reed slot 204 in a reed plate 205 . The radii 206 , 208 , 210 , 212 , 214 , 216 are provided along the reed 202 and the upper and lower portions of the flanks 218 , 220 of the reed 202 to improve the aerodynamics of the airflow traveling between the reed 202 and the reed plate 205 during harmonica play. These radii are preferably in the range of about 0.001 to 0.0025 inches. An advantage of these radii is reducing undesirable edge tones usually causing discordant “whistle” sounds emanating from the closing action of the reed 202 .
Referring now to FIG. 23, in another aspect of the present invention, the comb 232 of the harmonica is principally a wedge-shaped structure having a top surface 234 sloped at an angle α with respect to vertical and a bottom surface 236 angled at an angle β with respect to vertical. This aspect of the present invention alters the acoustic properties of the air space 238 within the comb 232 and thereby affects the timbre of the sound produced. The angles α and β can each be in the range of approximately 75 to 105 degrees.
Referring now to FIG. 24, in another aspect of the present invention, the comb 252 of the harmonica can be reduced to a height h 1 . The advantages of this configuration are twofold. First, the relatively close distance d 1 of the reeds 254 , 256 in the cell 258 improves their interaction during harmonica play. Accordingly, blow bends and draw bends are more readily performed by the harmonica player. This feature is particularly desirable on the first four and last four holes of a conventional ten-hole diatonic harmonica. Second, the volume of the cavity 258 , being reduced from a typical volume, resists the player from reducing his/her mouth cavity to such a considerable degree than is conventionally needed for blow bending, overblowing, and overdrawing procedures. This feature is most desirably utilized on the last four holes of a conventional ten-hole diatonic harmonica. The height h 1 is preferably in the range of 3.5 to 4.5 mm or most preferably about 4.0 mm as compared to the typical height dimension of about 6.2 mm. In order to maintain a normal opening at the lips of the player, outward flares 260 , 262 are provided, respectively, at the front edge of the reed plates 264 , 266 .
Referring now to FIG. 25, another aspect of the present invention is shown wherein the comb 272 is increased to a height h 2 . The advantages of this configuration are twofold. First, the increased distance d 2 between the two reeds 274 , 276 in the cell 278 reduces their interaction. Accordingly, dissonant overblows and overdraws can be avoided. This feature is most desirable on the last seven holes of a ten-hole diatonic harmonica. Second, the volume of the cavity 278 , being increased from its normal volume, resists the player from increasing his/her mouth cavity to a point greater than currently required for a draw bending procedure. This feature is most desirable on the first four holes of a diatonic harmonica. The height h 2 is preferably in the range of about 7.0 to 8.5 mm or most preferably 8.0 mm as compared to the typical height dimension of about 6.2 mm. To maintain a normal opening for the lips of the player (not shown), inward flares 280 , 282 are provided, respectively, at the front edge of the reed plates 284 , 286 .
Referring now to FIG. 26, a conventional comb 312 is shown having all cells of substantially the same width or approximately 4.2 mm. Referring next to FIG. 27, in accordance with an aspect of the present invention, the volume of each of the lower three cells 334 , 335 , 336 is increased and the volume of the upper two cells 342 , 343 is decreased by comparable enlargement or reduction of the widths of these cells. The range for the width of these cells with reduced or enlarged widths is preferably from about 3 mm to 6 mm.
Referring now to FIG. 28, in another aspect of the present invention, the reeds 362 , 364 of the harmonica can be mounted on their respective reed plates 368 , 370 so that their respective roots 369 , 371 are positioned in a substantially axial alignment with respect to each other. This provides the benefit of increasing the interaction between the reeds, thereby providing the improved play benefits previously described for other aspects of the present invention.
Referring now to FIGS. 29 and 30, in another aspect of the present invention, the thickness t of the reed plate 382 can be in the range from about 1.5 to 2 mm. In contrast, a conventional harmonica has reed plates with thicknesses typically in the range of about 0.9 to 1.0 mm. This provides the advantage of increasing the amount of time the reed 386 spends within the slot 387 , and thereby avoids leakage that occurs when the tip 388 of the reed 386 passes completely through the slot 387 . FIG. 30 presents an enlarged view of section 30 — 30 of FIG. 29 that shows the detail of the reed plate 384 near the tip 392 of the reed 390 . An additional feature of this reed plate 384 is a taper angle θ, corresponding to the arc of the reed 390 during its flexion. The inclusion of this taper angle θ also serves to reduce the leakage created by a gap 394 formed between the tip 392 of the reed 390 and the internal surface 396 of the reed slot 391 , which gap 394 widens as the reed 390 flexes into the reed slot 391 . The taper angle θ is typically in the range of approximately one to seven degrees.
Referring now to FIG. 31, in another aspect of the present invention, a flexible member 402 is affixed at one end of the flexible member 402 to a surface 403 of the reed plate 404 . The length and width of this member 402 are each slightly larger than the reed slot. Therefore, when air pressure is provided that causes the reed 406 to open, this normally resiliently biased member 402 is forced against the reed slot thereby substantially closing off air leakage. When air pressure is applied causing this reed 406 to close, the flexible member 402 is deflected from the source of air pressure, thereby not substantially affecting the function of the associated reed 406 . This feature is beneficial for the draw reeds of the first three holes of a conventional diatonic harmonica, wherein excessive loss of air pressure is experienced when the player attempts to play a blow note, and also wherein overblows are not performed, thus the draw reed is not required to operate in the opening fashion. In the preferred embodiment, the flexible member is made from about 0.004″ thick polyethylene, but any suitable material of equivalent thickness and stiffness may be used.
It can be appreciated that the improvements described herein need not be applied to all 20 reeds, but could be applied to only one reed, or some other reasonable combination of reeds of a harmonica.
Whereas certain terms of relative orientation such as “upper” and “lower” have been used herein to describe the invention, these terms are intended for purposes of illustration only and are not intended to limit the scope of the present invention. In addition, 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 arrangements 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.
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Harmonica structures designed for enhancing harmonica play are disclosed. In one aspect, a reed comb is provided with a common bridge having reeds formed integrally therewith. The reed plate has a plurality of reed slots formed therein and is adapted to receive the reeds of the reed comb into corresponding slots formed in the reed plate. A stepped portion formed in the reed plate is adapted to receive a reed of the reed comb therein to permit substantial encasement of the reed within the reed slot. A key benefit of this arrangement is to resist leakage of air between the reed plate and the flanks of the reed during harmonica play. The reed plate can also include a first stepped portion upon which the roots of the reeds are positioned and a second stepped portion positioned adjacent to the tips of the reeds. Other structures are disclosed that include a radiused surface formed on a portion of the reed or on the surface of the reed slot in which the reed is positioned. A substantially wedge-shaped comb having angled top and bottom surfaces can also be provided. The height of the comb and the thickness and structure of the reed plates can also be adjusted to achieve a variety of acoustical objectives. The width of the cells in the comb can also be adjusted to vary cell volume. In addition, substantial axial alignment of the roots of a given pair of reeds can be made to provide different acoustical results for the harmonica. The walls of the cells in the comb can also be tapered to alter acoustical effects. A flexible structural member can also be used in conjunction with the reed plate to enhance harmonica play.
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RELATED APPLICATIONS
[0001] This application corresponds to PCT/EP2O15/000077, filed Jan. 19, 2015, which claims the benefit of German Application No. 10 2014 001 167.4, filed Jan. 31, 2014, the subject matter of which are incorporated herein by reference in their entirety.
BACKGROUND OF THE INVENTION
[0002] The invention relates to a frame for a vehicle seat belt retractor comprising a back part and two side legs extending in parallel to each other starting from the back part, wherein a retaining aperture for a belt reel is provided in each side leg. The invention further relates to a vehicle structure for mounting a belt retractor in a vehicle as well as a sheet metal blank for a frame of a vehicle seat belt retractor.
[0003] Belt retractors comprising a back wall the surface of which contacts the vehicle body and is mounted thereto are known from the state of the art. The side legs on which the belt reel is supported extend at right angles away from said back wall, i.e. also at right angles from the vehicle body. Such frame is made in one piece from a sheet metal with the side legs being bent at right angles with respect to the back part. For this constructional design large sheet thicknesses of more than 2 mm are required, however, so as to ensure sufficient stability of the frame.
[0004] For reducing the sheet thicknesses of such frame from the state of the art frames are known in which the back wall is offset by 90° vis-à-vis the vehicle body so that it extends away from the vehicle body. On the back wall a retaining bracket is provided which is bent so that its surface contacts the vehicle body. In addition, a retaining fitting that serves for stiffening the retractor and the retaining bracket is provided. This design helps to reduce the sheet thicknesses to 1.7 mm, wherein additional lands are required between the side legs so as to ensure the stability of this frame.
SUMMARY OF THE INVENTION
[0005] It is the object of the invention to provide a frame for a vehicle seat belt retractor that has a smaller sheet thickness and nevertheless satisfies the necessary stability requirements. It is a further object of the invention to provide a vehicle structure for mounting a belt retractor in a vehicle which has a lower weight as well as a sheet metal blank for a frame by which material-saving manufacture of a frame for a seat belt retractor is possible.
[0006] For achieving the object a frame for a vehicle seat belt retractor is provided comprising a back part, two side legs extending in parallel to each other starting from the back part, wherein a retaining aperture for a belt reel is provided in each side leg, and comprising a mounting structure for mounting the frame fixed to the vehicle, wherein the mounting structure includes a retaining bracket having a mounting hole for a retaining means and at least one deformable deformation element. The frames known from the state of the art are fully adjacent to the vehicle body. The forces occurring in a case of restraint have to be fully absorbed by the frame; therefore the latter has to be designed to be very stiff. The frame according to the invention is based on the consideration to absorb the load peaks at the beginning of the restraining operation by a deformation of the mounting structure. Only after deformation of the frame the load is completely transferred from the frame to the vehicle body. Since the deformation element is provided on the mounting structure, at the beginning of the restraining operation initially only said mounting structure but not the entire frame is deformed so that the function of the frame is maintained.
[0007] Preferably, with such frame the retaining bracket is arranged on a free edge of the back part and is bent especially at right angles relative thereto so that the surface of the back part cannot fully contact the vehicle body. Full-surface contact of the frame to the vehicle body would impair deformation of the mounting structure. When the deformation element is deformed it is also possible that the angle between the back part and the retaining bracket varies and thus the back part is bent up relative to the retaining bracket.
[0008] In order to fasten the frame additionally to the vehicle body a mounting hook especially projecting at right angles which engages in a corresponding hole on the vehicle body may be provided at the retaining bracket.
[0009] Preferably the back part, the side legs and the retaining bracket are integrally formed of a sheet metal, wherein the side legs and the retaining bracket are bent at right angles relative to the back part. Thus the frame includes as few components as possible so that simple and quick fabrication of the frame is possible. The frame may be manufactured, for example, of a punched sheet metal blank.
[0010] The deformation element may be arranged at a distance from the retaining bracket and may include a contact surface located in a plane with the retaining bracket. In this embodiment it is possible that merely the retaining bracket and the deformation element are adjacent to the vehicle body. The deformation element is arranged so that, when the webbing is tensioned, compressive formed is exerted against the vehicle body on the deformation element. The deformation element is deformed with the side legs and the back part being tilted about the retaining bracket. Consequently, in this embodiment the frame is swiveled about the retaining bracket and the first load peak is taken up by deformation of the deformation element. The deformation element may as well be configured so that it is not moved against the vehicle body and does not contact the latter before load is applied.
[0011] In order to achieve a preferably high load bearing capacity by the deformation element, the retaining bracket is preferably located at a first end of the frame and the deformation element is located at a second end. In particular, the deformation element is provided in the unwinding direction of the webbing ahead of the retaining bracket so that, when tensile force is applied to the webbing, the deformation element is forced against file vehicle body.
[0012] For preventing the side legs of the frame from contacting the vehicle body end thus fern affecting the deformation of the deformation element, the frame and especially the side legs are cot out between the retaining bracket and the deformation element. This ensures that the frame contacts the vehicle body only by the support element and the retaining bracket, i.e. the mounting structure. Especially the degree of deformation of the deformation element may also be affected by the geometry of the cutout. The deformation element may deform, for example, until the side legs or other parts of the frame contact the vehicle body, support the latter and in this way prevent or inhibit any further deformation of the deformation element.
[0013] In addition, a guide plate having a guide slot for the webbing may be provided on the frame. The guide plate is arranged, for example, on the side legs opposite to the back part so that the frame is additionally reinforced by the guide plate. The guide slot is located opposite to a plane formed by the retaining bracket, especially with respect to the retaining apertures for the belt reel, for instance with respect to the belt reel substantially radially opposite to the retaining bracket. The guide plate stiffens the frame and offers a mounting facility for the guide slot. The guide slot is spaced apart from the vehicle body so that the webbing is unwound in the case of blocking of the belt reel so that a compressive force acts on the deformation element. The guide element may be a separate component being mounted on the side legs after bending the latter. This facilitates the manufacture of a sheet metal blank, for example, as the design of the latter may be less complex.
[0014] The deformation element may be arranged on the guide plate, for Instance, so that the compressive force which is exerted on the webbing and on the frame, respectively, by the webbing contacting the guide slot may act directly on the deformation element via the guide element. Especially, the deformation element is formed by a bent edge of the guide plate.
[0015] A deformation element may equally be provided between the back part and the retaining bracket. The deformation element is deformed upon swivellng the frame about the retaining bracket and in this way can equally reduce a load peak. It is in particular also imaginable that the frame merely includes said second deformation element between the back part and the retaining bracket so that, apart from the retaining bracket, no other contact point of the frame is required on the vehicle body.
[0016] In order to increase the stability of the back part and/or of the side legs embossed patterns may be provided on the same so that they exhibit higher bending stiffness.
[0017] For achieving the object, moreover a vehicle structure for mounting a belt retractor in a vehicle is provided comprising a body part and a frame according to the invention, the retaining bracket and the deformation element being assigned to the body part. At an unloaded distance the deformation element may be arranged at a distance from the vehicle body and may be moved against the latter and contact the latter only when a tensile force acts on the frame.
[0018] Preferably the deformation element is arranged in a direction of unwinding the webbing at a distance from the retaining bracket and ahead of the same so that a compressive force may act on the deformation element when a tensile force is applied to the webbing while the belt reel is blocked.
[0019] Furthermore, for achieving the object a sheet metal blank for a frame according to the invention is provided, the sheet metal blank including a back part portion, a retaining bracket portion as well as two side leg portions. The side leg portions are provided at opposed edges of the back part portions and the retaining bracket portion is provided at an edge extending between said opposed edges. Between the side leg portions a recess having dimensions larger than those of the retaining bracket portion is formed. The frame is preferably punched out of a plane sheet metal part. The sheet metal blank according to the invention permits reducing the waste when plural such sheet metal blanks are punched out. Since the recess is larger than a retaining bracket portion, the retaining bracket portion of a neighboring sheet metal blank may extend into said recess so that plural sheet metal blanks can be arranged in a very space-saving manner relative to each other on a sheet metal part.
[0020] In such sheet metal blank a mounting hook formed by a punched cutout of the back part portion is provided at the retaining bracket portion. The mounting hook is bent relative to the back part portion and the retaining bracket portion so that it projects at right angles on the back side of the frame and can be mounted in a vehicle body.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] Further advantages and features are evident from the following description in connection with the enclosed drawings. In which:
[0022] FIG. 1 shows a perspective view of a frame according to the invention,
[0023] FIG. 2 shows a second perspective view of the frame of FIG. 1 ,
[0024] FIG. 3 is a top view onto the frame of FIG. 1 ,
[0025] FIG. 4 is a bottom view of the frame of FIG. 1 ,
[0026] FIG. 6 is a front view of the frame of FIG. 1 ,
[0027] FIG. 6 shows a side view of a vehicle structure according to the invention comprising the frame of FIG. 1 , and
[0028] FIG. 7 shows a sheet metal strip comprising two sheet metal blanks according to the invention for the frame of FIG. 1 .
DESCRIPTION
[0029] In FIGS. 1 to 5 a frame 10 for a vehicle seat belt retractor is illustrated. The frame 10 includes a back part 12 on which a side leg 16 is provided on each of opposite edges 14 . Each of the side legs 16 includes a retaining aperture 18 for a belt reel wherein a toothing 20 for blocking the belt reel is provided in the retaining aperture. For unwinding webbing the belt reel is rotated in a direction of rotation D.
[0030] A retaining bracket 22 which is arranged at an edge 24 disposed between the edges 14 is moreover provided on the back part 12 . The frame 10 in addition includes a guide plate 26 on which a guide slot 28 is provided through which the webbing of the seat belt is guided.
[0031] The back part 12 , the side legs 16 and the retaining bracket 22 are integrally fabricated of a sheet metal blank 30 shown in FIG. 7 . The side legs 16 are bent at right angles with respect to the back part 12 and extend substantially in parallel to each other away from the back part 12 . The retaining bracket 22 is bent normal to the plane of the back part 12 and in the opposite direction with respect to the side legs 16 and equally extends substantially at right angles away from the back part 12 .
[0032] The guide plate 26 is arranged opposite to the back part 12 at the side legs 16 . As is evident especially from FIG. 2 , recesses 32 through which projections 34 provided at the edge of the side legs 16 extend are arranged at the guide plate 26 . The projections 34 are bent or caulked on the back side of the guide plate 26 so that the guide plate 26 is tightly connected to the side legs 16 .
[0033] As is evident especially from FIG. 1 , the retaining bracket 22 includes a mounting hole 36 for a retaining means 50 (see FIG. 6 ) as well as a mounting hook 38 projecting at right angles which can get caught in a body part 52 , as will be explained hereinafter. The mounting hook 38 is formed by a punched cutout 40 of the back part 12 .
[0034] On both the back part 12 and the side legs 16 embossed patterns 42 , 44 are provided for increasing the stability of the back part 12 and the side legs 16 , respectively.
[0035] Moreover, a deformation element 46 formed by a bent edge of the guide plate 26 is provided at the end of the guide plate 26 opposed to the guide slot 28 . The deformation element includes a contact surface 43 that is arranged in a plane including the retaining bracket 22 , as is visible especially from FIG. 6 .
[0036] The deformation element 46 forms a mounting structure for the frame 10 together with the retaining bracket 22 .
[0037] As can be seen in FIG. 6 , the frame 10 is attached to a body part 52 by a retaining means 50 extending through the retaining bracket 22 . The mounting hook 38 extends into an aperture 54 at the body part 52 and is fixed within the same. The deformation element 46 contacts the body part 52 with the contact surface 48 but is not fixed thereto.
[0038] As the guide slot 28 of the guide plate 26 is arranged opposite to a plane formed by the retaining bracket 22 with respect to the retaining apertures 18 , the webbing is guided out of the frame 10 at a distance from the body part 52 .
[0039] When a tensile force is exerted on the webbing with the belt reel being blocked, it acts vertically downwards, related to FIG. 6 . Since the belt reel is fixed to the body part 52 by the retaining bracket 22 and by virtue of the distance of the guide slot 28 from the body part 52 a compression force F directed substantially perpendicularly against the body part 52 acts on the deformation element 46 and, respectively, on the contact surface 48 . Upon blocking of the belt reel this compression force F first causes the deformation element 46 to be deformed with the frame 10 being tilted about the retaining bracket 22 . This deformation helps to reduce the first load peak upon blocking of the belt reel so that lower load acts on the frame 10 and is transmitted to the body part 52 via the retaining means 50 .
[0040] Other than with the frames known from the state of the art, part of the force acting on the frame 10 via the webbing is reduced through deformation of the frame 10 and, resp., of the mounting structure of the frame 10 . Since the other components of the frame 10 in this way have to absorb lower load, they may be configured to be thinner. Especially the sheet thickness may be reduced to 1.5 mm. As moreover a deformation of the frame 10 is desired, the latter need not be so stiff that it cannot deform.
[0041] As is evident especially from FIG. 6 , the deformation element 48 is arranged at a distance from the retaining bracket 22 , with the retaining bracket 22 being arranged in particular on a first end of the frame 10 and the deformation element 46 is arranged on a second end of the frame 10 . Due to this large distance between the retaining bracket 22 and the deformation element 46 , the force F can act on the deformation element 46 with an as large lever arm as possible so that the deformation element may be designed to be stiffer and may reduce higher load.
[0042] Furthermore a recess 56 is formed at each of the side legs 16 between the retaining bracket 22 and the deformation element 46 . These recesses 56 prevent the side legs 16 from contacting the body part 52 and thus from inhibiting deformation of the deformation element 46 . In particular, the recesses 56 may be configured so that after defined deformation of the deformation element 46 the side legs 16 contact the body part 52 and prevent or inhibit further deformation of the deformation element 46 .
[0043] By deforming the deformation element 46 and tilting the frame 10 also the back part 12 is bent relative to the retaining bracket 22 . For example, between the retaining bracket 22 and the back part 12 a second deformation element may be provided which is equally deformed by such bending-up. Said second deformation element may equally reduce a load peak by the deformation.
[0044] Depending on the design of the frame 10 and, resp., of the vehicle structure, it is also possible that the lower end of the frame 10 with respect to FIG. 6 does not contact a vehicle body 52 . In such embodiment also merely a second deformation element may be provided between the retaining bracket 22 and the back part 12 .
[0045] In particular, the deformation element 46 of the mounting structure may be arranged at any position on the frame 10 . It has merely to be ensured that, when a tensile force acts on the frame 10 , the deformation element 46 is deformed by tilting, rotating, swiveling or displacing the frame 10 .
[0046] As already afore-explained, the frame 10 is manufactured of a plane sheet metal blank 30 as well as the guide plate 26 . FIG. 7 illustrates an example of such sheet metal blank 30 showing a sheet metal part 57 including several sheet metal blanks 30 .
[0047] The sheet metal blank 30 comprises a back part portion 58 , two side leg portions 60 and a retaining bracket portion 62 . The side leg portions 60 are provided on opposite edges at the back part portion 58 , the retaining bracket portion 82 is located on an edge disposed between the opposite edges. The side leg portions 60 mostly extend in a direction opposed to the retaining bracket portion 62 so that a recess 64 is formed between the former.
[0048] The dimensions of this recess 64 are larger than the dimensions of the retaining bracket portion 62 . In this way, as is evident from FIG. 7 , the retaining bracket portion 62 of an adjacent sheet metal blank 30 may be arranged in the recess 64 . The side leg portions 60 of adjacent sheet metal blanks 30 and, hence, the adjacent sheet metal blanks 30 in this way can be arranged very closely to each other, thus enabling the sheet metal blanks 30 to be arranged on the sheet metal part 57 in a material-saving manner. The waste of material can be reduced, which allows achieving better utilization of material.
[0049] As is visible especially in FIG. 7 , on the retaining bracket portion 62 a mounting hook portion 66 formed by a punched cutout 68 of the back part portion 58 is provided. In this way, the mounting hook 38 may be formed integrally with the retaining bracket 22 so that it is connected to the retaining bracket 22 in a more stable manner.
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A frame (10) for a vehicle seat belt retractor comprises a back part (12), two side legs (16) extending in parallel to each other starting from the back part (12), with a retaining aperture (18) for a belt reel being provided in each side leg (16), and a mounting structure for mounting the frame (10) fixed to the vehicle, wherein the mounting structure includes a retaining bracket (22) having a mounting hole (36) for a retaining means (50) and at least one deformable deformation element (46). Furthermore, in accordance with the invention a vehicle structure for mounting a belt retractor in a vehicle is provided comprising a body part (52) and a frame (10) according to the invention. Moreover, a sheet metal blank for such frame is provided.
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BACKGROUND
[0001] Voids in bones may exist because a diseased portion of the bone has been surgically removed or a bone has been damaged in an accident. These voids can lead to discomfort and structural instability, either of which may prompt a patient to seek ways to alleviate the pain and to obtain more structural support.
[0002] In response to these conditions associated with the presence of bone voids, researchers and clinicians have developed many different materials to fill the voids or to cause fusion between adjacent bones or between segments of a bone. These materials include, but are not limited to, temporary or permanent bone substitute materials that may be accompanied by one or more agents that help to promote healing.
[0003] However, the challenge of filling a bone void rests not only in formulating a suitable composition, but also in delivering the composition to the site of interest. One type of tool that is useful for the delivery of certain known compositions is the plunger type syringe.
[0004] Unfortunately, known syringes are imperfect because too frequently, material within the barrels of those syringes clog when bone graft material is the substance that one seeks to dispense. This causes either too much fluid or only fluid to be expelled from the syringe. Consequently, dehydrated bone graft material may become stuck inside the syringe barrel. Therefore, there is a need for new syringe designs that can more efficiently administer bone graft materials that are prone to clogging.
SUMMARY
[0005] Devices and methods for injecting bone graft materials into bone defects or bone grafting sites are provided. Through the use of these devices and methods, bone graft materials that are prone to clogging during delivery may be more efficiently delivered to a site of interest.
[0006] According to an embodiment of the present invention, there is a syringe assembly for dispensing bone graft material comprising a barrel having a first opening and a second opening, the barrel defining a cavity with curvature; and a flexible plunger, wherein the flexible plunger is sized to slide within and at least part of the plunger into and out of the cavity. Optionally, the syringe assembly will also comprise a cover for the first opening, wherein the cover optionally comprises a reversibly sealable opening such as a valve that allows substances to enter and to exit the cavity.
[0007] According to another embodiment of the present invention, there is a method for injecting bone graft materials comprising: loading a syringe comprising a barrel having a first opening and second opening, the barrel defining a curvature over at least ninety degrees; and a flexible plunger, wherein the flexible plunger is sized to slide within the cavity; and pushing the plunger toward the first opening, thereby forcing materials within the barrel to exit the syringe.
[0008] In various embodiments, the devices and methods of the present invention make use of a barrel that has a constant internal diameter. By creating a barrel that curves, the amount of material that is contained within the syringe can be increased without increasing the distance between the plunger and the needle. Furthermore, if the cross-section of the barrel is kept constant, compaction and clogging of the barrel by particulate material in the grafting material can be minimized. Additionally, in order to avoid clogging at the end at which material is dispensed, in some embodiments it may be advantageous for the opening at that end to have the same cross-section as the barrel or a cross-section that is larger than that of the barrel.
BRIEF DESCRIPTION OF THE FIGURES
[0009] In part, other aspects, features, benefits and advantages of the embodiments of the present invention will be apparent with regard to the following description, appended claims and accompanying drawings where:
[0010] FIG. 1A is a representation of an embodiment of a bone graft injection syringe according to the present invention, with a blunt dispensing end. FIG. 1B is a representation of the same syringe with a beveled tip or dispensing end.
[0011] FIG. 2A is a representation of another embodiment of a bone graft injection syringe according to the present invention. FIG. 2B is a bottom view of the syringe of FIG. 2A . FIG. 2C is a representation of a syringe similar to that of FIG. 2A , but the tip is beveled. FIG. 2D is a representation of a bottom view of the syringe of FIG. 2C .
[0012] FIG. 3A is a representation of another embodiment of a bone graft injection syringe according to the present invention. FIG. 3B is a bottom view of the syringe of FIG. 3A . FIG. 3C is a representation of a syringe similar to that of FIG. 3A , but the tip is beveled. FIG. 3D is a representation of a bottom view of the syringe of FIG. 3C .
[0013] FIG. 4A is a representation of another embodiment of a bone graft injection syringe according to the present invention. FIG. 4B is a bottom view of the syringe of FIG. 4A .
[0014] FIG. 5A is a representation of another embodiment of a bone graft injection syringe according to the present invention. FIG. 5B is a bottom view of the syringe of FIG. 5A .
[0015] It is to be understood that the figures are not necessarily drawn to scale. Further, the relation between objects in the figures may not be to scale, and may in fact have a reverse relationship as to size. The figures are intended to bring understanding and clarity to the structure of each object shown, and thus, some features may be exaggerated in order to illustrate a specific feature of a structure.
DETAILED DESCRIPTION
[0016] For the purposes of this specification and the appended claims, unless otherwise indicated, all numbers expressing quantities of ingredients, percentages or proportions of materials, and other numerical values used in the specification and claims, are to be understood as being modified in all instances by the term “about.” Accordingly, unless indicated to the contrary, the numerical parameters set forth in the following specification and attached claims are approximations that may vary depending upon the desired properties sought to be obtained by the present invention. At the very least, and not as an attempt to limit the application of the doctrine of equivalents to the scope of the claims, each numerical parameter should at least be construed in light of the number of reported significant digits and by applying ordinary rounding techniques.
[0017] Notwithstanding that the numerical ranges and parameters set forth herein are in some instances approximations, the numerical values set forth in the specific examples or embodiments are reported as precisely as possible. Any numerical value, however, inherently contains certain errors necessarily resulting from the standard deviation found in the respective testing measurements. Moreover, all ranges disclosed herein are to be understood to encompass any and all subranges subsumed therein. For example, a range of “1 to 10” includes any and all subranges between (and including) the minimum value of 1 and the maximum value of 10, that is, any and all subranges having a minimum value of equal to or greater than 1 and a maximum value of equal to or less than 10, e.g., 5.5 to 10.
[0018] Reference will now be made in detail to certain embodiments of the invention, examples of which are illustrated in the accompanying drawings. While the invention will be described in conjunction with the illustrated embodiments, it will be understood that the invention is not intended to be limited to those embodiments. On the contrary, the invention is intended to cover all alternatives, modifications, and equivalents that may be included within the invention as defined by the appended claims.
[0019] The headings below are not meant to limit the disclosure in any way; embodiments under any one heading may be used in conjunction with embodiments under any other heading.
DEFINITIONS
[0020] It is noted that, as used in this specification and the appended claims, the singular forms “a,” “an,” and “the,” include plural referents unless expressly and unequivocally limited to one referent.
[0021] As used herein, “bone graft material” refers to, for example, autogenous morselized bone graft, autogenous bone graft strips, allograft chips, demineralized bone matrix in putty, gel, or other forms, xenografts and fired bone, bone graft substitutes, such as hydroxyapatite, calcium carbonate, beta tricalcium phosphate, calcium sulfate or mineralized collagen, collagen-ceramic mixtures, natural or synthetic polymers, such as collagen particles, meshes, sponges, and gels, hyaluronic acid and derivatives thereof, liposomes or other natural biomaterials known as potential implants, or carriers of therapeutic agents, such as cytokines, growth factors, cells, antibiotics, analgesics, chemotherapeutic drugs, and the like, synthetic polymers, such as alpha-hydroxy polyesters, including polylactic acid, polyglycolic acid and their copolymers, polydioxanone, as well as poly methyl methacrylate, separately, in mixture or in admixture with any therapeutic agents, and bone graft replacements, such as recombinant bone morphogenetic proteins. In at least one embodiment, bone graft material includes granules sold under the tradename MasterGraft™.
[0022] The term “practitioner” or “user” means a person who uses or is using the methods and/or devices of the current disclosure on the patient. These terms include, without limitation, doctors (e.g., surgeons, interventional specialists, and physicians), nurses, nurse practitioners, other medical personnel, clinicians, veterinarians, and scientists.
[0023] The term “mammal” refers to organisms from the taxonomy class “mammalian,” including but not limited to humans, other primates such as chimpanzees, apes, orangutans and monkeys, rats, mice, cats, dogs, cows, horses, etc. In various embodiments, the mammal is a human patient.
[0024] The term “syringe” refers to a device that has a barrel and plunger. Material may be placed in the barrel by drawing back upon the plunger, which is in the barrel. The negative pressure in the barrel draws the material through an opening e.g., the end of the barrel itself or through a hollow needle and up into the barrel. The needle (which includes all thin hollow tubes, regardless of how sharp they are), when present, may be attached to the barrel through an adapter such as a valve at the first opening. The adapter when present connects the needle to the barrel and may for example, comprise a valve that can seal the connection between the barrel and the needle and then upon exertion or removal of an appropriate force open the connection between the barrel and the needle. Alternatively there may be no needle and the material may enter and exit the barrel directly through a spout and/or adapter and/or valve and/or end of the barrel. In other embodiments, material may be placed into the barrel through an opening or port that can be closed (e.g., sealed) that is not the opening or port through which material is deposited at a site of interest. Thus, the material may be loaded through an opening in the barrel on for example the side of the barrel. Material can be dispensed by pushing down upon the plunger.
[0025] As noted above, associated with the syringe or as part of the syringe assembly there may also be a needle. In some embodiments, the needle may be used to hydrate bone graft material prior to injecting it, but the bone graft material is no loaded through the needle.
[0026] The term “treating” and the phrases “treatment of a disease” and “treatment of a condition” refer to executing a protocol that may include the use of the devices and methods herein and/or administering one or more bone graft materials to a patient (human, normal or otherwise, or other mammal), in an effort to diagnose and/or to alleviate signs or symptoms of the disease or condition. Alleviation can occur prior to signs or symptoms of the disease or condition appearing, as well as after their appearance. Thus, “treating” or “treatment” includes “preventing” or “prevention” of disease or undesirable condition. In addition, “treating” or “treatment” does not require complete alleviation of signs or symptoms, does not require a cure, and specifically includes, but includes protocols that have only a marginal effect on the patient.
[0027] Syringes
[0028] In one embodiment, there is a bone graft injection syringe assembly for dispensing bone graft material. The syringe comprises a barrel and a flexible plunger.
[0029] The barrel has a first opening and optionally a second opening. The barrel defines a cavity with a curvature over at least ninety degrees. A “cavity with a curvature” is in its simplest embodiment, a cavity that has a center that moves along an arc. The arc may for example have a constant radius, or it may have increasing and/or decreasing radius. For example, the arc may have a constant radius over about 90 degrees to about 360 degrees or over about 90 degrees to about 120 degrees or over about 120 degrees to about 150 degrees or over about 150 degrees to about 180 degrees or over about 180 degrees to about 210 degrees or over about 210 degrees to about 240 degrees or over about 240 degrees to about 270 degrees or over about 270 degrees to about 320 degrees or over about 320 degrees to about 360 degrees.
[0030] If the radius increases or decreases, then the barrel may be referred to as forming a spiraling arc. The phrase spiraling arc includes arcs that extend over more than 360 degrees and arcs that extend over less than 360 degrees. The spiraling arc may in some embodiments have an increasing or decreasing radius over about 90 degrees to about 720 degrees or over about 90 degrees to about 120 degrees or over about 120 degrees to about 150 degrees or over about 150 degrees to about 180 degrees or over about 180 degrees to about 210 degrees or over about 210 degrees to about 240 degrees or over about 240 degrees to about 270 degrees or over about 270 degrees to about 320 degrees or over about 320 degrees to about 360 degrees or over about 360 degrees to about 420 degrees or over about 420 degrees to about 480 degrees or over about 480 degrees to about 540 degrees or over about 540 degrees to about 600 degrees or over about 600 degrees to about 660 degrees or over about 660 degrees to about 720 degrees or more. Further, the rate of the increase in radius may be constant or irregular and a barrel may, in some embodiments have ranges that have portions with increasing radii and constant radii or portions with decreasing radii and constant radii or portions with both increasing and decreasing radii and optionally one or more portions with constant radii. In some embodiments, the radii move in two-dimensions and in some embodiments, they move in three-dimensions.
[0031] The cavity of the barrel may have an irregular or regular three dimensional shape such as a tube that possesses curves that move in either a clockwise or counterclockwise direction. In some embodiments, the barrel maintains a constant lumen size. Thus, the barrel may form a tube or cylinder with a constant diameter. In some embodiments, the cross-section of the tube or cylinder is a circle, an oval or an ellipse.
[0032] In some embodiments, the curvature forms a cylindrical coil. A cylindrical coil is a shape that when viewed from a side, appears to be similar to a coil. Thus, the barrel may, for example, form a coil that has a real or imaginary axis that is oriented parallel to one or both ends of the barrel and/or the plunger, and the coils loop around the axis. The end of the barrel through which the plunger is moved may be connected to (and in some embodiments, run seamlessly into) the coil either at an edge of the coil or away from the edge, e.g., in the center of coil through a pieces that forms a cavity that is connected to a portion of the barrel along the edges of the barrel. Similarly, the other end of the barrel (the dispensing end) may be connected to (and in some embodiments, run seamlessly into) the coil section either at an edge of the coil or away from the edge, e.g., in the center of coil through a pieces that forms a cavity that is connected to a portion of the barrel along the edge of the coil. The coils may have constant and/or variable (e.g., increasing or decreasing) radii.
[0033] The barrel may contain a first region that is not connected to the second region and the first region may terminate at a first opening through which substances can enter or exit the cavity. This first opening may be located at one end of the arc and optionally may comprise a short straight region of, for example, less than 5 cm, less than 4 cm, less than 3 cm, less than 2 cm, or less than 1 cm. This opening may for example comprise a valve that is reversibly closable, and thus protects the integrity of the contents of the barrel from being contaminated or dispensed undesirably. The valve may be in the form of an adapter that reversibly opens when subjected to positive and/or negative pressure may be located at the first opening. In some embodiments, materials may be dispensed through the adapter to the site of interest of through another piece that is connected to the adapter. Alternatively, there may be a cap that can be reversibly associated with this end to prevent leakage or contamination when the syringe contains bone graft material, but the syringe is not in use.
[0034] The second region may be straight, and may be where the plunger is loaded; however, in some embodiments, the barrel contains no regions that are straight. If there is a first region that is straight, this first region may be next to and seamlessly run into a region that contains the aforementioned arc curvature. The first region may in some embodiments run directly into an arc with a constant curvature (or constant radius) or the first region may run into the center of a hypothetical circle with the arc coming off of it and increasing its curvature or the first region may turn into the portion of the arc that has a decreasing radius of curvature at the arc's largest radius point. If the second region is straight, its length may, for example, be less than 5 cm, less than 4 cm, less than 3 cm, less than 2 cm, or less than 1 cm, and it may run directly into an arc with a constant curvature (or constant radius) or the second region may run into the center of a hypothetical circle with the arc coming off of it and increasing its curvature or the second region may turn into the portion of the arc that has a decreasing radius of curvature at the arc's largest radius point.
[0035] As noted above, the first end and the second end of the barrel may both have straight regions. These straight regions may have axes that are parallel to each other. They may alternatively not be parallel to each other. In some embodiments, they are parallel to each other but do not exist in the same plane. In some embodiments in which they are not parallel to each other, they are askew.
[0036] In some embodiments, the barrel has a valve that is situated somewhere along the length of the barrel. Through this valve, hydration prior to injection can be accomplished. There also may be one or more vents through which displaced air may escape.
[0037] The syringe assembly may also comprise a hollow needle, which may for example be attached to the front opening. The needle may be selected to be a size that has hollow tubing that is large enough for the bone graft material to move through, and long enough to provide access to the desired site. The needle may for example be attached to the syringe by a luer lock fitting, threading, friction fit connection or combinations thereof.
[0038] The syringe may also comprise a plunger that may in some embodiments be flexible, thereby allowing it to move through a curved barrel (e.g., by sliding). As persons of ordinary skill in the art are aware, a plunger has a first end that is in contact with the material to be pushed through the syringe. There is also a second end that is distal to the first end. Connecting the two ends is a rod, cylinder or other connecting structure (which may be referred to as a connector) that is designed in a manner that when a force is applied to the second end, the force transfers through the connector and to the first end, thereby pushing the material through the syringe. A flexible plunger is able to transfer this force while sliding within a curved barrel.
[0039] The plunger may be inserted into the second end of the barrel through the second opening of the barrel. In some embodiments, the plunger may be able to be completely disassociated from the barrel by a pulling force. In other embodiments, the connector may move through the second opening but the first end of the plunger, which may have a greater diameter than the connector is precluded from moving through the second opening by a physical structure at the end of the barrel.
[0040] In some embodiments the length of the barrel is from about 5 cm to about 50 cm or about 5 cm to about 10 cm or about 10 cm to about 20 cm or about 20 cm to about 30 cm or about 30 cm to about 40 cm or about 40 cm to about 50 cm. The length is measured with respect to the distance traveled along the path of the barrel.
[0041] In some embodiments, the cross-section of the barrel is a circle and has an internal radius of about 0.1 cm to about 1 cm or about 0.2 cm to about 0.4 cm or about 0.3 cm to about 0.6 cm or about 0.6 cm to about 1 cm.
[0042] In some embodiments, the volume of the barrel is from about 0.1 cc to about 50 cc or from about 1 cc to about 5 cc or from about 2 cc to about 10 cc or from about 4 cc to about 20 cc or from about 10 cc to about 20 cc or from about 20 cc to about 30 cc or from about 25 cc to about 40 cc or from about 30 cc to about 50 cc.
[0043] The plunger preferably has a connector that enables it to be pushed sufficiently far in the barrel to force out the material contained therein. The combined size of the length of the connector and the thickness of the end of the plunger that pushes the material is in some embodiments at least as long as the length of the barrel. The plunger may in some embodiments have a spacer attached to it that contacts the bone graft material and enhances expulsion of it when force is applied to the plunger, thereby causing it to slide and to expel the bone graft material.
[0044] The end of the barrel through which material is dispensed to a site of interest may in some embodiments have a cross-section that is the same as the cross-section of the barrel or at least 70%, or at least 80% or at least 90% of the cross-section of the lumen of the barrel. Note that when the barrel has lumen cross-sections that vary, the aforementioned percentages are relative to the widest cross-sections.
[0045] The barrel of the present invention may be made by methods that are now known to persons of ordinary skill in the art for manufacturing syringe tubes or that become known, and that upon reading this disclosure, become appreciated as being of use in connection with the present invention. In order to obtain a barrel with curvature, one may wind up a flexible plastic tube and place it in a cartridge or injection molding chamber design. One may then place a cap on top.
[0046] In some embodiments, the syringe is ergonomically designed. The ergonomic design may for example comprise finger adapters and/or an hourglass outer body. By way of a non-limiting example, there may be a pair of opposed finger grips at one end and a bayonet mount at the other end. The finger grips may, for example, include a D-shaped ring and a curved finger rest extending from the barrel to allow the practitioner to grip the syringe assembly while sliding the plunger through the barrel.
[0047] In various embodiments, the device includes dose indicator markings (e.g., numbers, lines, letters, radiographic markers, etc.) to indicate the amount of material delivered. For example, the barrel of the syringe may contain markings in cubic centimeters, millimeters or ounces or combinations thereof.
[0048] Certain embodiments of the present invention may be further understood by reference to the accompanying figures. In FIG. 1A , a syringe 1 is shown. At a first end 2 bone graft material may be loaded and dispensed.
[0049] At the other end is a plunger 6 with a flexible connection part 5 (also known as a connector) that can bend along the arc of the barrel of the syringe. The connector is shown with a break to denote that its length is longer than shown in the figure. The end of the plunger (the spacer) 4 that contacts the bone graft material spans the lumen of the barrel 3 , which is constant. The spacer may be designed of a material (e.g., rubber) and be a size that prevents backflow of bone graft material. Thus, it forms a movable seal. The syringe is shown containing bone graft material 7 that can be pre-loaded by a manufacturer or loaded by a practitioner at the time of use.
[0050] Note that the barrel is not limited to a 2-dimension plane. A first section is shown in the foreground, and the second section, which has an increasing curvature, runs behind the first section.
[0051] Other embodiments may be illustrated by reference to the syringe assembly of FIG. 1B . The assembly 8 has a syringe body with a constant lumen size 12 . The plunger has a handle 9 and a connection part 10 that extends to the spacer 13 . Force exerted by the spacer 13 on the contents 11 to be expelled, forces them toward and out of the barrel at end 14 . The connector is shown as broken in order to denote a length that is longer than shown in the figure. As with other embodiments, a needle is optional.
[0052] FIGS. 2A and 2B show another embodiment of the present invention. In FIG. 2A , the syringe assembly 15 is shown from the side. At one end there is a plunger 16 that is connected to the connector 17 and through which force can be applied and transferred to spacer 20 . The plunger travels through the barrel 22 of the syringe. The barrel is shown wrapped around a cylinder 18 , which may be a material such as plastic or metal. Part of the barrel is shown cut away so as to illustrate the location of the spacer and connector. The cylinder helps the syringe to retain its coil shape. Material 19 may be dispensed out of the end 23 of the syringe that is distal to the plunger handle.
[0053] FIG. 2B shows the syringe of FIG. 2A from a bottom view. For reference the barrel 22 , the cylinder 18 and the end 23 through which material is dispensed are identified.
[0054] FIG. 2C shows a syringe 24 that is similar to that of FIG. 2A , except, the end 31 through which material is dispense is beveled. Thus, shown are the handle 25 , the connector 26 and the spacer 29 of the plunger, as well as the barrel of the syringe 28 and the bone graft material 30 . Similarly, there is a cylinder 27 around which the coil is wrapped.
[0055] FIG. 2D is a bottom view of FIG. 2C . For reference the barrel 28 , cylinder 27 and end for dispensing 31 are shown.
[0056] FIG. 3A shows another of a syringe assembly 32 of the present invention. The barrel 36 is shown less tightly wound than the barrel of FIGS. 2A and 2C . For reference, shown are the plunger handle 33 , the connector 34 , the spacer 37 , the cylinder 35 around which the barrel is wound, the bone graft material 38 and blunt end 39 of the syringe, through which material is dispensed.
[0057] FIG. 3B shows the bottom view of the assembly of FIG. 3A . For reference, identified are the barrel 36 , the cylinder 35 and the end 39 through which material is dispensed.
[0058] FIGS. 3C and 3D are similar to FIGS. 3A and 3B respectively. However, the end 47 through which material is dispensed is beveled. Thus, the assembly 40 shows a plunger handle 41 with a connector 42 that travels within barrel 44 to spacer 45 , which pushes the bone graft material 46 out of opening 47 .
[0059] FIG. 4A shows another embodiment of the present invention. In this syringe assembly 48 , the barrel 51 forms a coil shape, but is not wrapped around a cylinder. As with other embodiments, the plunger handle 49 is shown and force exerted on it may travel through the connector 50 to spacer 52 . The force causes bone graft material 53 to exit through the beveled end 54 of the assembly.
[0060] FIG. 4B shows a bottom view of the assembly of FIG. 4A . Identified are the barrel 51 and opening 54 .
[0061] FIG. 5A shows a coil syringe assembly in which coils of the barrel 58 are spaced (i.e., the side of one coil does not touch the side of the next coil as in FIG. 4A ). For reference, also shown is the plunger handle 56 , the connector 57 , the spacer 59 , the bone graft material 60 and the opening of the syringe 61 .
[0062] FIG. 5B shows a bottom view of the assembly of FIG. 5A . For reference, the barrel 58 and the end through which material is dispenses 61 are shown.
[0063] The syringe can be made from a variety of materials such as plastic, glass or metal or any combination thereof. For example, it may be made from a clear lipid resistant polycarbonate plastic.
[0064] Needles, which unless otherwise specified also refer to cannulas, may be tubes that are made from materials, such as for example, polyurethane, polyurea, polyether(amide), PEBA, thermoplastic elastomeric olefin, copolyester, and styrenic thermoplastic elastomer, steel, aluminum, stainless steel, titanium, metal alloys with high non-ferrous metal content and a low relative proportion of iron, carbon fiber, glass fiber, plastics, ceramics or combinations thereof. The needle may optionally include one or more tapered regions. In various embodiments, the needle may be beveled. The needle may also have a tip style vital for accurate treatment of the patient depending on the site for implantation. Examples of tip styles include, for example, Trephine, Cournand, Veress, Huber, Seldinger, Chiba, Francine, Bias, Crawford, deflected tips, Hustead, Lancet, or Tuohey. In various embodiments, the needle may also be non-coring and have a sheath covering it to avoid unwanted needle sticks.
[0065] The preferable dimensions of the needle will, among other things, depend on the site for implantation. For example, the width of the epidural space is only about 3-5 mm for the thoracic region and about 5-7 mm for the lumbar region. Thus, the needle, in various embodiments, can be designed for these specific areas. Some examples of lengths of the needle may include, but are not limited to, from about 50 to 150 mm in length, for example, about 65 mm for epidural pediatric use, about 85 mm for a standard adult and about 110 mm for an obese adult patient. The thickness of the needle will also depend on the site of implantation. In various embodiments, the thickness includes, but is not limited to, from about 0.05 to about 1.655. The gauge of the needle may be the widest or smallest diameter or a diameter in between for insertion into a human or animal body. The widest diameter is typically about 14 gauge, while the smallest diameter is about 22 gauge. In various embodiments the gauge of the needle is about 18 to about 22 gauge.
[0066] Plungers
[0067] The plunger may be made from materials such as for example, polyurethane, polyurea, polyether(amide), PEBA, thermoplastic elastomeric olefin, copolyester, and styrenic thermoplastic elastomer, steel, aluminum, stainless steel, titanium, metal alloys with high non-ferrous metal content and a low relative proportion of iron, carbon fiber, glass fiber, plastics, ceramics or combinations thereof. In some embodiments, the plunger has a spacer, a connector and handle.
[0068] In various embodiments, the distance that the plunger advances is proportional to the force applied by the practitioner, and thus a practitioner can vary the rate at which he or she dispenses material, and the practitioner can also dispense less than the entire contents of the syringe by discontinuing the force on the plunger. In other embodiments, the plunger can be associated with a trigger mechanism. When activated, the trigger mechanism can cause the plunger to move further into the barrel and cause a predetermined volume of the contents of the barrel to be dispensed. In some embodiments, the activation of the trigger will cause the plunger to move forward a sufficient distance to dispense all of the contents of the barrel or about one-half of the contents, or about one-third of the contents, or about one-quarter of the contents or about one-fifth of the contents or about one-sixth of the contents or about one-eighth of the contents or about one-tenth of the contents or about one-twelfth of the contents or about one-twentieth of the contents.
[0069] In some embodiments, upon activation of the trigger the plunger may cause the syringe to dispense from about 0.1 cc to about 50 cc of from about 0.1 cc to 1 cc or from about 1 cc to about 5 cc or from about 5 cc to about 10 cc or from about 10 cc to about 15 cc or from about 15 cc to about 20 cc or from about 20 cc to about 25 cc.
[0070] In some embodiments, in a given syringe assembly the plunger may be configured to have both a trigger mechanism that can allow for a fixed amount of volume to be dispensed and a standard configuration that allows the practitioner to dispense any amount of volume, wherein the amount is directly proportional to the force applied.
[0071] Bone Graft Material
[0072] Bone graft materials can include bone particles from fully mineralized bone, and demineralized bone particles and combinations thereof. The bone particles can be autograft, allograft, xenogenic, transgenic bone particles or a combination thereof.
[0073] In some embodiments, the bone graft material includes bone cements. Bone cements are commonly provided in two or more components. The first component is usually a powder and the second component is usually in liquid form. Examples of bone cement materials include those based on acrylate materials that can react by polymerization to form acrylate polymers.
[0074] In some embodiments, the bone cement comprises powder that includes, for example, calcium phosphate based powders and poly-methyl-methacrylate based powders. Any of various osteoconductive powders, such as ceramics, calcium sulfate or calcium phosphate compounds, hydroxyapatite, magnesium and Si based cements, deproteinized bone, corals, and certain polymers, can alternatively or additionally be used in the bone cement.
[0075] Typically, a bone cement can be formed by mixing a liquid acrylate monomer with a powder such as acrylate polymer using a mixing element, where the mixing can be accomplished by hand or machine. The resulting mixture has a paste or dough-like consistency. Typically, the components of the mixture react, involving polymerization of the acrylate monomer and copolymerization with the acrylate polymer particles. The viscosity of the cement composition increases during the reaction, resulting in a hard cement. The curing reaction of a bone cement material is generally exothermic.
[0076] Typically, the bone cement is prepared prior to injection by mixing bone-cement powder (e.g., poly-methyl-methacrylate (PMMA)), a liquid monomer (e.g., methyl-methacrylate monomer (MMA)), an x-ray contrast agent (e.g., barium sulfate), and an activator of the polymerization reaction (e.g., N,N-dimethyl-p-toluidine) to form a fluid mixture. Other additives including but not limited to stabilizers, drugs, fillers, dyes and fibers may also be included in the bone cement. Because the components react upon mixing, immediately leading to the polymerization, the components of bone cement should be kept separate from each other until the user is ready to form the desired bone cement. Once mixed, the user must work very quickly because the bone cement sets and hardens rapidly.
[0077] Other examples of bone cement compositions and/or their uses are discussed in US Patent Publication No. 20080109003, U.S. Pat. No. 7,138,442; U.S. Pat. No. 7,160,932; U.S. Pat. No. 7,014,633; U.S. Pat. No. 6,752,863; U.S. Pat. No. 6,020,396; U.S. Pat. No. 5,902,839; U.S. Pat. No. 4,910,259; U.S. Pat. No. 5,276,070; U.S. Pat. No. 5,795,922; U.S. Pat. No. 5,650,108; U.S. Pat. No. 6,984,063; U.S. Pat. No. 4,588,583; U.S. Pat. No. 4,902,728; U.S. Pat. No. 5,797,873; U.S. Pat. No. 6,160,033; and EP 0 701 824, the disclosures of which are herein incorporated by reference.
[0078] In some embodiments, other additives can be mixed with the bone cement and this includes bioactive substances. Thus, one or more bioactive substances can be combined with the bone cement by soaking or immersing the bone cement in a solution or dispersion of the desired bioactive substance(s). Bioactive substances include physiologically or pharmacologically active substances that act locally or systemically in the host. In certain applications, the bone cement can be used as a time-release drug delivery device for drugs or other bioactive substances that are to be delivered to the surgical site.
[0079] Bioactive substances that can be readily combined with the bone cement include, e.g., collagen, insoluble collagen derivatives, etc., and soluble solids and/or liquids dissolved therein; antiviricides, particularly those effective against HIV and hepatitis; antimicrobials and/or antibiotics such as erythromycin, bacitracin, neomycin, penicillin, polymycin B, tetracyclines, biomycin, chloromycetin, and streptomycins, cefazolin, ampicillin, azactam, tobramycin, clindamycin or gentamicin, etc.; biocidal/biostatic sugars such as dextran, glucose, etc.; amino acids; peptides; vitamins; inorganic elements; co-factors for protein synthesis; hormones; endocrine tissue or tissue fragments; synthesizers; enzymes such as collagenase, peptidases, oxidases, etc.; polymer cell scaffolds with parenchymal cells; angiogenic agents or polymeric carriers containing such agents; collagen lattices; antigenic agents; cytoskeletal agents; cartilage fragments; living cells such as chondrocytes, bone marrow cells, mesenchymal stem cells, natural extracts, genetically engineered living cells or otherwise modified living cells; DNA delivered by plasmid or viral vectors; tissue transplants; demineralized bone powder; autogenous tissues such as blood, serum, soft tissue, bone marrow, etc.; bioadhesives, bone morphogenic proteins (BMPs); growth and differentiation factors (GDFs); osteoinductive factor; statin; fibronectin (FN), osteonectin (ON); endothelial cell growth factor (ECGF); cementum attachment extracts (CAE); ketanserin; human growth hormone (HGH); animal growth hormones; epidermal growth factor (EGF); interleukin-1 (IL-1); human alpha thrombin; transforming growth factor (TGF-beta); insulin-like growth factor (IGF-1); platelet derived growth factors (PDGF); fibroblast growth factors (FGF, bFGF, etc.); periodontal ligament chemotactic factor (PDLGF); somatotropin; bone digestors; antitumor agents; immuno-suppressants; permeation enhancers, e.g., fatty acid esters such as laureate, myristate and stearate monoesters of polyethylene glycol, enamine derivatives, alpha-keto aldehydes, etc.; or nucleic acids. When employed, the total amount of bioactive substance can represent from about 0.1 to about 60 weight percent of the osteoimplant.
[0080] In some embodiments, the bioactive agent is mixed before, with or after the bone cement is added to the container. In some embodiments, the bioactive agent comprises the family of proteins known as the transforming growth factor-beta (TGFβ) superfamily of proteins, which includes the activins, inhibins, or bone morphogenetic proteins (BMPs). In some embodiments, the active agent includes at least one protein from the subclass of proteins known generally as BMPs. BMPs have been shown to possess a wide range of growth and differentiation activities, including induction of the growth and differentiation of bone, connective, kidney, heart, and neuronal tissues. See, for example, descriptions of BMPs in the following publications: BMP-2, BMP-3, BMP-4, BMP-5, BMP-6, and BMP-7 (disclosed, for example, in U.S. Pat. Nos. 5,013,649 (BMP-2 and BMP-4); 5,116,738 (BMP-3); 5,106,748 (BMP-5); 5,187,076 (BMP-6); and 5,141,905 (BMP-7)); BMP-8 (disclosed in PCT WO 91/18098); BMP-9 (disclosed in PCT WO 93/00432); BMP-10 (disclosed in PCT WO 94/26893); BMP-11 (disclosed in PCT WO 94/26892); BMP-12 or BMP-13 (disclosed in PCT WO 95/16035); BMP-15 (disclosed in U.S. Pat. No. 5,635,372); BMP-16 (disclosed in U.S. Pat. No. 6,331,612); MP52/GDF-5 (disclosed in PCT WO 93/16099); or BMP-17 or BMP-18 (disclosed in U.S. Pat. No. 6,027,917). The entire disclosure of these references is herein incorporated by reference. Other TGF-proteins that may be useful as the active agent of the bone cement paste include Vgr-2 and any of the growth and differentiation factors (GDFs), such as, for example, GDF-5.
[0081] A subset of BMPs that may be used in certain embodiments includes BMP-2, BMP-4, BMP-5, BMP-6, BMP-7, BMP-8, BMP-9, BMP-10, BMP-11, BMP-12 or BMP-13. In some embodiments, the composition contains two or more active agents (e.g., BMP-2 and BMP-4). Other BMPs and TGF-proteins may also be used.
[0082] The active agent may be recombinantly produced, or purified from another source. The active agent, if a TGF-β protein such as a BMP, or other dimeric protein, may be homodimeric, or may be heterodimeric with other BMPs (e.g., a heterodimer composed of one monomer each of BMP-2 and BMP-6) or with other members of the TGF-β superfamily, such as activins, inhibins and TGF-β (e.g., a heterodimer composed of one monomer each of a BMP and a related member of the TGF-β superfamily). Examples of such heterodimeric proteins are described, for example in published PCT Patent Application WO 93/09229.
[0083] In some embodiments, the amount of growth factor, (e.g., bone morphogenic protein) may be sufficient to cause bone growth. In some embodiments, the growth factor is rhBMP-2 and is contained in the bone graft material in an amount of from 1 to 2 mg per cubic centimeter of the bone graft material. In some embodiments, the amount of rhBMP-2 morphogenic protein is from 2.0 to 2.5 mg per cubic centimeter (cc) of the bone graft material.
[0084] In some embodiments, the growth factor is supplied in a liquid carrier (e.g., an aqueous buffered solution). Examples of aqueous buffered solutions include, but are not limited to, TE, HEPES (2-[4-(2-hydroxyethyl)-1-piperazinyl]ethanesulfonic acid), MES (2-morpholinoethanesulfonic acid), sodium acetate buffer, sodium citrate buffer, sodium phosphate buffer, a Tris buffer (e.g., Tris-HCL), phosphate buffered saline (PBS), sodium phosphate, potassium phosphate, sodium chloride, potassium chloride, glycerol, calcium chloride or a combination thereof. In various embodiments, the buffer concentration can be from about 1 mM to 100 mM. In some embodiments, the BMP-2 is provided in a vehicle (including a buffer) containing sucrose, glycine, L-glutamic acid, sodium chloride, and/or polysorbate 80.
[0085] The bone graft material may be mixed with additional therapeutic agents. Examples of therapeutic agents include but are not limited to IL-1 inhibitors, such Kineret® (anakinra), which is a recombinant, non-glycosylated form of the human interleukin-1 receptor antagonist (IL-1Ra), or AMG 108, which is a monoclonal antibody that blocks the action of IL-1. Therapeutic agents also include excitatory amino acids such as glutamate and aspartate, antagonists or inhibitors of glutamate binding to NMDA receptors, AMPA receptors, and/or kainate receptors. Interleukin-1 receptor antagonists, thalidomide (a TNF-α release inhibitor), thalidomide analogues (which reduce TNF-α production by macrophages), quinapril (an inhibitor of angiotensin II, which upregulates TNF-α), interferons such as IL-11 (which modulate TNF-α receptor expression), and aurin-tricarboxylic acid (which inhibits TNF-α), may also be useful as therapeutic agents for reducing inflammation. It is further contemplated that where desirable a pegylated form of the above may be used. Examples of still other therapeutic agents include NF kappa B inhibitors such as antioxidants, such as dithiocarbamate, and other compounds, such as, for example, sulfasalazine.
[0086] Examples of therapeutic agents suitable for use also include, but are not limited to, an anti-inflammatory agent or an analgesic agent. Anti-inflammatory agents include, but are not limited to, apazone, celecoxib, diclofenac, diflunisal, enolic acids (piroxicam, meloxicam), etodolac, fenamates (mefenamic acid, meclofenamic acid), gold, ibuprofen, indomethacin, ketoprofen, ketorolac, nabumetone, naproxen, nimesulide, salicylates, sulfasalazine [2-hydroxy-5-[-4-[C2-pyridinylamino)sulfonyl]azo]benzoic acid, sulindac, tepoxalin, and tolmetin; as well as antioxidants, such as dithiocarbamate, steroids, such as cortisol, cortisone, hydrocortisone, fludrocortisone, prednisone, prednisolone, methylprednisolone, triamcinolone, betamethasone, dexamethasone, beclomethasone, fluticasone or a combination thereof.
[0087] Suitable analgesic agents include, but are not limited to, acetaminophen, bupivicaine, fluocinolone, lidocaine, opioid analgesics such as buprenorphine, butorphanol, dextromoramide, dezocine, dextropropoxyphene, diamorphine, fentanyl, alfentanil, sufentanil, hydrocodone, hydromorphone, ketobemidone, levomethadyl, mepiridine, methadone, morphine, nalbuphine, opium, oxycodone, papavereturn, pentazocine, pethidine, phenoperidine, piritramide, dextropropoxyphene, remifentanil, tilidine, tramadol, codeine, dihydrocodeine, meptazinol, dezocine, eptazocine, flupirtine, amitriptyline, carbamazepine, gabapentin, pregabalin, or a combination thereof.
[0088] In some embodiments, a statin may be used. Statins include, but are not limited to, atorvastatin, simvastatin, pravastatin, cerivastatin, mevastatin (see U.S. Pat. No. 3,883,140, the entire disclosure is herein incorporated by reference), velostatin (also called synvinolin; see U.S. Pat. Nos. 4,448,784 and 4,450,171 these entire disclosures are herein incorporated by reference), fluvastatin, lovastatin, rosuvastatin and fluindostatin (Sandoz XU-62-320), dalvastain (EP Appln. Publn. No. 738510 A2, the entire disclosure is herein incorporated by reference), eptastatin, pitavastatin, or pharmaceutically acceptable salts thereof or a combination thereof. In various embodiments, the statin may comprise mixtures of (+) R and (−)-S enantiomers of the statin. In various embodiments, the statin may comprise a 1:1 racemic mixture of the statin.
[0089] One method of making the bone graft material includes adding the powder to the container and adding the liquid and other components to the container and mixing them with a mixing element. The mixing element can be placed in or attached to the upper opening of the container and the mixing element stirred by hand or machine until the desired consistency of the slurry or paste or liquid is reached. Optionally, the mixture can include one or more other optional components such as any of binders, fillers, plasticizers, biostatic/biocidal agents, surface active agents, bioactive substances, or reinforcing components. The syringe is then filled with the bone graft material and then delivered to the anatomic site as discussed above.
[0090] The bone graft material can be injected at the desired anatomic site, for example, a hard tissue repair site, e.g., one resulting from injury, defect brought about during the course of surgery, infection, malignancy or developmental malformation, or the like. The bone graft material can be utilized in a wide variety of orthopedic, periodontal, neurosurgical and oral and maxillofacial surgical procedures such as the repair of simple and compound fractures and non-unions, external and internal fixations, joint reconstructions such as arthrodesis, general arthroplasty, cup arthroplasty of the hip, femoral and humeral head replacement, femoral head surface replacement and total joint replacement, repairs of the vertebral column including spinal fusion and internal fixation, tumor surgery, e.g., deficit filling, discectomy, laminectomy, excision of spinal cord tumors, anterior cervical and thoracic operations, repairs of spinal injuries, scoliosis, lordosis and kyphosis treatments, intermaxillary fixation of fractures, mentoplasty, temporomandibular joint replacement, alveolar ridge augmentation and reconstruction, onlay bone grafts, implant placement and revision, sinus lifts, etc. Specific bones that can be repaired or replaced with the osteoimplant herein include the ethmoid, frontal, nasal, occipital, parietal, temporal, mandible, maxilla, zygomatic, cervical vertebra, thoracic vertebra, lumbar vertebra, sacrum, rib, sternum, clavicle, scapula, humerus, radius, ulna, carpal bones, metacarpal bones, phalanges, ilium, ischium, pubis, femur, tibia, fibula, patella, calcaneus, tarsal or metatarsal bones.
[0091] In some embodiments, the bone cement comprises two separate components, one component being liquid and a second component being solid and the bone cement is mixed with the top opening while being exposed to room air.
[0092] Methods of Use
[0093] According to another embodiment, the present invention provides a method for injecting both graft materials. The method comprises loading a syringe of any of the embodiments of the present invention with a bone graft material; and pushing the plunger toward a first opening, thereby forcing the materials to exit the syringe. The syringe may be used to deliver bone graft material to anatomical structures during surgical procedures in order to aid in the bone regeneration process.
[0094] In operation, when a practitioner applies force to the exposed end of the plunger to express the plunger, the distal end of the plunger, which is the end that contacts the bone graft material, and may have a plunger seal or spacer, forces the bone graft material through the inner chamber of the barrel and out of the first end of the barrel. At the first end there may optionally be an adapter that permits the material to move through it to the hollow portion of a needle, and as desired to a surgical site. The aforementioned spacer (also referred to as the plunger seal) is designed to expel all of the contents in the inner chamber without allowing any of those contents to pass behind it. The spacer may, for example, be made of rubber, silicone, or plastic or combinations thereof.
[0095] In order to further facilitate movement of bone graft material through the barrel, blood or other fluid may be introduced to the bone graft material within the barrel. For example, a liquid, gel or fluid may be added to the chamber of the barrel either before or after the addition of the bone graft material. The fluid may, for example, be introduced by a needle or other device through an adapter at the first end of the barrel. The adapter permits materials to enter or exit upon the creation of a vacuum or addition of force, respectively. Alternatively, the liquid, gel or fluid, and/or bone graft materials may be introduced through a side port in the barrel or at the second end of the barrel if an orifice is present there.
[0096] The various fluids that may be added to the inner chamber include sterile water, saline, blood, or blood components including plasma, platelet-rich plasma, buffy coat, autologous growth factors or other concentrated blood components, red blood cells, white blood cells or platelets in any combination, as well as cryoprecipitates. Other suitable and intended fluids include bone marrow, as well as growth factor solutions suspensions or gels, which include any of the well known growth factors, such as Platelet-Derived Growth Factor (PDGF), Transforming Growth Factor Beta (TGF-β), Insulin-Like Growth Factor (IGF), Fibroblast Growth Factor (FGF), Epidermal Growth Factor (EGF), Vascular Endothelial Growth Factor (VEGF), Bone Morphogenetic Proteins (BMPs), and vectors for gene therapy. Further, cellular solutions, suspensions, and materials including osteoblasts, osteoprogenitor cells, chondroblasts, stem cells, or fibroblasts may also be used, as well as solutions or suspensions containing other therapeutic agents such as antibiotics, analgesics, antithrombinolytics, or chemotherapeutic agents. Further, bone graft replacements, such as recombinant bone morphogenetic proteins, may be added.
[0097] In some embodiments, the bone graft materials may for example, comprise one or more of ceramic particles, and bone particles, each of which can improve efficacy of bone grafting products and provide compression resistance. The bone graft materials may also, or alternatively, comprise collagen (including cross-linked collagen) demineralized bone matrix particles, growth factors, antibiotics, analgesics, and combinations thereof.
[0098] In some embodiments, the bone graft replacement material comprises a putty, a bone cement or combinations thereof. Bone cements are commonly provided in two or more components. The first component is usually a powder and the second component is usually in liquid form. Examples of bone cement materials include but are not limited to those based on acrylate materials that can react by polymerization to form acrylate polymers. Typically, a bone cement can be formed by mixing a liquid acrylate monomer with a powder such as acrylate polymer using a mixing element, where the mixing can be accomplished by hand or machine. The resulting mixture has a paste or dough-like consistency. Typically, the components of the mixture react, involving polymerization of the acrylate monomer and copolymerization with the acrylate polymer particles. The viscosity of the cement composition increases during the reaction, resulting in a hard cement. The curing reaction of a bone cement material is generally exothermic.
[0099] Kits
[0100] The invention also provides a kit for use in mixing a fluid with a porous or non-porous solid bone graft materials. The kit comprises a syringe assembly as discussed in the foregoing paragraphs, and may also include a container having a solid or porous particulate or granular bone graft material, such as an optional vial or container of a bone promoting agent. The solid material may be hydroxyapatite granules, for example. The bone repair promoting agent may be in solid or liquid form, and may include (for example) blood or a component thereof, or natural or recombinant bone growth factors, or other agents useful for stimulating bone repair or growth.
[0101] In some embodiments, such solids can include, for example, autogenous morselized bone graft, autogenous bone graft strips, allograft chips, demineralized bone matrix in putty, gel, strip, or other forms, xenografts and fired bone. The solids can also be bone graft substitutes, such as hydroxyapatite, calcium carbonate, beta tricalcium phosphate, calcium sulfate or mineralized collagen. In addition, bone graft materials may comprise natural or synthetic polymers such as collagen particles, meshes, sponges, and gels, hyaluronic acid and derivatives thereof, liposomes or other natural biomaterials known as potential implants, or carriers of therapeutic agents, such as cytokines, growth factors, cells, antibiotics, analgesics, chemotherapeutic drugs, and the like.
[0102] It will be apparent to those skilled in the art that various modifications and variations can be made to various embodiments described herein without departing from the spirit or scope of the teachings herein. Thus, it is intended that various embodiments cover other modifications and variations of various embodiments within the scope of the present teachings.
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A syringe that has a barrel with curvature is provided. The curvature enables a greater volume of bone graft materials to be housed than in a straight syringe without increasing the absolute distance from the handle of the plunger to dispensing end of the syringe. Additionally by maintaining a constant diameter, the barrel permits bone graft material to be dispersed with reduced likelihood of clogging.
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BACKGROUND OF THE INVENTION
The present invention generally concerns heat conservation devices for clothes dryers and more particularly an exhaust air diversion device with lint scrubber apparatus adapted to be positioned in the exhaust air vent pipe of a clothes dryer for diverting warm, humid exhaust air from the dryer into the interior environment of a home.
Electric and gas heated clothes dryers have become common household appliances during the past several decades for drying clothes inside homes after washing. These dryers essentially operate by tumbling the wet clothes in a large revolving cylinder or drum while forcing hot air through the cylinder to pick up the moisture from the clothes and carry it out of the dryer. It is conventional to vent or exhaust the warm, humid air to the outside of the house.
In recent years, however, the rapid rise in energy costs for homeowners has made the practice of venting or exhausting the hot air from a clothes dryer to the outside a conspicous waste of energy resulting from loss of heat as well as humidity which could be utilized at least to some extent in the environment inside the home. The practice of venting this air outside is particularly inefficient in the winter months when it is quite common, in fact necessary in many geographical locations, to concurrently use furnaces for heating and humidifiers for adding humidity to the air in the inside environment in the home at the same time the warm, humid air from the clothes dryer is being exhausted to the outside.
There are several problems associated with simply venting the exhaust from the dryer directly into the inside environment of the home which have resulted in the conventional practice of venting or exhausting the air to the outside. One of the problems is that the exhaust air from the dryer contains a certain amount of lint which is picked up from the clothes. Even though most dryers include some provisions for lint traps or screens, none of these conventional devices supplied by the manufacturers are efficient enough to eliminate all the lint in the exhaust air, and projecting the lint into the inside environment of the home is quite undesirable from both health and a practical cleaning standpoint. Another problem of course is the inability to regulate the heat and humidity to desirable levels during the several seasons of the year if the exhaust is simply vented directly into the inside environment.
SUMMARY OF THE INVENTION
Accordingly, it is an object of the present invention to provide a novel and improved heat recovery device which is capable of diverting the air from the outside exhaust vent pipe of a conventional clothes dryer and the like for discharge into the inside environment of a home.
It is also an object of the present invention to provide a heat recovery device including apparatus for scrubbing lint from the exhaust air of a clothes dryer.
It is another object of the present invention to provide a heat recovery device as described above with convenient lint removal and cleaning apparatus.
A still further object of the present invention is to provide a heat recovery device for placement in the exhaust air vent pipe of a conventional clothes dryer including a diversion valve for selectively diverting dryer exhaust air into the interior environment of a home or alternatively allowing the exhaust air to pass to the outside of the home.
The heat recovery device of the present invention includes an enclosed chamber having an inlet port for receiving exhausted air from a clothes dryer, an indoors exhaust opening through which the dryer exhaust air can be discharged into the interior environment of a home, and scrubber means within the chamber for removing lint from the exhausted dryer air prior to discharge into the interior environment. The scrubber means includes a series of ducts opening into an enlarged plenum and a baffle plate on one side of the plenum for dispersing and reducing the velocity of the airstream while changing its direction of flow through the chamber by means of slots so as to allow lint particles to settle out of the air.
The indoors exhaust opening is also provided with final filter means in the form of several layers of expanded aluminum mesh to filter any remaining lint particles in the air so that only warm, humid air with no lint particles is discharged into the interior home environment. The device also has a lint tray positioned at the bottom of the plenum which is removable from the front of the device to facilitate removing and disposing of the lint trapped in the plenum.
The device also includes a bypass duct and a valve which is operative to selectively divert the exhaust air from the dryer either into the interior environment of the home or allowed to pass to the outside of the home as desired at any particular time to maintain the optimum of heat and humidity in the home whille the dryer is operating.
Other objects, advantages and capabilities of the present invention will become more apparent as the description proceeds taken in conjunction with the accompanying drawings, in which:
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a conventional home clothes dryer equipped with the heat recovery device of this invention;
FIG. 2 is a perspective view of the heat recovery device shown with the final filter and the lint tray removed, a portion of the inner filter being cut away to reveal the entire lint tray;
FIG. 3 is a front elevation of the heat recovery device with the final filters removed and the lint tray in place;
FIG. 4 is a plan view of the heat recovery device with the filter attached in place, a portion of the grill frame being cut away to reveal the relative position of the filter elements; and
FIG. 5 is an enlarged cross-section of the heat recovery device taken along lines 5--5 of FIG. 4.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
A heat recovery device 10 formed in accordance with the present invention is shown in FIG. 1 attached to the warm air vent exhaust pipe 8 of a conventional home dryer D. The dryer D is shown for illustrative purposes only; it does not form a part of this invention. It is of conventional form with right and left side panels 1, 2, respectively, a front panel 3, top panel 4, and rear panel 5. A control or instrument panel 6 is provided toward the rear of the top panel 4, and an access door 7 is provided in the front panel 3 for loading and unloading the dryer D. The exhaust vent pipe 8 is conventional and extends from the rear of the dryer D to conduct the warm, moist exhaust air from the dryer to the outside of the house in the conventional manner.
The heat recovery device 10 of the present invention is placed in the exhaust vent pipe 8 for the purpose of diverting the warm, moist air being exhausted from the dryer into the interior environment of the home. Basically, the heat recovery device 10 is comprised of a chamber defined by right and left side panels 12, 14, respectively, rear panels 16, top lid 18, and bottom plate 30. The dryer exhaust air is introduced into the rear portion of the chamber through inlet port 34 where it is conducted by a series of ducts through a lint scrubber for removing any lint being carried by the dryer exhaust air prior to discharging the air into the interior home environment. The open front 20, as best seen in FIGS. 2 and 3, provides an interior outlet opening for discharging the exhaust air into the interior environment of the home.
As best seen in FIG. 5, the lint scrubber includes an initial duct 42 in communication with the inlet port 34 and an intermediate duct 52 adjacent the initial duct 42. The initial duct 42 is formed by partition 44 on one side and partition 46 on the other side. Intermediate duct 52 is also defined by a common partition 46 on one side and a partial partition 48 extending downwardly into the enlarged plenum 60 such that initial duct 42 and intermediate duct 52 are situated adjacent each other and in communication with each other at one end in a maze-like configuration. The intermediate duct 52 which is somewhat larger in cross-sectional area than initial duct 42, is connected to initial duct 42 at their common ends by a curved chute 54. The discharge end of intermediate duct 52 opens into an enlarged plenum 60.
The enlarged plenum 60 serves the purpose of decreasing the velocity of the airstream such that lint particles are allowed to settle to the bottom of the plenum 60. Baffle plate 70 is positioned across the front part of the plenum 60 to further disperse the airstream and reduce the velocity thereof to assist in settling of the lint particles from the airstream.
Consequently, the warm, moist, lint-laden exhaust air from the dryer is introduced into the chamber through inlet port 34 and is conducted from the inlet port 34 upwardly through initial duct 42 into the curved chute 54 where its direction is reversed into a downward flow into intermediate duct 52 which has an enlarged cross-sectional area thereby reducing the velocity of the airstream to some extent. The air then continues flowing from intial duct 52 downwardly into the enlarged plenum 60 where its velocity is significantly reduced into the sides of the plenum and the airstream is dispersed by baffle plates 70. Since the airstream in the enlarged plenum 60 is effectively dispersed and reduced in velocity, it is no longer capable of carrying or sustaining the lint. Consequently, the lint L settles to the bottom of the plenum 60 as shown in FIG. 5. The air then exits in a dispersed manner through slots 72 and 78 in the baffle plate 70.
It is significant that the configuration of the baffle plate 70 is particularly adapted to enhance the efficiency of the scrubber action of the plenum 60 by providing an upper section 74 across the front portion of the top half of the plenum 60 and a lower inclined section 76 forwardly and downwardly from the common bend 75 between the upper vertical section 74 and the lower inclined section 76. This configuration provides the plenum 60 with a somewhat larger cross-section near the bottom than near the top, and the slope of the lower section 76 provides a more effective surface against which the flowing air near the bottom of the plenum impinges to reduce its velocity thereby allowing greater efficiency in settlement of the lint. It is also significant to note that the outlet slots 72 in the upper section 74 of the baffle plate are more numerous than the outlet slots 78 in a lower section of the baffle plate. This distribution of a substantial portion of the total cross-sectional area of the outlet holes in the baffle plate toward the upper portion provides the additional advantage of forcing most of the airstream to again reverse direction and flow upwardly in the plenum 60 in order to escape. This reversal of direction of the air in combination with the substantially lower velocity toward the central and lower portions of the plenum 60 further enhances the efficiency of the scrubber action for removing the lint L from the airstream.
Even though the scrubber just described is quite efficient, there is always some portion of the lint in the airstream that does not settle out and is continuously carried through the outlet slots 72, 78 in the baffle plate 70. These particles of lint are usually finer and smaller in size, but it would still be undesirable to discharge these lint particles into the interior environment of a home. Therefore, after the air passes through the baffle plate 70, but prior to discharge into the home environment, it is forced to pass through a series of final filters 22, 24 which positively filter out the remaining lint in the airstream by physically prohibiting the lint particles from passing therethrough. As best seen in FIGS. 2-5, the final filter includes two filter elements 22, 24, positioned over the interior outlet opening 20 of the chamber. Each filter element is preferably comprised of expanded aluminum mesh and is retained in place over the opening 20 by a grill 26 supported by a grill frame 28. The internal length and width dimensions of the grill frame are slightly larger than the length and width dimensions of the chamber so that the grill frame 28 can be inserted over the edges of the chamber, as best seen in FIGS. 4 and 5.
The grill 26 and grill frame 28 are strapped in place across the interior outlet opening 20 by resilient or stretachable upper strap 110 and lower strap 116. The upper strap is permanently affixed at one end to the downwardly protruding lip 19 on the left side of the top lid 18 on anchor pin 114 by a fastener 113. The opposite end of the strap 110 has an eye 111 adapted for removable attachment to a similar anchor pin 112 on the opposite side of the top lid 18. The lower strap 116 is similarly permanently affixed at one end on the left side of the chamber in a similar manner by fastener 119 and has an eye 117 at its opposite end for removable attachment to anchor pin 118 on the lower right side of the chamber. Inwardly extending lips 13, 15 of side panels 12, 14, respectively, also assist in retaining the filter elements 22, 24 in place by preventing them from falling inwardly into the interior outlet opening 20.
For convenience of removing lint from the scrubber, a removable lint tray 100 is provided at the bottom of the plenum 60, as best seen in FIGS. 2 and 5. The lint tray 100 includes a flat bottom portion 102 positioned on the bottom of the plenum 60 and a front panel 101 extending upwardly from the flat bottom portion 102 near the forward portion of the tray 100. Since it is important to eliminate any air flow or current in the bottom portion of the plenum 60 in order to allow complete settlement of the lint in that portion of the plenum, a fabric seal 106 such as felt, is provided in the front panel portion 101 of the lint tray 100 to seal around the edges of the front panel 101. As best seen in FIG. 5, this seal 106 is retained in the panel 101 between a front clamping plate 104 and a back retainer plate 105. As illustrated in FIGS. 3 and 5, this fabric seal 106 seals the front panel 101 of the tray 100 against both the sides and the top of the tray access opening defined by the sides 12, 14 of the chamber and a forwardly extending lip 77 of the baffle plate 70.
Tray guides 108 are provided on both sides of the plenum 60 to guide the flat bottom portion 102 of the lint tray 100 into its proper horizontal position at the very bottom of the plenum 60. It can be appreciated therefore that lint L in the plenum 60 will settle on the flat bottom portion 102 of the lint tray 100 and can be removed from the plenum by removing the tray 100 from the plenum and disposing of the lint thereon. To facilitate removal, a handle 107 is provided on the forward face of the front panel 101 of the tray 100.
Since it may not always be desirable to divert all of the warm moist air from the dryer into the interior environment of a home, such as during the summer when the primary object of the occupants will be to cool the interior air and de-humidify it rather than heat and humidify it, the heat recovery device of the present invention is also provided with a bypass so that the dryer exhaust air can be vented to the outside of the home in the conventional manner when desired. Referring again to FIGS. 4 and 5, a bypass duct 82 is provided at the rear of the chamber to conduct the exhaust air from inlet port 34 to outlet port 36 which is connected into the conventional exhaust vent pipe leading to the outside of the home. The bypass duct 84 is defined by the back panel 16 of the chamber, side panels 12, 14 of the chamber, and partition 44 which extends downwardly to the vicinity of the inlet port 34.
A damper or valve 84 is pivotally mounted on a shaft 86 extending transversely from one side of the chamber to the other at the bottom of partition 44 such that the valve plate is rotatable to close off the entrance to the bypass duct 82 and divert the flow of air into the initial duct 42 in the position shown in FIG. 5 or alternatively to block off the initial duct 42 and divert the flow of air into bypass duct 82 as illustrated by the position shown in phantom lines 96. A fabric seal 90 made of felt fabric is also provided to seal the sides and ends of the valve 84. The fabric seal 90 is held in place by being sandwiched between facia plates 88 and 89 allowing a small portion of the fabric to extend beyond the sides and ends of the plates to effect the seal.
Similar fabric seals 94, 95 are provided around the shaft 86 and are secured in place by being positioned between partition 44 and a clamping plate 92. The cross shaft 86 extends from one side of the chamber through to the exterior of the other side as best seen in FIGS. 2-4. A control handle 98 is also provided on the right end of shaft 86 to facilitate manual operation of the gate valve 84 from the outside of the heat recovery device 10.
It is readily apparent that the valve 84 can be adjusted at any position intermediate of deflecting the airstream to either the initial duct 42 or the bypass duct 82 to allow only a portion of the air to be discharged into the interior environment as desired.
Since the inlet and outlet ports 34, 36, respectively, are of standard diameter for conventional exhaust vent pipes, the lower portion of partition 46 is slanted downwardly and forwardly to form an inclined deflector chute 62 to direct the incoming stream of air to the zone occupied by the valve 84 near the respective mouths of initial duct 42 and bypass duct 82. A similar upper inclined deflector chute 83 is also provided near the top of the bypass duct 82 extending from the curved chute 54 to the upper lid near the forward side of outlet port 36. Both the lower deflector chute 62 and the upper deflector chute 83 enhance the laminar flow of the stream of air into and out of the chamber and minimize locations of turbulence or locations which may tend to collect deposits of lint.
Although the present invention has been described with a certain degree of particularity, it is understood that the present disclosure has been made by way of example and that changes in detail of structure may be made without departing from the spirit thereof.
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A heat recovery device is adapted for placement in the heat exhaust vent pipe of a conventional clothes dryer. The device includes a scrubber for primary removal of lint from the dryer exhaust and a final filter means for removing small particles of lint remaining prior to allowing the warm, humid dryer exhaust air to pass into the atmosphere of the interior environment of a home. The scrubber includes a series of ducts opening into an enlarged plenum and a baffle plate in the plenum to inhibit streamlined flow of air allowing the lint to settle to the bottom of the plenum, and the final filter includes a series of expanded aluminum screens or mesh for positively prohibiting passage of lint into the atmosphere. A clean-out tray is provided at the bottom of the plenum to facilitate removal of lint from the plenum for disposal. The device also includes a bypass duct for passing the dryer exhaust air through the device and to the outside of the home and a valve for selectively directing the flow of air through the scrubber or through the bypass duct as desired.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to shift lever control devices for use in wheeled motor vehicles of a type having an automatic transmission mounted therein, and more particularly to shift lever control devices of a floor-mounted type which has the shift lever slidably moved in a cranked guide slot.
2. Description of the Prior Art
One conventional shift lever control device of the floor-mounted type is disclosed in Japanese Utility Model First Provisional Publication No. 60-195225.
However, due to its inherent construction, the conventional device of the publication is compelled to have additional switches, such as overdrive switch, first speed switch and the like, with increase in gear speeds needed. As is known, usage of additional switches causes the shift lever control device to have a complicated and highly cost construction. Furthermore, the usage of the additional switches requires a complicated movement of the shift lever because the ON-OFF operations of these switches must be controlled by the movement of the shift lever in sequential manner.
SUMMARY OF THE INVENTION
It is therefore an object of the present invention to provide a shift lever control device of the floor-mounted type, which is free of the above-mentioned drawbacks.
According to the present invention, there is provided a shift lever control device which is equipped with only one switch for detecting various shift positions of the shift lever.
According to a first aspect of the present invention, there is provided a shift lever control device which comprises pivot means for permitting a shift lever to pivot in both first and second directions which are perpendicular to each other; a bracket which is pivotal together with the shift lever in the first direction, the bracket having a mounting portion; a cam plate rotatably mounted on the mounting portion, the cam plate being engaged with the shift lever so that when the shift lever pivots in the second direction, the cam plate is rotated on the mounting portion; check means for making the rotational movement of the cam plate in a snap action manner; means defining a cam surface on a periphery of the cam plate; and a single switch having a sensor pin which slidably contacts with the cam surface of the cam plate, the switch selectively assuming ON and OFF conditions in response to the rotational movement of the cam plate.
According to a second aspect of the present invention, there is provided a shift lever control device which comprises means for defining a cranked guide slot along and in which a shift lever slidably moves, the slot including a first laterally extending part, a first longitudinally extending part, a second laterally extending part and a second longitudinally extending part which are connected in order; pivot means for permitting the shift lever to pivot in both first and second directions which are perpendicular to each other, the first direction being the direction along which the first and second longitudinal parts of the guide slot extend and the second direction being the direction along which the first and second laterally extending parts of the guide slot extend; a bracket which is pivotal together with the shift lever in the first direction, the bracket having a mounting portion; a cam plate rotatably mounted on the mounting portion, the cam plate being engaged with the shift lever so that when the shift lever pivots in the second direction, the cam plate is rotated on the mounting portion; check means for making the rotational movement of the cam plate in a snap action manner; means defining a cam surface on a periphery of the cam plate; and a single switch having a sensor pin which slidably contacts with the cam surface of the cam plate, the switch selectively assuming ON and OFF conditions in response to the rotational movement of the cam plate.
BRIEF DESCRIPTION OF THE DRAWINGS
Other objects and advantages of the present invention will become apparent from the following description when taken in conjunction with the accompanying drawings, in which:
FIG. 1 is a vertically sectional view of a shift lever control device according to the present invention;
FIG. 2 is a view taken from the direction of the arrow "II" of FIG. 1; and
FIG. 3 is a view taken from the direction of the arrow "III" of FIG. 1.
DETAILED DESCRIPTION OF THE INVENTION
Referring to FIGS. 1 to 3 of the drawings, there is shown a shift lever control device 1 which the present invention embodies.
Throughout the specification, the terms "front", "rear", "left", "right", "forward", "rearward", and the like are to be understood with respect to a vehicle body to which the shift lever control device of the invention is mounted.
As is best seen in FIG. 1, the shift lever control device 1 comprises a base bracket 5 which is securely disposed on a floor panel 3 of the vehicle body. Two, viz., right and left side walls 5b are raised from the base bracket 5, between and by which a first pivot pin 7 is supported. Rotatably disposed about the first pivot pin 7 is a hollow rotation shaft 9. The hollow of the rotation shaft 9 through which the first pivot pin 7 passes is denoted by reference mark 9a . The rotation shaft 9 is formed with a raised upper portion which has a through bore 9b. The through bore 9b extends perpendicular to the axis of the hollow 9a of the rotation shaft 9.
A second pivot pin 11 passes through the through bore 9b for pivotally connecting leg portions of a generally U-shaped bracket 13 to the raised upper portion of the rotation shaft 9.
Thus, the rotation shaft 9 and the bracket constitute a so-called "universal joint".
A connecting lever 49 extending from an automatic transmission (not shown) is secured to the universal joint to move therewith.
A shift lever 15 is secured at its lower end to a base portion of the bracket 13. Thus, the shift lever 15 is pivotal forward and rearward about the first pivot pin 7 as well as leftward and rightward about the second pivot pin 11.
A check holder bracket 17 extends upward from the rotation shaft 9. Thus, the forward and rearward pivoting of the shift lever 15 induces an integral movement of the check holder bracket 17 about the first pivot pin 7.
The check holder bracket 17 is formed with a flat top portion 17a on which a check mechanism 21 is mounted.
As is seen from FIG. 2, the check mechanism 21 comprises a generally circular cam plate 24 which is rotatably mounted through a pivot pin 19 to the flat top portion 17a of the check holder bracket 17. Thus, the cam plate 24 is rotatable about the pin 19 in the directions of the arrow "X".
The cam plate 24 has two pawl portions 24a and 24a by and between which a rounded recess 24c is defined for slidably receiving therein a cylindrical portion of the shift lever 15. It is now to be noted that when the shift lever 15 is pivoted rightward and leftward, that is, in the directions of the arrow "Y" (see FIG. 2) about the second pivot pin 11, the cam plate 24 is rotated in the directions of the arrow "X".
The cam plate 24 has, at a diametrically opposed portion of the rounded recess 24c, a check plate 26 secured thereto through rivets 25. The check plate 26 has a waved peripheral portion which comprises two spaced rounded projections and a rounded recess 27 which is defined between the two rounded projections. Slidably engaged with the waved peripheral portion of the check plate 26 is a roller 31 which is rotatably connected through a pin 28 to an intermediate portion of a biasing pivotal lever 29. The lever 29 has one end 29a which is pivotally connected through a pin 32 to the flat top portion 17a of the check holder bracket 17 and the other end 29b to which a biasing spring 30 extending from a front end of the flat top portion 17a is connected. Due to the biasing force of the spring 30, the roller 31 is pressed against the waved peripheral portion of the check plate 26, and thus, the pivotal movement of the cam plate 24 about the pivot pin 19 is effected in a so-called "snap action manner". More specifically, the cam plate 24 can be pivoted from its center position as shown in FIG. 2 to its rightmost or leftmost angled position in a snap action manner.
The cam plate 24 has a cam surface 42b near a shift switch 23 which is secured to the flat top portion 17a of the check holder bracket 17. The shift switch 23 has a sensor pin 23a which slidably and operatively to contacts to the cam surface 42b.
As will be understood from FIG. 3, when, due to shifting of the shift lever 15 from "drive position" D to "overdrive position" OD, or from "second speed position" S to "first speed position" F, the cam plate 24 is pivoted from the center position to its rightmost angled position or to its leftmost angled position, and the cam surface 24b of the cam plate 24 causes the shift switch 23 to assume ON condition.
Referring back to FIG. 1, designated by numeral 47 is a position plate which is secured to the base bracket 5. The position plate 47 has an aperture whose upper periphery constitutes a check cam surface 48. Operatively engaged with the check cam surface 48 is a check pin 46. The check pin 46 is fixed to a cancel rod (not shown) which is axially slidably disposed in the shift lever 15 and biased upward by a spring (not shown). Thus, the check pin 46 is pressed against the check cam surface 48 of the position plate 47. The cancel rod has at its top a push button (not shown).
Designated by numeral 40 is s shift lever housing which is supported by front and rear brackets 5a and 5a raised from the base bracket 5. The housing 40 has an integral upper flat wall 41 (see FIG. 3).
As is seen from FIG. 3, the upper flat wall all is formed with a longitudinally extending cranked guide slot 42 through which the cylindrical portion of the shift lever 15 passes. Thus, the shift lever 15 is compelled to move along a cranked way which is defined by the cranked guide slot 42. As is seen from FIG. 3, the guide slot 42 comprises a first laterally extending part 42a, a first longitudinally extending part 42b which is connected to the part 42a through a normally bent part 42c, a second laterally extending part 42d connected to the part 42b and a second longitudinally extending part 42e connected to the part 42d. The second longitudinally extending part 42e is the longest, as shown.
Beside the first laterally extending part 42a, there are provided gear position marks "1" (1'st speed) and "2" (2'nd speed), and beside the first longitudinally extending part 42b, there is provided a gear position mark "3" (3'rd speed). Beside the second laterally extending part 42d, there are provided gear position marks "D" (drive) and "OD" (over drive), and beside the second longitudinally extending part 42e, there are provided gear position marks "N" (Neutral), "R" (Reverse) and "P" (Parking). These position marks "1", "2", "3", "OD", "D", "N", "R", and "P" indicate the positions (viz., First, Second, Third, Overdrive, Drive, Neutral, Reverse and Parking positions) which the associated transmission can assume. These position marks are constructed to be illuminated from within by a known illumination device mounted in the shift lever housing 40.
The marks "1", "D", "N", "R" and "P" are laid on a first imaginary line and the other marks "2", "3" and "OD" are laid on a second imaginary line which is in parallel with the first imaginary line.
Between the first and second imaginary lines of the marks, there are aligned six light emitting diodes (LED) 44, each diode being positioned beside the corresponding mark, as shown. Each diode becomes energized to emit light when the shift lever 15 comes to a corresponding gear position.
Although not shown in the drawings, a known inhibitor switch is arranged on the position plate 47 to sense a longitudinal position of the shift lever 15.
In the following, the operation will be described with reference to the drawings.
For ease of understanding, the description will be commenced with respect to a condition wherein the shift lever 15 assumes "P" (Parking) position. Under this condition, the check pin 46 of the cancel rod is latchingly engaged with a frontmost notch of the check cam surface 48 of the position plate 47, and the cam plate 24 assumes the center position as shown in FIG. 2, having the rounded recess 27 of the check plate 26 operatively engaged with the spring biased roller 31.
When the push button on the top of the shift lever 15 is pushed to cancel the latched engagement of the check pin 46 with the frontmost notch of the position plate 47 and then the shift lever 15 is pulled rearward with the push button kept pushed, the shift lever 15 is permitted to move toward "D" (Drive) position (see FIG. 3). During this movement, the shift lever 15 pivots about the first pivot pin 7, and the cam plate 24 (see FIG. 2) is kept unchanged.
When, upon arrival at "D" position, the shift lever 15 is applied with a suitable force, the same is permitted to move to "OD" (Overdrive) position (see FIG. 3). During this movement, the shift lever 15 pivots about the second pivot pin 11, and the cam plate 24 (see FIG. 2) is forced to turn to the rightmost angled position in a snap action manner. Due to this pivoting of the cam plate 24, the shift switch 23 changes its condition from "OFF" to "ON". This "ON" signal is used for changing the condition of the automatic transmission from "D" (Drive) condition to "OD" (Overdrive) condition.
When then the shift lever 15 is applied with a suitable force, the same can be moved to the 7 (3'rd speed) position. During this movement, the shift lever 15 pivots above the first pivot pin 7 and the cam plate 24 keeps the rightmost angled position. The inhibitor switch senses this movement of the shift lever 15 and thus the transmission can change its condition from "OD" condition to 7 (3'rd speed) condition.
When then the shift lever 15 is applied with a suitable force, the same can be moved to the S (2'nd speed) position. During this movement, the shift lever 15 universally pivots about both the first and second pivot pins 7 and 11, and the cam plate 24 (see FIG. 2) is forced to turn from the rightmost angled position to the center position as shown in FIG. 2. Either one of the shift switch 23 and the inhibitor switch can sense this position change, and thus, the transmission can change its condition from T (3'rd speed) condition to S (2'nd speed) condition.
When then the shift lever 15 is applied with a suitable force, the same can be moved to the F (1'st speed) position. During this movement, the shift lever 15 pivots about the second pivot pin 11 and the cam plate 24 (see FIG. 2) is forced to turn from the center position to the leftmost angled position. Due to this pivoting of the cam plate 24, the shift switch 23 can sense the position change of the shift lever 15. Thus, the transmission can change its condition from S (2'nd speed) condition to F (1'st speed) condition.
The shifting of the shift lever 15 from F (1'st speed) position to "P" (Parking) position is carried out in a reversed manner.
As will be understood from the foregoing description, in the present invention, the shift switch 23 can sense not only the position change of the shift lever 15 between "D" and "OD" positions but also the position change between S and F positions. In other words, in the present invention, four positions "D", "OD", S and F of the shift lever 15 can be sensed by only a single shift switch 23. This is very advantageous in obtaining a shift lever control device which has a simple and low-cost construction. Furthermore, usage of only one switch induces a simple and smooth movement of the shift lever because the movement requires only the ON-OFF operation of the single switch.
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A shift lever control device is disclosed which comprises a pivot structure for permitting a shift lever to pivot in both first and second directions which are perpendicular to each other; a bracket which is pivotal together with the shift lever in the first direction and has a mounting portion; a cam plate rotatably mounted on the mounting portion and engaged with the shift lever so that when the shift lever pivots in the second direction, the cam plate is rotated on the mounting portion; a check structure for making the rotational movement of the cam plate in a snap action manner; a structure defining a cam surface on a periphery of the cam plate; and a single switch having a sensor pin which slidably contacts with the cam surface of the cam plate, so that the switch selectively assumes ON and OFF conditions in response to the rotational movement of the cam plate.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to an ice island structure for location over a submerged drill site in offshore waters, and to a drilling method utilizing the ice island structure for drilling prior to grounding of the ice island structure upon the sea bed.
2. Description of the Prior Art
One method advanced in the prior art for oil drilling off the coast of Alaska utilizes a floating barge as the drilling platform. However, if the barge is allowed to become frozen into the shelf ice, drilling must be suspended until the next year.
In my U.S. Pat. No. 3,738,114, entitled "Method and Apparatus for Forming Ice Island for Drilling or the Like," issued June 12, 1973, a method and apparatus is disclosed for forming an ice island on natural ice, and increasing its mass and height until it is grounded with sufficient freeboard to enable its use as a secure and immovable base for drilling. The method and apparatus involve location of a drilling barge at the offshore drill site during a thaw period. The barge freezes in the shelf ice at the onset of winter, and concentric, spaced apart inner and outer walls are constructed around the barge on the shelf ice. The shelf ice space between the walls is repeatedly flooded and allowed to freeze until the weight of the ice mass causes it to sink and ground upon the sea bottom. Extensions are added to the walls to maintain adequate freeboard as the sinking proceeds. This securely fixes the position of the ice island so that drilling operations can take place without danger of the drill pipe being wedged or sheared away by movement of the surrounding shelf ice.
One difficulty with the foregoing method and apparatus is that construction of the ice island was necessarily delayed until the surrounding ice had frozen thick enough to support the weight of the inner and outer walls and the usual construction and assembly equipment. This shortened the period of time during the winter which could be utilized to pump in and freeze water to build up the mass of the ice island. In my U.S. patent application, Ser. No. 167,931, filed July 14, 1980, now U.S. Pat. No. 4,325,656 entitled "Apparatus and Method for Forming Offshore Ice Island Structure," I show an improved method and apparatus for forming an ice island which uses buoyant inner and outer walls which can be assembled in open water. Naturally forming ice locks in the inner and outer walls in fixed relationship and provides a base enabling layered flooding and freezing in the annular space between the walls. Layers of ice, approximately two to three inches per day, are built up to increase the mass of the ice island and gradually cause it to sink. During such sinking extensions are added to the walls to maintain adequate freeboard.
The ice mass growth or accumulation is continued until sufficient excess weight is developed to ground the island and resist the lateral forces encountered on fixed shelf ice break-up. In a typical twenty foot water depth, such excess weight is achieved with an ice island approximately thirty feet high, which would provide about ten feet of freeboard.
The desired excess weight and proper freeboard is reached much earlier in the winter season than was possible with the method and apparatus of my patent, enabling earlier use of the island for drilling or other applications.
Unfortunately, none of the foregoing systems of the prior art provide a means for drilling prior to grounding of the ice island, without exposing the drilling equipment to possible damage because of movement of adjacent shelf ice.
SUMMARY OF THE INVENTION
In one embodiment of the present invention, buoyant concentric inner and outer walls form part of an offshore ice island structure and are connected together and located over a drill site in waters which normally freeze in the winter. The frozen area between the inner and outer walls is flooded, the water is allowed to freeze, and the process repeated, with upper extensions periodically being added to the walls. The natural buoyancy of ice maintains a freeboard area upon which the layers of water can be added, and the weight of the accumulated ice eventually sinks the island and grounds or rests it solidly upon the sea bottom.
According to the present invention, drilling can begin long prior to such grounding. Drilling can begin when the fixed ice shelf is about six inches thick, which is normally attained by mid-November. For this purpose a jack-up barge is located inside the inner wall when it is first assembled. The barge preferably includes an elongated central portion or "moon" pool opening to the sea.
Usual drilling apparatus rides on skids or tracks straddling the pool for changing the position of the drilling apparatus along the length of the pool. In addition, flexible coupling of the floating barge to the inner wall permits the barge to be swiveled about a vertical axis for changing the circumferential position of the drilling apparatus. Consequently, the location of the drilling axis, which extends downwardly through the pool, can be adjusted to compensate for any movement of the ice island caused by movement of the surrounding shelf ice under the influence of wind and tide.
The shelf ice shift experienced in many areas of the Alaskan North Slope region, which is a region of particular interest, is small enough that the compensating adjustment of the drilling axis provided by the present apparatus is ample. As a result, drilling can begin very early in the winter season without danger of loss of the drill string prior to grounding of the ice island. Further, if drilling core tests proves the area to be unproductive prior to grounding, drilling can be discontinued and the ice buildup of the island continued until the island is just short of grounding. The island can then be moved by tugs during the next thaw to a more promising location in deeper waters. The existing mass plus the ice accumulated in the second cold season permit grounding of the island in the deeper waters leaving an undisturbed natural seabed.
The floating barge preferably includes vertically oriented jack-up legs having lower openings with lift pumps and conduit means to pump water out of the tops of the legs and onto the frozen area between the inner and outer walls. The legs are movable downwardly to engage the sea bottom and support the barge for use as a convenient working platform. Water can then be pumped from within the inner wall to permit construction of a permanent sub-seabed work pit. This protects valving and transfer piping from damage by any natural or artificial structure which passes over the work pit. In addition, it enables the ice island to be later moved to another location with minimum sea bed clearances over the work pit area, preserving maximum island growth commensurate with flotation.
A sub-seabed cover is preferably used to protect valving in the sub-surface work pit, including the usual blowout preventer.
The ice island structure also may include a means to enable the barge to be moved to a new drill site independently of the grounded ice island. To accomplish this, the inner wall area is flooded below the suspended barge, and upper layer of water is allowed to freeze to form an ice plug. The barge legs are then jacked up to lower the barge onto a sledge placed on the ice plug, the leg openings in the plug are closed off, and water is pumped into the inner wall below the plug to hydraulically raise the plug and the barge to a position enabling the barge to be sledged onto the adjacent surface of the ice island for transport elsewhere. In another method, upper extensions are made to the inner wall, the barge is jacked to a level higher than the extensions, support elements are attached to the inner wall to extend below the barge, the inner wall is flooded to cover the support elements, and the water is frozen in a plug at the level of the wall extensions. The barge legs are jacked up to lower the barge onto a sledge placed on the frozen plug, and the support elements transfer most of this load to the inner wall extensions. The barge is thereafter sledged onto the surrounding ice island surface and then skidded over the outer protective wall onto the ice-snow build-up on the weather side of the outer wall.
Other objects and features of the invention will become apparent from consideration of the following detailed description taken in connection with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a plan view of the present ice island structure as the same would appear with the floating barge in operating position;
FIG. 2 is an enlarged partial plan view of the inner wall of the ice island structure, particularly illustrating the floating barge and the drilling apparatus carried by the barge;
FIG. 3 is an enlarged view taken along the line 3--3 of FIG. 2;
FIG. 4 is an enlarged view taken along the line 4--4 of FIG. 3;
FIG. 5 is a view taken along the line 5--5 of FIG. 2;
FIG. 6 is a view similar to FIG. 5, but illustrating the grounded ice island structure, and the barge supported on its legs within the ice island inner wall;
FIG. 7 is a diagrammatic plan view of the floating barge, particularly illustrating axial moveability of the drilling apparatus;
FIG. 8 is a view similar to FIG. 7, particularly illustrating the swiveling capability of the barge to adjust the circumferential position of the drilling axis;
FIG. 9 is a view similar to FIG. 6, but illustrating the barge raised upon its supporting legs, and the inner wall flooded;
FIG. 10 is a view similar to FIG. 9, and illustrating freezing of water within the inner wall to form an ice plug;
FIG. 11 is a view similar to FIG. 10, illustrating the fully formed ice plug, and lowering of the barge onto a sledge located on the ice plug;
FIG. 12 is a view similar to FIG. 11, illustrating the barge supported upon the inner wall, the barge legs raised, the leg openings closed with ice, and water being injected into the area below the ice plug;
FIG. 13 is a view similar to FIG. 12, illustrating hydraulic raising of the plug to ready the barge for sledging onto the adjacent ice island surface; and
FIG. 14 is a view similar to FIG. 13, illustrating another means for forming an ice plug for sledging the barge onto the adjacent ice island surface, in this case the ice plug being frozen onto support elements carried by the outer wall for supporting the weight of the barge.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the drawings, there is illustrated an ice island structure 10 for use in gaining access to offshore oil and the like in cold regions such as north of 70 degrees north latitude, and particularly the North Slope of Alaska. The structure 10 comprises, generally, concentric, peripherally continuous and vertically oriented inner and outer caissons or walls 12 and 14, respecively, defining an intervening annular space 16.
As more particularly described in my copending patent application Ser. No. 167,931, filed Jan. 14, 1980, and entitled "Apparatus and Method for Forming Offshore Ice Island Structure," the space 16 is the area within which water is frozen layer upon layer to form an ice island for use as a platform for drilling equipment, storage tanks, power supplies, refrigeration and heating equipment, pumping equipment, and other necessary working tools. The island can also be used as a ship docking facility, or to store off-loaded materials for later transport to shore, or for use as a processing or storage base for negative temperature liquefaction hydrocarbons.
As seen in FIGS. 3 and 4, the inner wall 12 is made of sections of edge connected sandwich structure comprising spaced apart, relatively heavy plate steel reinforced with a plurality of vertically oriented I-beams 17, and is filled with thermal insulating material 19. The wall 12 is connected by cables 18 to the outer wall 14 to stabilize and fix the relative locations of the walls.
Although the size and freeboard of the ice island structure 10 will vary according to the particular application and the depth of water within which it is to be located, the inner diameter of the wall 12 in one embodiment is approximately 300 feet. A typical drill site would be about four to seven miles offshore in approximately 3 to 4 fathoms. This size of wall is ample to accommodate a floating barge 20, provide room for a working crew to cap the well or wells that are drilled, and also provide access to the sea bottom for construction of a work pit, as will be seen.
The inner wall 12 preferably includes internal compartments in its lower portion to provide buoyancy. The wall is fabricated at some convenient work site remote from the planned location of the ice island, and is assembled around the barge 20 in the open sea at the drill site.
The outer wall 14 is also buoyant and it is assembled in surrounding relation and connected to the inner wall 12. Its diameter depends upon the mass and area of ice necessary to firmly hold the island in position once it is grounded. This will be a function of the coefficient of friction of the sea bottom, and the ice-shelf shift forces. As is well known in the art, the ice mass of the grounded island will draw heat from the sea bed and thus transform the sea bed into a rigid permafrost condition, thereby increasing resistance of the ice island to any ice shelf lateral shift forces. In the embodiment illustrated, the diameter is approximately 1,000 feet, the final height being sufficient to extend from the bottom and provide freeboard gravitational weight sufficient to overcome any lateral forces which may be encountered. In most close inshore locations, a minimum of 5 to 10 feet of freeboard is desirable to shelter the barge 20 and other equipment from the forces of wind, sea, and ice thaw shift. If desired, the outer wall 14 could be angled on the ice encroachment side to aid in fracturing shelf ice into blocks through uplift upon the angled surface.
The open sea assembly or fabrication of the buoyant inner and outer walls 12 and 14 greatly simplifies the logistics of commencing construction of the ice island structure 10 before the onset of winter, thereby enabling maximum utilization of the full ten month cold season typical in arctic regions for rapidly freezing water to form the island. Although the phrase "open sea" is used, the assembly of the ice island structure could be delayed until thin shelf ice has formed, and has become fixed in position, in which case the wall components could be punched through such thin shelf ice by any suitable means. If anchorage of the walls to the sea bottom is permitted, drilling could begin immediately. Thus, drilling can begin as soon as the walls are fixed in position, either by anchorage or by being frozen in fixed position in the shelf ice. If the applicable drilling laws and regulations permit early drilling, the walls 12 and 14 could be assembled in open water in September and anchored to the sea bottom. If early drilling is not permitted, shelf ice begins to form in October and drilling can begin in early November when the ice is about 6 inches thick.
The floating barge 20 is preferably made approximately 290 feet long and, as best seen in FIGS. 2, through 6, comprises a buoyant, compartmented hull 22 provided with living quarters for workmen, food stores, drill water storage, fuel tanks, maintenance and repair rooms, and all of the other necessities for surviving and working in the rigorous arctic regions. The barge hull 22 is characterized by a rectangular, elongated opening or moon pool 24 which is open to the sea. It is approximately 126 feet long and 30 feet wide. Longitudinally extending skids or tracks 26 are arranged on opposite sides of the opening 24.
A drilling apparatus 28 is located on the tracks 26 and is longitudinally movable along the tracks 26 by any suitable means (not shown) whereby the drilling axis 30 of a drill rig 32 can be located anywhere along the length of the moon pool 24. The apparatus 28 also includes a cross carriage 33 which enables the apparatus to be moved laterally across a portion of the width of the pool 24.
The barge 20 is secured to the inner wall 12 by any suitable means, such as by crossed cables or wires 34 extending through fairleads 36 located at the corners of the barge hull 22. The wires 34 at each end of the barge hull 22 intersect, as seen in FIG. 2, and are connected to suitable pad eyes 38 carried by the inner wall 12, as seen in FIG. 3. With this arrangement, selective winching of certain ones of the wires 34 will swivel the barge 180 degrees in opposite directions, as shown diagrammatically in FIG. 8. This capability for adjusting the circumferential location of the drilling axis 30, in combination with the longitudinal and lateral adjustment of the location of the drilling axis 30, as seen in FIG. 7, permits the drill rig 32 to be utilized for drilling wells anywhere within an area approximately 200 feet in diameter. As will be seen, and equally important advantage of the adjustability of the location of the drilling axis 30 is that the drilling of a first well can commence as soon as it is cold enough to lock the ice island structure 10 in position relative to the surrounding fixed shelf ice.
As more fully explained in my co-pending patent application Ser. No. 167,931, once the shelf ice has formed sufficiently to anchor the ice island structure 10 in position, there are approximately seven months of sub-zero temperature remaining to build up and ground the structure 10.
If the island is to be provided with a relocation capability, refrigeration coils (not shown) are laid down, with support hangers (not shown) extending upwardly for bracing by superjacent ice build-up. Sea water at approximately 29 degrees Fahrenheit is pumped from within the inner wall 12 through openings 43 in the base of one or more of four legs 42 of the barge 20, and by means of pumps 45, also located in the legs. Preferably, a cantilever tower crane 71 is carried atop each of the legs (only one of which is illustrated in FIG. 6) and supports distribution hoses 72 which extend into the guadrants, respectively, of the annular space 16 to distribute sea water for ice formation, as required.
The water is pumped or flooded onto the surface of the area 16 in a thin layer by any suitable equipment (not shown). This is allowed to freeze, and the process is repeated to build up the height of the ice mass. An average of two to three inches of ice buildup takes place each day so that a 30 to 40 foot high ice mass can be built up in a typical cold season at the North Slope.
The ice mass is built up in a shallow dome shape (not shown) so that excess brine can flow outwardly for removal by sweeper-scrapers (not shown). Flexible hose or plastic covered cable, (not shown) can be used to form temporary dikes or dams 2 to 3 inches high to contain the water for freezing and to help concentrate leached out brine for removal by the sweeper-scrapers. This provides a denser, harder ice for better structural rigidity. Upper extensions are added to the walls 12 and 14 as necessary, and additional interconnecting bracing 18 is installed between the built up walls 12 and 14 for embedment in the formed ice. This process is normally continued until the island grounds upon the sea bottom, and is continued still further to insure a firm anchorage. The weight of the island, and particularly the freeboard mass will constrain it against lateral shifting under the shelf ice forces common in the North Slope region. However, long prior to grounding, and preferably immediately after the structure 10 first becomes frozen into the shelf ice, drilling is begun. This can be as early as November in the North Slope region, as previously indicated, since six inches or more of natural fixed ice form by November 15 between Pt. Barrow and Canada on the Beaufort sea shelf within the 10 fathom curve.
The water within the inner wall 12 is kept from freezing by placing insulating material, such as styrofoam blankets and chips on the surface, as schematically indicated at 43 in FIG. 2, and by discharging into it the heated water used for cooling equipment on the barge 20. The insulation 19 in the inner wall 12 aids in keeping the inner wall area ice free, and thermodynamic factors prevent loss of residual heat downwardly.
In the North Slope region of Alaska, typical movement of the fixed ice shelf due to tide and weather is slow and amounts to less the 30 feet in an approximately east-west direction, and somewhat less in a north-south direction during the fall and winter seasons.
The ice island structure 10, and particularly the drilling axis 30 of the drilling apparatus 28, is initially located in vertical alignment with the drill site axis 38, as best seen in FIG. 5. Suitable sensors (not shown) are employed to detect movement of the shelf ice. If such movement is detected after the drill 40 of the drill rig 32 has penetrated the ocean bottom, the barge 20 is swiveled and the drilling apparatus 28 is moved longitudinally and laterally in an amount sufficient to compensate for such shelf ice movement. This process of adjustment continues as long as necessary to maintain alignment of the axes 30 and 38. If the drilling does not prove to be productive, the ice island structure 10 need not be fixedly grounded, but could be moved during the next thaw period by tugs or the like to a more promising location after removal of some freeboard weight.
If the drilling appears promising, the ice island mass is built up to firmly ground it, as seen in FIG. 6. The anchor or swivel wires 34 are uncoupled, and the water, insulation and any ice within the wall 12 are cleared out.
The four jack legs 42 of the barge 20 are jacked down to support the barge in the position illustrated in FIG. 6. The jack means for operating the jack legs 42 are well known in the prior art and their description is omitted for brevity. The bottoms of the legs preferably include relatively large diameter pads or feet 46 which engage the sea bed in an increased area to distribute the weight of the barge and lessen penetration of the bottom by the legs 42. Such penetration could interfere with sub-seabed construction, as will be seen. Such feet 46 are made separable and for this purpose are connected to the legs 42 by shear pins or the like. If desired, the legs 42 can then be pulled up independently of the feet 46, as will be seen.
Once the area bounded by the inner wall 12 is cleared of water and ice, a work pit 48 is excavated to a depth of approximately 20 feet below the sea bed 44. A caisson 50 is cemented in around the perimeter of the pit 48, and around the usual blow out preventer (BOP) 52 and associated valving which are already established on the preliminary well below the sea bed 44. The area enclosed by the caisson 50 is leveled and a foundation floor is laid to support bracing for additional wells, and to support a suitable protective cover.
If additional wells are to be drilled, four or more may be drilled, two on each side of the original well, by fore and aft skidding of the drilling apparatus. If still more wells are to be drilled, then the area within the inner wall 12 is flooded by pumping water from outside through one or more conduits 72, FIG. 6, and through the leg openings 43 until the barge is refloated. The barge 20 is then reconnected to the wall 12 by the swivel wires 34 and then located in position for drilling the additional wells, as schematically indicated in FIG. 8. In a 200 foot work pit 48 as many as 20 to 26 wells can be drilled using the procedure previously described for the first well.
In the event that drilling is completed and it is desired to move the barge 20 independently of the ice island to another drill site for use with another ice island structure the area within the inner wall 12 is flooded, as seen in FIG. 10. One method of moving the barge comprises covering the upper portion of the inner wall 12 with a temporary plywood and plastic membrane or barrier 54 to provide a low friction surface on approximately the upper eight feet of the wall. Next, the barge 20 is jacked up on its legs 42 to the position shown in FIG. 9.
The upper layer of water within the flooded inner wall is allowed to freeze, against the membrane barrier 54, and a layer of water is then pumped onto the upper surface of the frozen layer by pumping means 56, as seen in FIG. 10. After this freezes the process is continued until an ice plug 58 is formed, as seen in FIG. 13.
Heavy, laterally extending support elements 60 are disposed between the ends of the barge 20 and the upper edge of the adjacent inner wall 12 to support the barge 20 in its raised position. Skid timbers or a sledge 62 are next placed on the ice plug 58 beneath the barge 20. The barge is then lowered onto the sledge 62.
Suitable heaters, hot oil injectors, or steam injectors 64 located within the legs 42 are operated to thaw one or two inches of the ice surrounding the legs 42. The legs 42 are then jacked up to the position illustrated in FIG. 12, the weight of the barge 20 being borne primarily by the inner wall 12 through load transfer from the support elements 60. Raising of the legs 42 is facilitated by separating and jettisoning the leg bases or feet 46, as by shearing of the shear pins (not shown).
Refrigeration coils 66 are placed in the leg openings left in the ice plug 58 by the raised legs 42, and the outlet conduit of the pumping means 56 is disposed downwardly through one of the leg openings so that water can be pumped into the area below the ice plug 58. The coils 66 freeze and plug the leg openings so that water cannot flow upwardly through them. Operation of the pumping means 56 hydraulically pressurizes the area beneath the ice plug 58 and raises the plug 58, sledge 62, and barge 20 to the position illustrated in FIG. 13. Sliding of the periphery of the plug 58 past the upper portion of the inner wall 12 is facilitated by the presence of the plywood and plastic barrier 54.
The sledge 62 and barge 20 can now be moved laterally by tractors or the like (not shown) to the surrounding surface of the ice island structure. Temporary ramps 68 of ice and snow are built up adjacent the inner wall 12, a suitable width of the outer wall 12 is removed to the level of the surrounding shelf ice, and the intervening ice island surface between the inner wall and the outer wall opening is sloped to permit the barge to be sledged onto the surrounding shelf ice 69. During the next spring thaw, the barge 20 can then be floated to another drill site.
Another and preferred method of sledging the barge 20 out of the area bounded by the inner wall 12 is illustrated in FIG. 14. In this method upper extensions 70 are connected to the upper edges of the existing inner wall 12, and the barge 20 is raised on its legs 42 to a position above the extensions 70. The area within the wall 12 is alternately flooded and frozen to form an ice plug which is fixedly frozen to and supported by the wall 12. This plug 58 is now located at the level of the ice surface between the walls 12 and 14.
The sledge 62 is placed on the ice plug 58 and the barge 20 is then lowered onto the sledge.
As before, the support elements 60, not seen in FIG. 14, are disposed between the barge 20 and the upper edge of the extensions 70 to support the barge upon the extensions during raising of the legs 42. The heaters (not shown) in the legs 42 are operated to melt the ice immediately adjacent the legs 42, and the legs 42 are jacked up or raised above the ice plug 58. Use of refrigeration coils is unnecessary to plug the leg openings. The barge 20 can then be sledged onto the surrounding ice island surface for transport to another drill site.
The foregoing ice island structure and drilling methods permit drilling very early in the winter. This saves one full season and makes maximum utilization of the opportunity not only to form the ice island, but also to drill. Under present regulations such drilling in the North Slope region must terminate on a particular deadline in the Spring, and it appears that more than one well could easily be drilled prior to this deadline date using the described system, as compared with the systems of the prior art. Further, the present system also makes it possible to abandon a drill site prior to grounding of the ice island if stratographic logging and core results of the first drilling proves to be unproductive. Of environmental interest is the fact that such abandonment leaves a clean, undisturbed natural sea-bed surface.
Details respecting preservation of the ice island structure during the thaw season, or relocation of the ice island during the thaw season, are set forth in my U.S. Pat. No. 3,738,114.
Various modifications and changes may be made with regard to the foregoing detailed description without departure from the spirit of the invention.
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An off-shore ice island structure for location over a submerged drill site in waters which normally freeze in winter. The structure includes a buoyant protective caisson which freezes in position over the drill site upon onset of winter. A barge floats on water kept unfrozen within the caisson, and is connected to the caisson so it can be swivelled generally about a vertical axis to adjust the circumferential location of the drilling axis of drilling apparatus carried on the barge. The drilling apparatus is movable relative to the barge to enable further adjustment of the drilling axis location. The arrangement enables the drilling axis to be maintained in substantial vertical alignment with the drill site despite movement of the caisson caused by the surrounding shelf ice. The caisson is part of an ice island structure whose mass is built up by successive flooding and freezing steps to ground it on the sea bed. The capability for fixing the location of the drilling axis despite shelf ice movement permits drilling operations to commence long prior to grounding of the ice island.
Various arrangements are disclosed for moving the barge from within the caisson for reuse at another drill site.
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BACKGROUND OF THE INVENTION
This invention relates to down-hole tools, and in particular, though not exclusively, to a time delay mechanism for use with down-hole tools.
Down-hole pressure actuated or initiated devices which may be, for example, suspended from "pack-off" devices tubing or casing well conduit are known, per se. Typical "pack-off" devices include bridge plugs such as GB 2 261 895 B (Petroleum Engineering Services Limited), incorporated herein by reference.
Known cyclic/shear devices suffer from a number of problem. For example, maximum pressure application from above is normally limited with known devices. Furthermore, a well conduit may be provided with a number of pressure actuated or initiated devices throughout its entirety problems exist in testing one or more of these devices without accidentally activating another.
SUMMARY OF THE INVENTION
It is an object of the present invention to obviate or mitigate the aforementioned disadvantages in the prior art.
According to a first aspect of the present invention, there is provided a time delay device for use with a down-hole tool comprising a first chamber communicable with a second chamber via at least one orifice (restrictor) and means for controllable transporting a fluid from said first chamber to said second chamber.
In a preferred embodiment the transport means comprises a first piston.
Further said second chamber may provide a second piston.
The second piston may be movable via applied pressure from a first position to a second position under the influence of movement of the first piston against the influence of biasing means within the second chamber.
The first and/or second chamber may be filled with a fluid such as silicone.
A one-way check valve may so be provided between the second chamber and the first chamber to allow fluid to flow from the second chamber to the first chamber.
The at least one restrictor between the first and second chambers may take the form of a Lee visco jet or other suitable contoured flow passage.
The flow rate of fluid through the at least one restrictor, and hence the time delay between the application of pressure to the first piston and the action of the second piston, may be varied by changing the flow characteristics of the at least one restrictor.
According to a second aspect of the present invention, there is provided a down-hole tool including a time delay mechanism comprising a first chamber communicable with a second chamber via at least one orifice (restrictor) and means for controllably transporting a fluid from said first chamber to said second chamber.
According to a third aspect of the present invention, there is provided a method of providing a time delay between the application of pressure and an action being carried out as a result of said application of pressure by providing a pressure responsive time delay device comprising a first chamber communicable with a second chamber via at least one orifice and means for controllably transporting a fluid from said first chamber to said second chamber.
According to a fourth aspect of the present invention, there is provided a down-hole pressure equalizing device comprising a body having at least one closing port and openable means for closing the at least one port wherein, in use, the closure means are controllably opened by means of a time delay mechanism.
According to a preferred embodiment, the time delay mechanism comprises a first piston and first piston chamber, the first piston chamber begin communicable with a second piston and piston chamber via at least one restrictor.
The second piston may be movable from a first position to a second position under the influence of movement of the first piston against the influence of biasing means within the second chamber.
Movement of the second piston to the second position may allow the closure means to open thereby equalizing pressure across the device.
The first and/or second chamber may be filled with a fluid such silicone.
The at least one restrictor may take the form of a Lee visco jet or may other suitably contoured flow passage.
The device may have connection means provided at or near an uppermost portion thereof for suspending the device from another device.
The body may be a cylindrical housing having a plurality of ports spaced around the circumference thereof, and the openable closure means may be a mandrel within the housing moveable therealong.
A one-way valve may also be provided between the second chamber and the first chamber to allow fluid flow from the second to the first chamber.
According to a fifth aspect of the present invention there is provided a method of controlling pressure down-hole by providing a down-hole pressure equalizing device comprising a body having at least one port and openable means for closing the at least one port the method comprising controllably opening the closure means by means of a time delay mechanism.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a partial cross-sectional side view of a down-hole pressure equalizing device incorporating a time delay mechanism according to one embodiment of the present invention.
DETAILED DESCRIPTION
An embodiment of the invention will now be described by way of example only with reference to the drawing.
Referring to the drawing, there is illustrated a down-hole pressure equalizing device, generally designated 5. The device 5 comprises a body in the form of an outer cylindrical housing 10 having a plurality of ports 15 provided around the circumference thereof. Within the housing 10 there is provided openable closure means for closing the at least one port comprising a latch mandrel 20. The closure means are controllably openable by means of a time delay mechanism which will now be described.
The time delay mechanism comprises a first piston 25 which is packed with silicone or other suitable viscous fluid and movably provided within a first piston chamber 30 which houses a restrictor 35. The restrictor in this embodiment is in the form of a Lee visco jet.
A shear ring 39 and shear ring retainer 40 are provided at a first end of the latch mandrel 20 between the mandrel 20 and the first chamber 30. Further a snap ring 45 is provided at a first end of the first chamber to restrict movement of the first piston 25. A T-seal 50 and T-seal back-up 55 are provided on an outer edge of the first piston 25 so as to provide a fluid-tight seal between the first piston 25 and an inner wall of the first chamber 30.
The device 5 as illustrated in FIG. 1 is shown in a closed position. As can be seen from FIG. 1, in the closed position, a pair of O-rings 60 provided on an outer surface of the mandrel 20 are located on either side of each port 15 so as to seal the ports 15.
The chamber 30 also houses a one-way check valve 30A which prevents flow out of the first chamber 30 but allows flow into the first chamber 30.
A further O-ring 61 is provided at an end of the first chamber 30 to provide a fluid-tight seal between the first chamber 30 and the mandrel 20.
The first chamber 30 communicates with a second piston chamber 65 via the restrictor 35. The second chamber 65 is formed from adjacent walls of a piston stop member 70, a collet support 75, the mandrel 20 and the first chamber 30. Provided within the second chamber 65 is a second piston 76 which is biased towards the first chamber by a coil spring 80. A T-seal 85 and T-seal back-up 90 are provided on an outer edge of the second piston 76 so as to provide a fluid-tight seal between the second piston 76 and an inner wall of the mandrel 76.
As seen from FIG. 1, in the closed position, the collet support 75 is connected via shear screws 95 to a collet 100 having collet fingers 105. The collet 100 is retained within a cylindrical body 110 having a snub nose.
Within the first and second chambers 30, 65, there is packed a substantially incompressible fluid material, e.g., silicone.
In use, pressure applied above the device 5 acts on the first piston 25 contained within the first chamber 30. The silicone packed in the first chamber 30 is displaced into the second chamber 65 via the restrictor 35. The displaced silicone acts on the second piston 76 and against spring 80. The time delay created by the restrictor 35 limits the stroke of the second piston 76 allowing pressure to be maintained above the device 5 for a pre-determined period of time. The restrictor 35 size and silicone viscosity dictate the specific time delay.
If the second piston 76 is allowed to contact the collet support 75 applied load is then transferred through the shear screws 95 which hold the collet 100 and collet support 75 together and can cause screws 95 to sheer. Sheering of the screws 95 permits downward travel of the collet support 75 thus de-supporting the collet 100 and allow travel of the mandrel 20. Communication from one end of the device 5 to the other is then accomplished.
It should be appreciated that if pressure applied above the device 5 is limited to a time period frame that does not permit a full stroke of the second piston 76, the spring 80, once pressure is bled off, will return the second piston 76 to its original position as shown in FIG 1. Displacement of the silicone back to the first chamber 30 is accomplished via the one-way "quick dump" check valve 30A housed in the first chamber 30.
It should also he appreciated that in the unlikely event of the primary actuation mode malfunctioning, the device 5 may be mechanically activated.
Referring to FIG. 1, the embodiment illustrated therein provides connection means, e.g., an internally threaded portion 115 by which the device 5 my be connected to a "pack-off" device (not shown).
The embodiment of the invention hereinbefore described is given by way of example only, and is not meant to limit the scope of the invention in any way. It should particularly be appreciated that the one-shot time delay ("TD") equalizing device 5 described hereinbefore is a tool that, when suspended from a "pack-off" device in a tubing or casing well conduit, provides for multiple pressure cycling from above. Only when pressure has been applied for a predetermined time period will the equalization mechanism actuate. Thus, erroneous actuation is sought to be avoided. The time delay feature facilitates maximum pressure application from above that is normally limited with traditional cycle/equalizing device.
The device described hereinbefore is but one example of a down-hole tool employing the present invention. Other examples of uses of the time delay mechanism include utilization as a safety barrier to a pressure sensitive timer switch on a down-hole pyrotechnic setting tool, as a barrier to a pressure sensitive activation device for initiating the openning of a hydrostatic setting tool, or as a damper against unexpected pressure surges which could adversely affect the operation of pressure sensitive equipment.
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A time delay mechanism wherein there is provided a time delay between the application of a pressure to the mechanism and an action being carried out as a result of the application of said pressure. The mechanism may comprise a first piston and piston chamber and a second piston and piston chamber. Communication of a viscous fluid between said piston chambers may be achieved by means of at least one contoured flow passage.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to on-line character recognition apparatus and, more particularly, to an on-line character recognition apparatus having a group table memory in which characters and symbols can be associated with nominated characters and symbols.
2. Description of the Prior Art
FIG. 1 is a block diagram showing an outline of a conventional hand-written character recognition apparatus.
In FIG. 1, reference numeral 1 designates a tablet, 2 a recognition circuit, 3 a nominated character selecting circuit, 4 a character pattern generating circuit and 5 a display apparatus. According to the prior-art hand-written character recognition apparatus, as shown in FIG. 1, a hand-written character written on the tablet 1 is processed by the recognition circuit 2 and one or a plurality of nominated characters and symbols are thereby extracted for the hand-written character. A character code train of the nominated characters is supplied to the nominated character selecting circuit 3. The nominated character selecting circuit 3 selects a character code of the first position of nominated characters from the character code train supplied thereto, and the selected character code is supplied to the character pattern generating circuit 4. The character pattern generating circuit 4 generates a character pattern corresponding to the character code and the character pattern is displayed on the display apparatus 5. In general, when the user wants to select another one of nominated characters and symbols while watching the contents displayed on the display apparatus 5, if the user depresses a key on the tablet 1, a nominated character selection control signal is supplied to the nominated character selected circuit 3 which then selects the next nominated character.
Incidentally, in the case of the conventional hand-written character recognition apparatus, when the hand-written character is recognized, the user must write a character with great accuracy and care because the recognition circuit must recognize a very small difference between a pair of similar hand-written characters.
For example, a great burden is imposed on the user when the user writes any of the following symbols ( { [ <, to write the symbol so that it is distinguishable from the other symbols by the recognition circuit.
Further, in order that all of these symbols can be distinguished by the recognition circuit, very small differences of these symbols must be distinguished and registered, which causes an increased recognition time and requires an increased capacity of the dictionary. Also, there is a restriction that the hand-written character can be recognized with accuracy.
Furthermore, a method for directly obtaining these characters and symbols from the JIS (Japanese Industrial Standards) code or for searching these characters and symbols from a table imposes a large burden on the user.
OBJECTS AND SUMMARY OF THE INVENTION
Accordingly, it is an object of the present invention to provide an improved character recognition apparatus which can substantially eliminate the aforenoted shortcomings and disadvantages encountered with the prior art.
More specifically, it is an object of the present invention to provide a character recognition apparatus having a reduced capacity dictionary memory.
It is another object of the present invention to provide a character recognition apparatus in which the recognition time can be reduced.
It is still another object of the present invention to provide a character recognition apparatus in which the recognition speed can be increased.
It is a further object of the present invention to provide a character recognition apparatus in which the description of character and symbol can be simplified so that time and labor can be saved.
It is yet a further object of the present invention to provide a character recognition apparatus whose application range can be enlarged.
As an aspect of the present invention, a character recognition apparatus comprises input means for obtaining hand-written information, character dictionary memory means for storing characteristics of characters and symbols, character recognition means for determining a first character or symbol from the hand-written information in association with characteristics of characters and symbols stored in the character dictionary memory means, group table memory means for storing group tables of characters and symbols, wherein each of the group tables is represented by a nominated character or symbol, display means for displaying the first character or symbol and one of the group tables representing the first character or symbol, if the first character or symbol is one of the nominated characters or symbols, and a group changing means connected to the group table memory means for changing group tables of the group table memory means.
In the preferred embodiment, the group changing means includes genre display means for displaying a selected genre of characters or symbols and means for adding a character or symbol to one of the group tables by selecting a character or symbol of a selected genre displayed by the genre display means. The groups changing means further includes means for deleting a character or symbol from one of the group tables by selecting a displayed one of the characters or symbols of the one of the group tables.
The preceding, and other objects, features and advantages of the present invention will be apparent in the following detailed description of an illustrative embodiment when read in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram showing an example of a conventional character recognition apparatus;
FIG. 2 is a block diagram showing an embodiment of a character recognition apparatus according to the present invention;
FIG. 3 is a flow chart to which references will be made in explaining the operation of the character recognition apparatus of FIG. 2;
FIGS. 4A-4C are schematic diagrams showing examples of group tables of characters and symbols, respectively;
FIG. 5 (formed of FIGS. 5A and 5B drawn on two sheets of drawings to permit the use of a suitably large scale) is a flow chart to which reference will be made in explaining the operation of the character recognition apparatus of FIG. 2; and
FIGS. 6A-6C are schematic diagrams used to explain the operation of the present invention, respectively.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
An embodiment of a character recognition apparatus according to the present invention will hereinafter be described with reference to FIG. 2 to FIGS. 6A-6C.
FIG. 2 is a circuit block diagram showing an embodiment of the character recognition apparatus according to the present invention. In FIG. 2, reference numeral 10 designates a tablet, 11 an interface circuit, 12 a system control apparatus, 13 a hand-written character recognition apparatus, 14 a character dictionary memory, 15 a buffer memory for nominated characters and symbols, 16 a character table changing apparatus, 17 a character group table memory and 18 a display apparatus, respectively.
Character group tables shown in, for example, FIGS. 4A and 4B are provided in the character group table memory 17. As shown in FIGS. 4A and 4B, a group representing different series of characters or symbols are written on the leftmost portions of the character group tables and the corresponding series of characters or symbols similar to the group are written on the right sides of the leftmost portions respectively. It is needless to say that the character group tables are not limited to similar characters and symbols and characters and symbols which are not similar can be put into character group tables as shown in FIG. 4C.
Only these groups representing characters or symbols are registered in the character dictionary memory 14. When the user wants to output a desired character belonging to a certain character or symbol group, the user manually writes the group representing character on the tablet 10 and reads out data of a corresponding group table with reference to the character group table and selects desired character to be delivered so that this character is obtained instead of the group representing character.
A normal mode of the character recognition apparatus shown in FIG. 2 will be described with reference to a flow chart forming FIG. 3.
Referring to FIG. 3, following the Start of operation, the user enters a certain character on the tablet 10 in a manual fashion. The hand-written information is supplied through the interface circuit 11 to the system control apparatus 12 and is thereby processed. Then, corresponding stroke data is supplied from the system control apparatus 12 to the hand-written character recognition apparatus 13. In step 21, the hand-written character recognition apparatus 13 recognizes the hand-written character by comparing stroke data with the writing order or the like with reference to the character dictionary memory 14. In step 22, the recognized result is supplied to the nominated character buffer memory 15 through the system control apparatus 12 in the form of JIS code and evaluated point.
It is determined in the next decision step 23 by the system control apparatus 12 through the hand-written character recognition apparatus 13 with reference to the character group memory 17 whether or not the recognized character supplied to the nominated character buffer memory 15 has a character group table. If the character does not have any character group table as represented by a NO at step 23, the routine proceeds to step 24. In step 24, the nominated character is read out from the nominated character buffer memory 15 and is display on the display apparatus 18. If on the other hand the character has a group table as represented by a YES at step 23, then the routine proceeds to step 25. In step 25, the corresponding character group table data is read out from the character group table memory 17 and then added to the nominated character stored in the selected genre buffer memory 15. Then, the routine proceeds to step 24 whereat the nominated character and the accompanying character group table data are read out from the nominated character buffer memory 15 and displayed on the display apparatus 18.
When the user wants to select a desired character from the character group table data other than the first nominated character, the user must select the desired character. Then, the display apparatus 18 displays the character that the user selects instead of the first nominated character.
Since only the group representing characters are registered on the character dictionary memory 14 as described above, the storage capacity of the dictionary can be reduced, which provides a reduced recognition time and an increased recognition speed. Further, only the group representing characters are registered in the character dictionary memory 14 and other group characters need not be registered in the character dictionary memory 14 so that the description of the character can be made easy and simplified, which saves time.
A changing mode in which the contents of the character group table memory 17 shown in FIG. 2 are changed will be explained with reference to a flow chart forming FIG. 5 and schematic diagrams forming FIGS. 6A-6C.
If the character recognition apparatus of this embodiment is set in the changing mode, the displayed state of the display apparatus 18 is changed to a pattern shown in FIG. 6A. In FIG. 6A, a display portion 43 displays a hand-written character, a display portion 44 displays the content of the nominated character buffer memory 15 (see FIG. 2) and a display portion 45 displays menus. The menus are [input character again], [stop], [registration] and [character selection] as will be described later. Although [(] is already displayed on the display portions 43 and 44 at its portion in which characters of the first nominated character are displayed, as shown in FIG. 6A, for obtaining a better understanding of the present invention, [(] is not yet displayed in the initial state in actual practice.
Referring to FIG. 5, following the Start of operation, in step 30, a character of, for example, [(] is entered and displayed on the display portion 43 by means of the input tablet 10. In the next step 31, the hand-written character is recognized by the hand-written character recognition apparatus 13 with reference to the character dictionary memory 14. A recognized result is supplied to and stored in the nominated character buffer memory 15. In the next step 32, the character group table of the character group table memory 17 is checked and the checked result is displayed at step 33 whereat the hand-written character [(] is displayed on the display portion 44 of FIG. 6A as the first nominated character. FIG. 6A shows the condition that the character is not yet registered in the character group table.
It is determined in step 34 by the character table changing apparatus 16 whether or not the menu is selected. If a NO is obtained at step 34, then the routine returns to step 34 and the step 34 is repeated until a YES is obtained. On the other hand, if a YES is obtained at step 34, the routine proceeds to the respective menus, that is, steps 35, 36, 37 and 38. In step 35, the character is entered one more time and a group representing character is determined. In step 36, the changing mode is stopped, and in step 37, a registration to a character group table is done. While, a selection of the character to be changed is done in the step 38.
Incidentally, if the user hits [character selection] on the display portion 45 of FIG. 6A, the displayed condition of the display apparatus 18 is changed as shown in FIG. 6B. As shown in FIG. 6B, the display portions 46 and 47 perform the displays exactly the same as those of the display portions 43 and 44 in FIG. 6A. The display portion 48 displays thereon selected genres of characters and symbols. If the user hits one of the selected genres of characters and symbols, for example, [symbols and numerals] on the display portion 48 in step 39, a table of genres selected is displayed on a display portion 51 in step 40 as shown in FIG. 6C. In FIG. 6C, display portions 49 and 50 carry out displays exactly the same as those of the display portions 43 and 44 in FIG. 6A. If in step 41 the user selects one of the symbols, for example, [{] on the display portion 51, then data of this selected symbol is input to the nominated character buffer memory 15 and displayed on the display apparatus 18 in step 33. Accordingly, the display portion 50 in FIG. 5C displays thereon the character [{] after the first nominated character [(].
In a like manner, the character to be grouped is selected, stored in the nominated character buffer memory 15 and is displayed on the display portion 50.
After the character selection is ended, [registration] on the display portion 45 is selected in step 37 and the character recognition apparatus of this invention is set to the registration mode. In the next step 42, the character table changing apparatus 16 reads out the contents of the nominated character buffer memory 15 and registers the read-out contents to the character group table of the character group memory 17.
Under this condition, if the patterns of FIGS. 6A and 6B are displayed, the display portions 44 and 47 display thereon the character other than the first nominated character, for example, [{] and so on. If the user wants to delete a character of the grouped characters which are registered, then the user selects the character to be deleted from the grouped characters on the display portion 47 under the condition that the pattern of FIG. 6B is displayed, the thus hit character is erased from the display and the content of such character also is erased from the nominated character buffer memory 15. When the user hits [registration], data of such character is deleted from the character group table of the character group table memory 17.
As described above, the character group table of the character group table 17 can be made freely and desired characters and symbols or the like can be registered freely.
As described above, according to the present invention, since the grouped character accompanying with the nominated character which results from recognizing input character, symbol or the like is output with reference to the character group memory, only the character and symbol which can become the nominated character and symbol are registered in the character dictionary memory, which provides a reduced capacity of dictionary and a reduced recognition time, thus the recognition speed is increased. Further, since only the group representing characters are written as character and symbol or the like, the description of the character, symbol or the like can be simplified, which can save time and labor. Furthermore, since the content of the character group table is changed, a desired character group table for the user can be made freely, which provides an enlarged application range of this character recognition apparatus.
Having described a preferred embodiment of the invention with reference to the accompanying drawings, it is to be understood that the invention is not limited to that precise embodiment and that various changes and modifications thereof could be effected by one skilled in the art without departing from the spirit or scope of the novel concepts of the invention as defined in the appended claims.
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A character recognition apparatus is comprised of an input device for obtaining hand-written informations, a character dictionary memory for storing characteristics of characters and symbols, a character recognition device for determining character or symbol of the hand-written informations in association with characteristics of characters and symbols stored in the character dictionary memory, a group table memory for storing group tables of characters and symbols, a display device for displaying thus recognized character or symbol and associated character or symbols, if the recognized character or symbol is registered in the group table memory and a device connected to the group table memory for changing group tables of the group table memory.
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[0001] The present invention generally relates to a light-emitting diode and a method for fabricating the same.
[0002] Light-emitting diodes (LEDs) are playing an increasingly important role in our daily life. Traditionally, LEDs are become ubiquitous in many applications, such as communications and other areas, such as mobile phones, appliances and other electronic devices. Recently, the demand for nitride based semiconductor materials (e.g., having Gallium Nitride or GaN) for opto-electronics has increased dramatically for applications such as video displays, optical storage, lighting, medical instruments, for-example. Conventional blue light-emitting diodes (LEDs) are formed using semiconductor materials of nitride, such as GaN, Al GaN, InGaN and AlInGaN. Most of the semiconductor layers of the aforementioned-typed light emitting devices are epitaxially formed on electrically non-conductive sapphire substrates. Since the sapphire substrate is an electrically insulator, electrodes cannot be directly formed on the sapphire substrate to drive currents through the LEDs. Rather, the electrodes directly contact a p-typed semiconductor layer and an n-typed semiconductor layer individually, so as to complete the fabrication of the LED devices. However such configuration of electrodes and electrically non-conductive nature of sapphire substrate represents a significant limitation for the device operation. For example, a semi-transparent contact needs to be formed on the p-layer to spread out the current from p-electrode to n-electrode. This semi-transparent contact reduces the light intensity emitted from the device due to internal reflectance and absorption. Moreover, p and n-electrodes obstruct the light and reduce the area of light emitting from the device. Additionally, the sapphire substrate is a heat insulator (or a thermal insulator) and the heat generated during the device operation can not be effectively dissipated, thus limiting the device reliability.
[0003] FIG. 1 shows one such conventional LED. As shown therein, the substrate is denoted as 1 . The substrate 1 can be mostly sapphire. Over the substrate 1 , a buffer layer 2 is formed to reduce the lattice mismatch between substrate 1 and GaN. The buffer layer 2 can be epitaxially grown on the substrate 1 and can be AlN, GaN, AlGaN or AlInGaN. Next, an n-GaN based layer 3 , a multi-quantum well (MQW) layer 4 , and a p-GaN layer 5 are formed in sequence. An etching method is employed to form an exposing region 6 on the n-GaN based layer 3 . An electrical conductive semi-transparent coating is provided above the p-GaN layer 5 . Finally, the n-electrode 9 and p-electrode 8 are formed on selected electrode areas. The n-electrode 9 is needed on the same side of device as p-electrode to inject electrons and holes into the MQW active layer 4 , respectively. The radiative recombination of holes and electrons in the layer 4 emits light. However, limitations of this conventional LED structure include: (1) Semi-transparent contact on p-layer 5 is not 100% transparent and can block the light emitted from layer 4 ; (2) current spreading from n-electrode to p-electrode is not uniform due to position of electrodes; and (3) heat is accumulated during device operation since sapphire is a thermal and electrical insulator.
[0004] To increase available lighting area, vertical LEDs have been developed. As shown in FIG. 2 , a typical vertical LED has a substrate 10 (typically silicon, GaAs or Ge). Over the substrate 10 , a transition metal multi-layer 12 , a p-GaN layer 14 , an MQW layer 16 , a n-GaN layer 18 are then formed. The n-electrode 20 and the p-electrode 22 are then formed on selected areas as electrodes.
[0005] US patent Application No. 20040135158 shows one way to realize vertical LED structure by (a) forming a buffering layer over a sapphire substrate; (b) forming a plurality of masks over said buffering layer, wherein said substrate, said buffering layer and said plurality of masks jointly form a substrate unit; (c) forming a multi-layer epitaxial structure over said plurality of masks, wherein said multi-layer epitaxial structure comprises an active layer; extracting said multi-layer epitaxial structure; (d) removing said remaining masks bonding with a bottom side of said multi-layer epitaxial structure after extracting; (e) coating a metal reflector over said bottom side of said multi-layer epitaxial structure; (f) bonding a conductive substrate to said metal reflector; and (g) disposing a p-electrode over an upper surface of said multi-layer structure and an n-electrode over a bottom side of said conductive substrate.
SUMMARY
[0006] In one aspect, a method for fabricating a light emitting diode includes forming a multilayer epitaxial structure above a carrier substrate; depositing at least one metal layer above the multilayer epitaxial structure; removing the carrier substrate.
[0007] Implementations of the above aspect may include one or more of the following. The carrier substrate can be sapphire. The deposition of the metal layer does not involve bonding or gluing the metal layer to a structure on the substrate. The depositing of the metal layer can apply using electro chemical deposition, electroless chemical deposition, CVD chemical vapor deposition, MOCVD Metal Organic CVD, PECVD Plasma enhance CVD, ALD Atomic layer deposition, PVD Physical vapor deposition, evaporation, or plasma spray, or the combination of these techniques. The metal layer can be single or multi-layered. In case that the metal layer is a multi-layer, a plurality of metal layers with different composition can be formed and the layers could be deposited using different techniques. In embodiment, the thickest layer is deposited using electro or electroless chemical deposition
[0008] In another aspect, a method for fabricating a light emitting diode includes providing a carrier substrate; depositing a multilayer epitaxial structure; depositing one or more metal layers above the multilayer epitaxial structure; defining one or more mesas using etching; forming one or more non-conductive layers; removing a portion of the non conductive layers; depositing at least one or more metal layers; removing the carrier substrate.
[0009] Implementations of the above aspect can include one or more of the following. The metal layers could have same or different composition and deposited using various deposition techniques. The carrier substrate removal can be done using laser, etching, grinding/lapping or chemical mechanical polishing or wet etching, among others. The carrier substrate can be sapphire, silicon carbide, silicon, germanium, ZnO or gallium arsenide. The multi layer epitaxial structure can be a n-type GaN layer, one or more quantum wells with InGaN/GaN layers, and a p-type AlGaN/GaN layer. The one or more metal layers above the multi layer epitaxial structure can be Indium Tin Oxide (ITO), Ag, Al, Cr, Ni, Au, Pt, Pd, Ti, Ta, TiN, TaN, Mo, W, a refractory metal, or a metal alloy, or a composite of these materials. An optional doped semiconductor layer can be formed between the multi layer epitaxial structure and the metal layers. The mesa can be defined using a polymer (for example: resist) or a hard mask (for example: SiO2, Si3N4, Aluminum). The non-conductive layer can be SiO 2 , Si 3 N 4 , a diamond element, a non-conducting metal oxide element or a ceramic element or a composite of these materials; The non-conductive layer could be a single layer or could have a plurality of non-conductive layers (for example: SiO2 on Si3N4). In one implementation, the non-conductive layer is the sidewall passivation layer or passivation layer. A portion of the non conductive layer can be removed by lifting off or dry etching to expose a conductor layer with or without using a masking layer. The conductor layer can be one or more metal layers. The one or more metal layers can be deposited using physical vapor deposition (PVD), chemical vapor deposition (CVD), plasma enhanced CVD (PECVD), evaporation, ion beam deposition, electro chemical deposition, electroless chemical deposition, plasma spray, or ink jet deposition. The metal layer can include chromium (Cr), platinum (Pt), nickel (Ni), Copper, Copper on a barrier metal material (for examples: Titanium Nitride, Tungsten, Tungsten nitride, tantalum nitride , molybdenum (Mo), tungsten (W) or a metal alloy. One or more of the additional metal layers can be formed by electro chemical plating or electroless chemical plating. The additional metal layer can be copper (Cu), nickel (Ni), gold (Au), aluminum (Al), or an alloy thereof. A conductive passivation (protecting the metal layer) layer can be deposited, and can be a metal, nickel (Ni), chromium (Cr), or zinc (Zn), Gold, Pt, Pd. The passivation layer comprises one of: non conductive metal oxide (Hafnium oxide, Titanium oxide, Tatalum oxide), Silicon dioxide, Silicon Nitride or a polymer material.
[0010] In one embodiment, Ag/Pt or Ag/Pd or Ag/Cr is used as a mirror layer, Ni is used as a barrier for Gold as a seed layer for electroplating. The mirror layer (Ag, Al, Pt, Ti, Cr for example) is deposited and then a barrier layer such as TiN, TaN, TiWN, TiW stuffed with Oxygen is formed above the mirror layer before electro or electroless chemical deposition of a metal such as Ni, Cu, W. For electrochemical deposition of copper, a seed layer is deposited using CVD, MOCVD, PVD, ALD, or evaporation process; some of the seed materials for Copper are W, Au, Cu or Ni, among others.
[0011] In another method for fabricating a light emitting diode, the process includes providing carrier substrate; depositing a multilayer epitaxial structure; depositing one or more metal layers above the multilayer epitaxial structure; etching one or more mesas; forming one or more non conductive layers; removing a portion of the non conductive layers; depositing one or more metal layers; removing the carrier substrate.
[0012] Implementations of the above method may include one or more of the following. The metal layers could have same or different composition and deposited using various deposition techniques. The carrier substrate removal can be done using laser, etching, grinding/lapping or chemical mechanical polishing or wet etching, among others. The carrier substrate can be sapphire. The depositing the metal layer can be electro chemical deposition (ECD) or electroless chemical deposition (ElessCD); before depositing the metal layer using electro chemical or electroless chemical deposition techniques, an optional step for a seed conductive layer is employed (for example Copper, Nickel, tungsten seed layers deposited first using evaporation, sputtering or CVD, MOCVD before ECD of Copper, Nickel). The depositing the metal layer can include CVD, PECVD, PVD, evaporation, or plasma spray. Electrodes can be placed on the multilayer structure. One or more additional metal layers can be formed above the original metal layer.
[0013] In another method for fabricating a light emitting diode, the process includes providing carrier substrate; depositing a multilayer epitaxial structure; etching one or more mesas; forming one or more non conductive layers; removing a portion of the non conductive layers; depositing one or more metal layers; removing the carrier substrate.
[0014] Implementations of the above method may include one or more of the following. The metal layers could have same or different composition and deposited using various deposition techniques. The carrier substrate removal can be done using laser, etching, grinding/lapping or chemical mechanical polishing or wet etching, among others. The carrier substrate can be sapphire. The depositing the metal layer can be electro chemical deposition (ECD) or electroless chemical deposition (ElessCD); before depositing the metal layer using electro chemical or electroless chemical deposition techniques, an optional step for a seed conductive layer is employed (for example Copper, Nickel, tungsten seed layers deposited first using evaporation, sputtering or CVD, MOCVD before ECD of Copper, Nickel). The depositing the metal layer can include CVD, PECVD, PVD, evaporation, or plasma spray. Electrodes can be placed on the multilayer structure. One or more additional metal layers can be formed above the original metal layer to protect the underlayer metal.
[0015] In a further aspect, a method for fabricating a light emitting diode includes forming a multi layer epitaxial structure above a substrate (such as a sapphire substrate, for example), depositing a metal layer above the epitaxial layer (using electro or electroless chemical plating on top of a seed metal layer; Copper or nickel plating on top of a seed layer of copper or nickel or Tungsten or Pd deposited using evaporation, CVD, PVD sputtering. The seed layer are deposited on a barrier metal of TaN, TiN, TiWN, TiWOx or Tungsten Nitride ), and removing the substrate (using laser lift-off technique, wet etching or CMP, for examples).
[0016] In one implementation, the multi-layer epitaxial structure includes a reflective metal layer coupled to the metal plating layer; a non-conductive passivation layer coupled to the reflective metal layer; a p-GaN layer coupled to the passivation layer; a multi-quantum well (MQW) layer coupled to the p-GaN layer; a n-GaN layer coupled to the MQW layer; an n-electrode coupled to the n-GaN layer.
[0017] The metal layer can be single or multi-layered. In case that the metal layer is a multi-layer, a plurality of metal layers with different composition can be formed and the layers could be deposited using different techniques. In embodiment, the thickest layer is deposited using electro or electroless chemical deposition
[0018] In one embodiment, Ag/Pt or Ag/Pd or Ag/Cr is used as a mirror layer, Ni is used as a barrier for Gold as a seed layer for copper plating which is used as the bulk substrate. The mirror layer (Ag, Al, Ti, Cr, Pt for example) is deposited and then a barrier layer such as TiN, TaN, TiWN, TiW stuffed with Oxygen is formed above the mirror layer before electro or electroless chemical deposition of a metal such as Ni or Cu. For electrochemical deposition of copper, a seed layer is deposited using CVD, MOCVD, PVD, ALD, or evaporation process with Au, Cu or Ni, among others.
[0019] In yet another aspect, a method for fabricating a light emitting diode, includes forming a multi-layer epitaxial structure over a sapphire substrate, wherein the multi-layer epitaxial structure comprises a multi-quantum well (MQW) layer; coating a metal plating layer above the multi-layer epitaxial structure; removing the sapphire substrate; and providing an n-electrode on the surface of the multi-layer structure. The p-electrode is couple to the metal plating layer or the metal plating layer itself is acting as the p-electrode.
[0020] Implementations of the above aspect may include one or more of the following. The metal plating layer can be formed by electro or electroless chemical plating. The metal plating layer can also be formed using electroless chemical plating and by protecting the sapphire substrate with a polyimide layer. The sapphire substrate can be removed using laser lift-off (LLO) technique. The multilayer epitaxial layer can have a reflective metal layer coupled to the metal plating layer; a passivation layer coupled to the reflective metal layer; a p-GaN layer coupled to the passivation layer; a n-GaN layer coupled to the MQW layer; an n-electrode coupled to the n-GaN layer; and the metal plating layer is a p-electrode or having a p-electrode coupled to the metal plating layer. In another aspect, a vertical device structure for a light-emitting device(LED) can be fabricated by forming a multi-layer epitaxial structure over a sapphire substrate, wherein the multi-layer epitaxial structure comprises an multi-quantum well (MQW) active layer; coating a metal layer above the multi-layer epitaxial structure; removing the sapphire substrate; and providing an n-electrode on the surface of the multi-layer structure and the metal layer is a p-electrode or having a p-electrode coupled to the metal layer .
[0021] The metal layer can be single or multi-layered. In case that the metal layer is a multi-layer, a plurality of metal layers with different composition can be formed and the layers could be deposited using different techniques. In embodiment, the thickest layer is deposited using electro or electroless chemical deposition
[0022] In one embodiment, Ag/Pt or Ag/Pd or Ag/Cr is used as a mirror layer, Ni is used as a barrier for Gold as a seed layer for copper plating which is used as the bulk substrate. The mirror layer (Ag, Al, Ti, Cr, Pt for example) is deposited and then a barrier layer such as TiN, TaN, TiWN, TiW stuffed with Oxygen is formed above the mirror layer before electro or electroless chemical deposition of a metal such as Ni or Cu. For electrochemical deposition of copper, a seed layer is deposited using CVD, MOCVD, PVD, ALD, or evaporation process with Au, Cu or Ni, among others.
[0023] In yet another aspect, a vertical LED includes a multilayer epitaxial layer formed above a temporary substrate; a metal plating layer formed above the multilayer epitaxial layer, before depositing the metal layer using electro chemical or electroless chemical deposition techniques, an optional step for a seed conductive layer is employed (for example Copper, Nickel, tungsten seed layers deposited first using evaporation, sputtering or CVD, MOCVD before ECD of Copper, Nickel), wherein the temporary substrate is removed using laser-lift-off after forming the metal plating layer.
[0024] In one embodiment, Ag/Pt or Ag/Pd or Ag/Cr is used as a mirror layer, Ni is used as a barrier for Gold as a seed layer for copper plating which is used as the bulk substrate. The mirror layer (Ag, Al, Ti, Cr, Pt for example) is deposited and then a barrier layer such as TiN, TaN, TiWN, TiW stuffed with Oxygen is formed above the mirror layer before electro or electroless chemical deposition of a metal such as Ni or Cu. For electrochemical deposition of copper, a seed layer is deposited using CVD, MOCVD, PVD, ALD, or evaporation process with Au, Cu or Ni, among others.
[0025] In another aspect, a vertical light emitting diode includes a metal plating layer; a reflective metal layer coupled to the metal plating layer; a passivation layer coupled to the reflective metal layer; a p-GaN layer coupled to the passivation layer; a multi-quantum well (MQW) layer coupled to the p-GaN layer; a n-GaN layer coupled to the MQW layer; an n-electrode coupled to the n-GaN layer; and a p-electrode coupled to the metal plating layer.
[0026] In one embodiment, Ag/Pt or Ag/Pd or Ag/Cr is used as a mirror layer, Ni is used as a barrier for Gold as a seed layer for copper plating which is used as the bulk substrate. The mirror layer (Ag, Al, Ti, Cr, Pt for example) is deposited and then a barrier layer such as TiN, TaN, TiWN, TiW stuffed with Oxygen is formed above the mirror layer before electro or electroless chemical deposition of a metal such as Ni or Cu. For electrochemical deposition of copper, a seed layer is deposited using CVD, MOCVD, PVD, ALD, or evaporation process with Au, Cu or Ni, among others.
[0027] Advantage of the invention may include one or more of the following. No wafer bonding or glueing is used and the complex and lengthy and one at a time wafer bonding/glueing process is replaced by a less complex deposition process for example physical vapor deposition (PVD), chemical vapor deposition (CVD), plasma enhanced CVD (PECVD), evaporation, ion beam deposition, electro chemical deposition, electroless chemical deposition, plasma spray, or ink jet deposition. No semi-transparent contact is needed for the n-electrode since n-GaN conductivity is good, and as a result, more light output can be emitted from the LED device. Further, since only one electrode is needed on each side of the device, the LED electrode obstructs less light. Additionally, current can spread out uniformly from n-electrode to p-electrode, thus increasing LED performance. Moreover, the metal substrate can dissipate more heat than the sapphire substrate, so more current can be used to drive the LED. The resulting LED can replace the conventional LED at a smaller size. For the same LED size, the light output from vertical LED is significantly higher than the conventional LED for the same drive current.
BRIEF DESCRIPTION OF THE DRAWINGS
[0028] To better understand the other features, technical concepts and objects of the present invention, one may clearly read the description of the following preferred embodiments and the accompanying drawings, in which:
[0029] FIG. 1 shows a prior art conventional LED.
[0030] FIG. 2 shows a prior art vertical LED.
[0031] FIGS. 3-8 show operations in an exemplary process to fabricate a vertical LED.
DESCRIPTION
[0032] In reading the detailed description, the accompanying drawings may be referenced at the same time and considered as part of the detailed description.
[0033] Referring to FIGS. 3 to 8 , a manufacturing method for vertical LEDs is illustrated therein. In the description, the reference numerals given for the inventive device structure will be also used in the recitation of the steps of the inventive manufacturing method.
[0034] The process described below is for one embodiment with InGaN LEDs initially grown on sapphire. Electro or Electroless Chemical plating is then used to deposit a thick contact for electrical and thermal conduction for the resulting LED device. Electro or Electroless Chemical plating is used in lieu of wafer bonding. The process can be applied to any optoelectronic device where bonding was used to attach the epilayer to a new host substrate for improvement of optical, electrical and thermal properties.
[0035] Turning now to the diagrams, FIG. 3 shows a multi-layer epitaxial structure of an exemplary InGaN LED on a carrier 40 , which can be a sapphire substrate in one embodiment. The multi-layer epitaxial structure formed above the sapphire substrate 40 includes an n-GaN based layer 42 , an MQW active layer 44 and a contact layer 46 . The n-GaN based layer 42 having a thickness of about 4 microns, for example.
[0036] The MQW active layer 44 can be an InGaN/GaN (or AlGaN/GaN) MQW active layer. Once an electrical current is passed between the n-GaN based layer 42 and the contact=layer 46 , the MQW active layer 44 may be excited and thus generates a light. The produced light can have a wavelength between 250 nm to 600 nm. The p-layer can be a p + -GaN based layer, such as a p + -GaN, a p + -InGaN or a p + -AlInGaN layer and the thickness thereof may be between 0.01-0.5 microns.
[0037] Next, as shown in FIG. 4 , a mesa definition process is performed and p-type contacts 48 are formed above the contact layer 46 . The contacts 48 above the multi layer epitaxial structure can be Indium Tin Oxide (ITO), Ag, Al, Cr, Ni, Au, Pt, Pd, Ti, Ta, TiN, TaN, Mo, W, a refractory metal, or a metal alloy, or a composite of these materials (for example Ni/Au), among others. In addition, direct reflected Ag deposition as a metal contact could be also formed. In FIG. 4 , individual LED devices are formed following mesa definition. Ion coupled plasma etching is used to etch GaN into separate devices.
[0038] Next, as shown in FIG. 5 , a passivation layer 50 is deposited and reflective metal deposition is performed to form a reflective metal 52 such as Al, Ag, Ni, Pt and Cr, among others, in a window etched into the passivation layer 50 to allow the reflective metal 52 to contact layer 46 . The passivation layer 50 is non-conductive. The reflective metal 52 forms a mirror surface.
[0039] FIG. 6 shows that a thin metal layer or a multi-metal layer 53 (Cr, Pt, Pt/Au, Cr/Au, Ni/Au, Ti/Au, TaN/Au among others) is deposited over the structure to serve as a barrier/seed layer for the electro/electroless chemical plating process. However the depositing operation is not needed if an electroless process, sputtering or magneto-sputtering process is used in lieu of electroplating. A metal substrate layer 60 is deposited thereon.
[0040] Turning now to FIG. 7 , the multi-layer epitaxial structure is coated with a metal plating layer 60 using techniques such as electro and electroless chemical plating. With electroless chemical plating, the sapphire substrate 40 is protected using a polyimide layer or a coating that can be easily removed without damaging the sapphire or the electroless plated metal of a relatively thick metal such as Ni or Cu, among others.
[0041] Next, the sapphire substrate 40 is removed. In one embodiment shown in FIG. 8 , a laser lift-off (LLO) operation is applied to the sapphire substrate 40 . Sapphire substrate removal using laser lift-off is known, reference U.S. Pat. No. 6,071,795 to Cheung et al., entitled, “Separation of Thin Films From Transparent Substrates By Selective Optical Processing,” issued on Jun. 6, 2000, and Kelly et al. “Optical process for liftoff of group III-nitride films”, Physica Status Solidi (a) vol. 159, 1997, pp. R3-R4). Furthermore, highly advantageous methods of fabricating GaN semiconductor layers on sapphire (or other insulating and/or hard) substrates are taught in U.S. patent application Ser. No. 10/118,317 entitled “A Method of Fabricating Vertical Devices Using a Metal Support Film” and filed on Apr. 9, 2002 by Myung Cheol Yoo, and in U.S. patent application Ser. No. 10/118,316 entitled “Method of Fabricating Vertical Structure” and filed on Apr. 9, 2002 by Lee et al. Additionally, a method of etching GaN and sapphire (and other materials) is taught in U.S. patent application Ser. No. 10/118,318 entitled “A Method to Improve Light Output of GaN-Based Light Emitting Diodes” and filed on Apr. 9, 2002 by Yeom et al., all of which are hereby incorporated by reference as if fully set forth herein. In other embodiments, the sapphire substrate is removed by wet or dry etching, or chemical mechanical polishing
[0042] As shown in FIG. 8 , an n-type electrode/bond pad 70 is patterned on the top of n-GaN layer 42 to complete the vertical LED. In one embodiment, bond pad 70 such as Ni/Cr (Ni is in contact with n-GaN) can be deposited using CVD, PVP or ebeam evaporation; The bond pad 70 is formed by wet or dry etch with a masking layer or using lift-off techniques with a negative masking layer (negative masking layer presents where one does not want to have the materials)
[0043] The thin metal layer or film 53 is provided as a seeding material purpose of the metal plating layer 60 . The thin metal film 53 may be the same or different material with the metal plating layer 60 as long as the metal plating layer 60 may be plated on top of the film 53 using electro chemical deposition or electroless chemical deposition.
[0044] While the invention has been described by way of examples and in terms of preferred embodiments, it is to be understood that the invention is not limited thereto. On the contrary, it is intended to cover various modifications and similar arrangements and procedures, and the scope of the appended claims therefore should be accorded the broadest interpretation so as to encompass all such modifications and similar arrangements and procedures.
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Systems and methods for fabricating a light emitting diode include forming a multilayer epitaxial structure above a carrier substrate; depositing at least one metal layer above the multilayer epitaxial structure; removing the carrier substrate.
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CROSS REFERENCE
[0001] The present application is a Continuation under 35 U.S.C. §120 of U.S. patent application Ser. No. 10/601,328, entitled Adjustable Cleat, filed on Jun. 20, 2003, which in-turn claims priority under 35 U.S.C. § 119(e) to United States Provisional Patent Ser. No. 60/390,552, entitled: Adjustable Cleat, filed on Jun. 21, 2002, both of which are hereby incorporated by reference in their entirety.
FIELD OF THE INVENTION
[0002] The present invention relates to the field of power tools and particularly to a method and an apparatus for adjustable workpiece positioning.
BACKGROUND OF THE INVENTION
[0003] Accurate, repeatable workpiece positioning is critical to the overall level of craftsmanship for woodworkers. In some instances, an imprecise cut may require additional sanding which is time consuming. For certain tasks, such as cutting a beveled miter joint, an imprecise cut may effect the appearance of the finished product or require the user to re-cut the workpiece. Often woodworkers will conduct test cuts to ensure a correct fit or “work-up” to their final cut. These techniques are time consuming and may diminish user satisfaction. For example, positioning a piece of trim molding at the proper angle with respect to the miter saw fence for cutting may be difficult or time consuming, especially for a novice user. Additionally, another drawback to current positioning mechanisms is the difficulty in set-up and removal after use.
[0004] For example, a woodworker may use a C-clamp to position a piece of trim to a miter saw's fence. Thus, the user must retrieve the clamp, and subsequently remove the clamp after use. In another example, a positioning device such as a clamp is mounted integral to the power tool. Once again the user must remove the device should they desire to cut a large piece of wood or when additional deck space is required. Current positioning mechanisms for power tools fail to provide ease of use.
[0005] Workpiece positioning systems often are cumbersome. For example, even if the built-in clamp provides enough room for the desired workpiece the clamp often is in the user's way, such as by protruding into the operator area or the like. Positioning mechanisms when removed often take up space or require the user to place the device in a remote portion of the work space so as not to interfere with the desired task. Current integral securing mechanisms are cumbersome when in use or removed and thus does not meet user demands.
[0006] Another problem with integral positioning mechanisms is the inability to retrofit with existing power tools. For example, current positioning mechanisms are typically designed for a specific tool or for a specific manufacturer, thus a retrofit is often not possible.
[0007] Therefore, it would be desirable to provide an unobtrusive workpiece positioning apparatus capable of securing a workpiece while providing ease of use.
SUMMARY OF THE INVENTION
[0008] Accordingly, the present invention is directed to an apparatus and method for providing workpiece positioning for power tools such as miter saws, drill presses, mortise machines and the like. As will be appreciated the present invention allows for correct workpiece positioning while permitting easy unobtrusive storage.
[0009] The apparatus of the present invention includes an adjustable positioning device, such as a threaded rod. The adjustable positioning device may be mounted in a housing or power tool work deck. The positioning device is disposed in a housing recess, such that the apparatus does not interfere with positioning a workpiece.
[0010] Adjustably connected to the positioning device is a retention member. A retention member provides a cleat or stop for retaining a workpiece in a desired position. The retention member may pivot to achieve an extended orientation, such as beyond an external surface of the housing and a retracted orientation substantially contained within the housing recess.
[0011] A securing member is connected to the retention member. Securing members include, deformable tabs, spring biased devices such as tabs, buttons and the like for securing the retaining member in a desired orientation.
[0012] It is to be understood that both the forgoing general description and the following detailed description are exemplary and explanatory only and are not restrictive of the invention as claimed. The accompanying drawings, which are incorporated in and constitute a part of the specification, illustrate an embodiment of the invention and together with the general description, serve to explain the principles of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] The numerous advantages of the present invention may be better understood by those skilled in the art by reference to the accompanying figures in which:
[0014] FIG. 1 is an isometric view of an apparatus for providing workpiece positioning with a retention member;
[0015] FIG. 2A is a perspective view of an apparatus for providing workpiece positioning, including a retention member orientated in an extended orientation;
[0016] FIG. 2B is a perspective view of an apparatus for providing workpiece positioning, including a retention member orientated in a retracted orientation;
[0017] FIG. 3 is an exploded view of an apparatus for providing workpiece positioning including a threaded rod and a threaded segmented retention member;
[0018] FIG. 4 is a perspective view of an apparatus for providing workpiece positioning for miter sawing;
[0019] FIG. 5 is a flow diagram illustrating a method for providing workpiece positioning;
[0020] FIG. 6A is an perspective view of a retention member in an extended orientation with pivotal securing tabs; and
[0021] FIG. 6B is an exploded view of a retention member with pivotal securing tabs.
DETAILED DESCRIPTION OF THE INVENTION
[0022] Referring to FIG. 1 an apparatus 100 for providing workpiece positioning is shown. The apparatus 100 in the present embodiment includes a housing 102 . The housing 102 permits connection to a power tool deck, such as the deck of a miter saw, a drill press deck and the like. The housing 102 includes a recess 114 generally for mounting apparatus components. Those of ordinary skill in the art will appreciate that the present invention may be incorporated in a power tool deck and the like without departing from the spirit of the present invention. For example, a drill press may include a work deck containing the apparatus of the present invention.
[0023] An attachment device is connected to the housing for securing the apparatus 100 to, for example a miter saw deck. Attachment devices permit connecting the apparatus 100 to a work surface, thus providing additional work area while permitting secure workpiece positioning. In the present embodiment, a pair of slots 112 for receiving a screw, a pin, or the like is shown. In further embodiments, other attachment devices are contemplated, such as to permit retrofitting the present invention to a particular tool.
[0024] An adjustable positioning device is connected to the housing and is disposed generally in the housing recess 114 . A threaded rod 104 is utilized as an adjustable positioning device in the present embodiment. In further embodiments, other positioning devices are utilized, such as an advancing bar and friction stop, and the like for providing adjustable positioning. In another example the retention member is fitted with a friction lock so as to allow the retention member to adjust along a bar, a rod and the like for allowing movement along an axis. The threaded rod 104 is mounted to the housing 102 , substantially within the housing recess 114 and may be actuated by a user manipulating a knob 110 secured to an end of the rod 104 .
[0025] A retaining member 106 is adjustably connected to the threaded rod 104 . As may be seen in FIG. 4 the retaining member 406 provides a stop or cleat for retaining a workpiece, such as a piece of molding 420 in a desired position. Referring now to FIGS. 2A and 2B the retaining member 206 is adjustably connected to the threaded rod 204 . The retention member 206 is capable of pivotally obtaining an extended orientation, beyond an exterior surface of housing 202 and a retracted orientation (see FIG. 2B ), wherein the retention member 206 is contained substantially within housing recess 214 .
[0026] Referring to FIG. 1 a securing mechanism is connected to a retention member 106 . A pair of deformable tabs 108 are utilized to secure the retention member 106 in at least one of a extended orientation and a retracted orientation. Deformable tabs 108 are capable of being squeezed inwardly towards the retention member 106 and upon release springing outwardly from the retention member 106 . The deformable tabs 108 in the present example are capable of extending outwardly from the retention member 106 to engage an outer surface of a housing 104 . The tabs 108 in the present embodiment may be formed of metal plastic, such as nylon and the like. Alternatively, when a user desires to dispose the retention member 106 in a retracted orientation the deformable tabs 108 may be disengaged and pivoted, along with the retention member 106 generally into the housing recess 114 . See generally FIG. 2B . As may be best seen in FIG. 3 , a retention member 306 includes relief areas to permit the tabs 308 to move inwardly to allow for pivoting the retention member 306 into a housing recess.
[0027] Referring to FIGS. 6A and 6B in a further embodiment a securing mechanism is a pair of pivotal tabs 608 . The pivotal tabs are mounted generally in a recess formed in the retention member 606 . As desired a user may pivot the tab 608 outwardly to engage the housing or deck. The pivotal tabs 608 may be formed of metal, plastic such as nylon and the like. Further, the retention member 606 may include an aperture extending between the side recesses with a spring therein for extending the pivotal tabs generally outward. Those of skill in the art will appreciate that various biasing means may be employed to bias the pivotal tabs outward. For instance a coiled spring 622 may be utilized to bias the tab 608 .
[0028] Referring to FIG. 3 , a retention member 306 includes an aperture 316 with segmented threads for engaging threads included on a threaded rod 304 , thus the retention member 306 is capable of pivotally attaining an extended orientation and a retracted orientation. In further embodiments, a retention member pivots about a cylindrical pivot containing an aperture there through with threads for engaging corresponding threads on a threaded rod. In the further embodiment, the retention member main body includes a jacket for at least partially surrounding the cylindrical pivot, thus permitting extending and retracting the retention member. Those of ordinary skill in the art will appreciate that other systems for providing pivoting capability may be implemented without departing from the spirit of the present invention.
[0029] In further embodiments securing mechanisms include spring biased devices, such as tabs, buttons and the like for securing a retention member in a desired orientation. Those of ordinary skill in the art will appreciate that many securing mechanisms may be employed to secure the retention member in a desired orientation, without departing from the spirit and scope of the present invention.
[0030] Referring now to FIG. 5 a method 500 for providing retractable workpiece positioning for power tools is discussed. Initially, a workpiece such as a piece of trim or the like is positioned on the power tool deck 502 . The retention member is orientated into an extended orientation 504 so that the retention member provides a cleat or stop for positioning the workpiece. Extending the retention member 504 may include orientating the retention member such that securing mechanism, for example deformable tabs engage an exterior surface of an associated housing or tool deck. The retention member's position is adjusted 506 by directing the adjustable positioning device to the desired position. The desired task is performed 508 , such as cutting a trim piece. Optionally, the retention member may be retracted 510 for example by actuating the securing mechanism and pivoting the retention member below the work surface.
[0031] Further, it is understood that the specific order or hierarchy of steps in the methods disclosed are examples of exemplary approaches. Based upon design preferences, it is understood that the specific order or hierarchy of steps in the method can be rearranged while remaining within the scope of the present invention. The accompanying method claims present elements of the various steps in a sample order, and are not meant to be limited to the specific order or hierarchy presented.
[0032] It is believed that the retractable positioning apparatus of the present invention and many of its attendant advantages will be understood by the forgoing description. It is also believed that it will be apparent that various changes may be made in the form, construction and arrangement of the components thereof without departing from the scope and spirit of the invention or without sacrificing all of its material advantages. The form herein before described being merely an explanatory embodiment thereof. It is the intention of the following claims to encompass and include such changes.
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The present invention is directed to a method and system for providing workpiece positioning for power tools, such as miter saws. The apparatus includes an adjustable positioning device such as a threaded rod. A retention member is connected to the adjustable positioning device. The retention member is capable of pivotally obtaining an extended orientation and a retracted orientation to alternatively contact a workpiece disposed on the power tool deck and to retract into an unobtrusive storage orientation. The apparatus of the present invention allows for proper positioning while permitting ease of use and storage.
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CROSS REFERENCE TO RELATED APPLICATIONS
This application is a continuation-in-part of U.S. patent application Ser. No. 08/079,933, filed Jul. 30, 1993, now abandoned.
BACKGROUND OF THE INVENTION
The present invention relates to hand railing and more particularly to safety railing used at construction sites.
According to current Occupational Safety and Health Administration (OSHA) standards, safety railing must be provided at construction sites on elevated areas whether planar, concrete pads for instance, or inclined, e.g. stair case. OSHA standards require that the height of the railing for stair cases be at a minimum of approximately 36 inches from the surface. On planar surfaces the requirement is that the height be a minimum of approximately 42 inches.
Safety railing is necessary at construction sites to prevent accidents. Such railing prevents personnel from falling and also keeps loose tools and debris from being inadvertently kicked over the edge of an elevated surface. Examples of such safety railings are disclosed in the following U.S. Patents.
______________________________________Inventor(s) U.S. Pat. No.______________________________________Mocny et al. 3,756,568Marsh 3,881,698De Barbieri 3,848,854Arteau et al. 4,830,341Weinert 3,776,521______________________________________
Mocny disclose a removable guard rail stanchion having a two part post and two brackets for securing horizontal railings to the post. The brackets are fixed in position by bolts so that the openings of the brackets are facing upwardly for reception of the railings. The post and bracket assembly of Mocny are designed for use on a floor or concrete slab, but not on a stair case.
Marsh, De Barbieri, Arteau, and Weinert disclose examples of safety railings, but none are disclosed as being usable on a stair case, or on a combination of surfaces such as a stair case and landing.
SUMMARY OF THE INVENTION
The present invention is directed to temporary safety railing used at construction sites and various other areas where railing is required for limited lengths of time to prevent injury to workers. The railing includes a post constructed with a plurality of brackets that are pivotable about an axis that is perpendicular to the length of the post. Because the brackets are pivotable, the post can be used on a stair case or ramp to accommodate the angle of inclination of the stairs or ramp. Since all stairs or ramps do not have the same angle of inclination it is necessary for the bracket to be freely pivotable about an axis to meet the needs of different situations.
It is therefore an object of the present invention to provide a bracket that is pivotable about an axis to accommodate various inclinations of stairs or ramps. Further, it is an object of the present invention to provide post that can be utilized to transition from a stair case or ramp to a planar surface. Another object of the invention is to provide a bracket that can be pivoted from an inclined position when used on stairs to a horizontal position when used on a landing.
For a more through discussion of the present invention and its advantages, reference should be made to the attached drawings and detailed description of the preferred embodiment that follows.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side view illustrating a preferred embodiment of the present invention;
FIG. 2 illustrates a side view of a bracket of the present invention detached from the post;
FIG. 3 illustrates the post of FIG. 1 attached to a stair case and also used on a landing;
FIG. 4 illustrates a close up view of the post of FIG. 1, utilized to accommodate a stair case and a landing; and
FIG. 5 illustrates an alternative embodiment of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to FIG. 1, Post 10 is illustrated. Post 10 includes a vertically extending post member 12 made preferable of a hollow tubular steel post. Post member 12 is generally made from stock construction materials. Post member 12 is square in cross-section and includes on one face a pair of brackets 14 attached to post member 12 by screws or bolts 16. Bolts 16 operate as pivot axes for brackets 14, the operation of which will be explain more fully below.
Brackets 18 are attached to post member 12 by screws or bolts 20. Brackets 18 are similar in construction to brackets 14. Brackets 18 are attached to a face of post member 12 that is perpendicular to the face that contains brackets 14. Bolts 20 function similar to bolts 16, and thus allow brackets 18 to be pivotably attached to post member 12.
FIG. 2 is a close up view of the bracket 14. Bracket 14 includes a vertical member 22 having an aperture 24 at one end for reception of bolt 16. An L-shaped base member 26 is attached to the other end of vertical member 22 and includes a flanged portion 28 that extends upwardly towards the end of vertical member 22 that contains aperture 24. Positioned between the ends of vertical member 22 is an intermediate member 30. An aperture 32 is formed in intermediate member 30 for reception of a fastener, such as a nail or a screw, for attaching a railing to the bracket and hence to the post. The railing fits within space 34 defined by L-shaped base member 26 and intermediate member 30. Flange 28 is used to prevent the railing from moving away from the bracket before a fastener can be installed in aperture 32.
As shown in FIG. 1, a base 36 is attached to the bottom of post member 12. Positioned above base 36 is an attachment member 38 having an aperture similar to aperture 32. Base member 36 and attachment member 38 define a space 40 for reception of a toe board which is held in position by a fastener passing through the aperture in attachment member 38. In the landing situation, FIG. 3, a toe board 50 is included to prevent debris from being inadvertently kicked off the landing.
In FIG. 3, the post and bracket assembly are positioned on a staircase 42 having a number of treads 44. Railing members 46 are attached to brackets 14 on the staircase in angled position such that railing members 46 allow a person to grasp the railing while climbing staircase 42. At the top of staircase 42 is a landing 52 and a plurality of posts 12. The versatility of the invention allows the post to be used on a landing, as well as a staircase. However, the brackets 18 must be pivoted into the up position so that the railing members are at the proper height. It should be noted that brackets 14 can be used on the landing instead of the staircase and brackets 18 can be used on the staircase.
FIG. 4 illustrates the use of post 12 having four brackets 14 and 18. Brackets 14 are shown as being pivoted into an angled position to provide for staircase railing members 46. Brackets 18 are pivoted into the upper position to provide for horizontal railing members 48. Brackets 14 and 18 are shown with bracket 14 being positioned below bracket 18. However, the position of the brackets could be reversed. The post and bracket assembly thus allows for corners to be turned while using only a single post, and for the walking surfaces at the corner to be at different angles of inclination relative to each other.
An alternative embodiment of the invention is illustrated in FIG. 5. FIG. 5 shows a bracket 54 attached to post 12 by bolt 62 and nut 64 type fastener. Nut 64 is welded to post 12 to prevent turning, but nut 64 may be free rotatable relative to post 12 and tightened on bolt 62 by a wrench or similar tool. Bracket 54 is U-shaped with a pair of legs 56 and a base portion 58. Horizontal railing member 48 is positioned in the U-shaped bracket 54 with the railing 48 positioned on base portion 58. As bolt 62 or nut 64 is tightened, the legs 56 of U-shaped bracket 54 are brought together to clamp the horizontal railing in position. A tongue 60 is provided on one of the bracket legs to prevent over stressing of the bracket by stopping inward movement of legs 56. Additionally, tongue 60 also acts to support railing member 48 when the bracket is pivoted into the upper position, as shown in phantom in FIG. 5.
The present invention has been described above with regards to several preferred embodiments of the invention. Various modifications and equivalents will be apparent to persons of ordinary skill in the art. The invention desired to be secured by Letters Patent is defined by the claims that follow.
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The present invention relates to hand railing that complies with Occupational Safety and Health Administration (OSHA) regulations for hand railing on both landings and stair cases. The hand railing utilizes a post which can be converted by angling a bracket to accommodate various stair case inclinations. The brackets can also be pivoted into an upper position when used in a landing position to create horizontal railing supports.
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BACKGROUND OF THE INVENTION
The invention relates to a dryer for a textile fabric web, and to a method of drying a textile fabric web.
For drying textile fabric webs, dryers are known in which one or more drums are arranged in a housing. A textile fabric web is supplied to the dryer via an opening in the dryer compartment, the textile fabric web being wrapped around a large part of the periphery of the drum and then being discharged from the dryer compartment again. Usually, fresh air is also supplied via this opening, the fresh air being heated inside the dryer compartment and mixed with the circulating air in order to be able to absorb the greatest possible amount of moisture. While the fabric web is wrapped around the drum, the mixture of circulating air and fresh air flows through the fabric web, absorbs at least some of the moisture of the fibre web and is discharged again via the interior chamber of the drum. A volumetric sub-flow from this volumetric flow is discharged as exhaust air, the moist exhaust air being discharged via channels above the drums, which as a result of the rotating drums requires elaborate and expensive sealing and a high level of maintenance. In order to avoid the suction effect from the environment of the dryer, there have subsequently been added to the dryer compartment supply lines or channels for fresh air which can be coupled, for example, to a heat exchanger for heating the fresh air.
A previously described dryer is disclosed in DE 10 2009 016 019 A1. In dryers of this design the circulation of the fresh air takes place at right angles to the withdrawal direction of the moist air, that is to say at right angles to the drum axis, with the result that the air circulation inside the dryer compartment is disrupted. A further disadvantage is that, for reasons of lack of available space, modification is often complicated and it is not possible to couple the fresh air channel to a heat exchanger. Since the dryers are positioned very close together in a row of different processing units that treat the textile fabric web in succession, there is often no room subsequently to install a channel for fresh air between the units.
DE 1 729 499 A1 discloses a perforated drum dryer having intermediate compartments arranged at the end faces of the perforated drums. Fresh air is fed to these intermediate compartments and mixed with the drying air. Some of the used exhaust air is discharged via the fan chamber. The intermediate compartment is fixedly integrated in the dryer housing and cannot be retrofitted with a heat exchanger.
SUMMARY OF THE INVENTION
The problem of the invention is to provide a dryer for a textile fabric web in which guidance of exhaust air and fresh air can be effected in a way that is advantageous in terms of flow behaviour, wherein it is also possible, if required, subsequently to install a heat exchanger.
In accordance with the technical teaching of the invention, the dryer for a textile fabric web comprises a dryer chamber having at least one drum which is arranged in the dryer chamber and around at least part of which the fabric web is wrapped, wherein heated drying air flows through the fabric web and is discharged via an interior chamber of the drum, wherein the dryer has a separate additional compartment via which fresh air is supplied and exhaust air is discharged.
The features of the invention make it possible for the connections for the fresh air and the exhaust air to be arranged on the dryer in such a way that the air flow for the drying process in the dryer chamber 2 and inside the drum is not disrupted. As a result of the additional compartment, the drying air expands, so that its flow speed on leaving the drum is several times lower. Withdrawal of the exhaust air from the additional compartment has only an extremely small effect on the drying process. Furthermore, as a result of the reduced pressure in the additional compartment the fresh air can be freely drawn in and conducted into the heating and fan chamber.
In an advantageous arrangement of the invention, the additional compartment is arranged between an end face of the dryer and a heating and fan chamber. For energy-related reasons, the removal of the exhaust air from the drying air in the additional compartment is at its most optimum, because here the drying air has its lowest energy level. Accordingly, the loss of energy through the exhaust air is at its lowest. This results in a solution which is advantageous to the drying process in terms of flow behaviour and which can be arranged between the units arranged one after the other, irrespective of the available space. In addition, the clearly defined interface allows the use of a heat recovery means under optimum conditions. The energy balance can therewith be further improved.
Inside the additional compartment, the fresh air mixes with the drying air. Due to the fact that means for heating the fresh air and drying air are arranged inside the heating and fan chamber, the heated drying air has to travel only a short way to the dryer chamber, during which it does not cool down.
An energy-efficient improvement is achieved by constructing the means in the form of heat exchangers, the heat exchangers utilising the exhaust air from the additional compartment to heat the fresh air and drying air.
The fresh air and exhaust air flowing in the additional compartment can be separated from one another by means for division into segments. The additional compartment can likewise be divided into segments analogously to the number of drums. The individual segments can be separated from one another by walls in order that there is no exchange of air between the segments. By division into partly permeable segments, for example in the form of perforated plates, the exhaust air or the fresh air can be distributed to a plurality of segments. This can likewise be effected by means of guide plates.
The arrangement of the fans at the heating and fan chamber for circulating the drying air has the advantage that the dryer can be of relatively compact construction.
Inside the additional compartment there are arranged connections through which the drying air can be extracted from the dryer chamber or from the drums by means of the fans. The connections can in turn be constructed in a way that is advantageous in terms of flow behaviour in order to minimise flow losses.
The method according to the invention for drying a textile fabric web is characterised by the steps of heating drying air and conducting it into a dryer chamber in which a fabric web is wrapped around at least part of at least one drum arranged inside the dryer chamber, wherein the heated drying air flows through the fabric web and is discharged via an interior chamber of the drum, wherein fresh air is supplied to a separate additional compartment and exhaust air is discharged via the additional compartment.
The additional compartment has no effect on the flow conditions inside the dryer chamber and the drum. On entering the additional compartment the exhaust air undergoes a significant reduction in flow speed, whereas as a result of the reduced pressure in the additional compartment the fresh air can be freely drawn in and conducted into the heating and fan chamber.
A circulation system is created in which a mass sub-flow of exhaust air is withdrawn from the drying air and a mass sub-flow of fresh air is supplied thereto, the exhaust air being removed from the drying air at the location at which the drying air has its lowest energy level, namely in the additional compartment.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention is described in greater detail below with reference to a possible exemplary embodiment which is shown diagrammatically in the drawings, wherein
FIG. 1 : is a diagrammatic front view of a serial dryer;
FIG. 2 : is a view corresponding to FIG. 1 with a heat recovery means;
FIG. 3 : is a side view in section of the serial dryer according to the invention;
FIG. 4 : is a rear view of the serial dryer with the heating and fan chamber removed.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 shows a dryer 1 in the form of a serial dryer. Inside a dryer chamber 2 , three drums 3 a , 3 b , 3 c are arranged one after the other and with their axes 4 a , 4 b , 4 c in a row. A fabric web 5 is guided into the dryer chamber 2 via an inlet 6 . By means of a guide roller 7 , the fabric web 5 is guided first under the first drum 3 a , then above the second drum 3 b and subsequently under the third drum 3 c . By means of the guide roller 8 , the fabric web 5 is guided out of the dryer chamber 2 through an outlet 9 . Heated drying air flows through the fabric web 5 during its passage through the dryer chamber 2 , the drying air absorbing the moisture of the fabric web 5 and being extracted via the interior of the drums 3 a to 3 c.
According to the invention, there is arranged at the dryer chamber 2 an additional compartment 10 into which the channel 12 for the fresh air 11 and the channel 14 for the exhaust air 13 open.
The additional compartment 10 is constructed so as to be fully distinct and separate from the dryer chamber 2 . The heating and fan chamber 22 is arranged at the additional compartment 10 . The dryer chamber 2 is connected to the heating and fan chamber 22 by air channels above and below the drums 3 a - 3 c . The additional compartment 10 is connected to the dryer chamber 2 via the end-face openings of the drums 3 a - 3 c.
In FIG. 2 , the dryer 1 from FIG. 1 is equipped with an optional heat recovery means. The same parts have been given the same reference numerals. On the housing of the fan 15 adjoining the channel 14 there is positioned a further channel 16 which causes the exhaust air 13 to flow through a further heat exchanger 17 and discharges it via a channel 18 . The heat exchanger 17 is simultaneously connected to the channel 12 , so that before the fresh air 11 flows into the additional compartment 10 it has already undergone an increase in temperature as a result of the heat exchanger 17 . This optional retrofittable solution enables the thermal efficiency of the dryer 1 to be further increased.
Unlike the prior art, here the fresh air 11 does not flow directly into the dryer 1 , but first flows into the additional compartment 10 in which further heating takes place as a result of mixing with the drying air after it has flowed through the fabric web 5 . In previous designs, such intermixing of the fresh air with the drying air took place before flowing through the fabric web 5 , thus influencing the temperature of the drying air before the fabric web 5 . Utilising the difference in temperature between exhaust air 13 and fresh air 11 is sufficient to bring about a further increase in the thermal efficiency of the dryer 1 .
FIG. 3 shows a lateral section through a dryer 1 . The fans 19 a - 19 c , which extract the moisture-saturated drying air from the drums 3 a - 3 c , are flange-mounted on the heating and fan chamber 22 and are connected to the additional compartment 10 via connections 20 a - 20 c or adapters. On the opposite side, the drums 3 a - 3 d are likewise connected to the additional compartment 10 via connections. The drying air flows out of the drums 3 a - 3 c into the additional compartment 10 and from the additional compartment 10 via the connections 20 a - 20 c into the extraction cross-section of the respective fans 19 a - 19 c . In the region of the drum 3 a , the exhaust air is removed from the additional compartment 10 via a channel 14 which is arranged at the end face (see FIGS. 1 and 2 ). At the end of the channel 14 , a fan 15 provides the necessary air flow. The fresh air supply is effected in the region of the drum 3 c via the additional compartment 10 to which the channel 12 is connected at the end face.
As a result of the additional compartment 10 , the drying air expands, so that its flow speed on leaving the drum 3 a , 3 b , 3 c is several times lower. Furthermore, as a result of the reduced pressure in the additional compartment 10 , the fresh air 11 can be freely drawn in and thereby supplied to the heating and fan chamber 22 with drying air.
Inside the heating and fan chamber 22 there can be arranged heating elements 21 in the form of heat exchangers, one or more gas heaters or electric heaters, which heat the discharged drying air 11 , including the fresh air, to the drying temperature.
FIG. 4 shows a rear view of the dryer 1 , in which the heating and fan chamber 22 have been omitted. Here it is possible to see the openings of the drums 3 a - 3 c via which the drums 3 a - 3 c are connected to the additional compartment 10 by means of connections. The fresh air 11 is introduced into the additional compartment 10 via a channel 12 . Inside the additional compartment 10 there are arranged separating plates 23 in the form of perforated plates which divide the additional compartment 10 into segments, so that it is possible to influence the distribution of the fresh air to the individual fans 19 a - 19 c . It is likewise possible, by means of guide plates (not shown), to influence the distribution of the fresh air inside the additional compartment 10 , for example to separate it from the exhaust air.
From the additional compartment 10 , by means of the fans 19 a - 19 c the mixture of fresh air and drying air flows into the heating and fan chamber 22 . This is a circulation system from which a mass sub-flow in the form of exhaust air is withdrawn and to which a mass sub-flow in the form of fresh air is supplied.
The heating and fan chamber 22 is arranged as a separate compartment in the region of the rear end face of the dryer 1 , the additional compartment 10 being arranged in between. The drive means of the fans 19 a , 19 b , 19 c are arranged outside the heating and fan chamber 22 , the fan impellers are located inside. Each fan 19 a , 19 b , 19 c is associated with a drum 3 a , 3 b , 3 c . The fans 19 a , 19 b , 19 c are connected via connections 20 a - 20 b or adapters to the additional compartment 10 and the latter is connected, likewise via connections or adapters, to the drums 3 a , 3 b , 3 c.
REFERENCE NUMERALS
1 dryer
2 dryer chamber
3 a, b, c drum
4 a, b, c axis
5 fabric web
6 inlet
7 guide roller
8 guide roller
9 outlet
10 additional compartment
11 fresh air
12 channel
13 exhaust air
14 channel
15 fan
16 channel
17 heat exchanger
18 channel
19 a, b, c fan
20 a, b, c connection
21 heating element
22 heating and fan chamber
23 separating plate
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The invention relates to a dryer for a textile fabric web, comprising a dryer chamber ( 2 ) and having at least one drum ( 3 a ) which is arranged in the dryer chamber ( 2 ) and around at least part of which the fabric web ( 5 ) is wrapped, wherein heated drying air flows through the fabric web ( 5 ) and is discharged via an interior chamber of the drum ( 3 a ), characterized in that the dryer ( 1 ) has a separate additional compartment ( 10 ) via which fresh air ( 11 ) is supplied and exhaust air ( 13 ) is discharged.
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CROSS REFERENCE TO RELATED APPLICATION
This application is a division of application Ser. No. 09/994,506 filed on Nov. 27, 2001 now abandoned.
ORIGIN OF THE INVENTION
This invention was made by employees of the United States Government and may be manufactured and used by or for the Government for governmental purposes without the payment of any royalties.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a welding method and apparatus, and in particular, to a welding method and apparatus which separately plasticizes or melts the surfaces to be joined followed by a subsequent weld matrix mixing process.
2. Background of the Invention
Welding processes can be classified into one of two categories, fusion welding and solid state welding. Fusion welding involves melting material to be welded and includes such processes as MIG, TIG and VPPA welding. Solid state welding joins materials without a melting step and include the processes of friction stir and inertia welding. Fusion weld processes typically result in a dendritic type weld microstructure exhibiting inferior mechanical and structural properties. Such inferior material properties are generally seen in metals subsequent to melting. Conversely, solid state weld processes result in a non-dendritic grain structure exhibiting properties superior to those produced with fusion welding processes.
Both fusion welding and solid state welding have respective limitations. As indicted above, fusion welding compromises the microstructure of the material and thus lessens the physical properties and characteristics of the material. Solid state welding such as inertia welding is limited to rounded structures such as pipe or rod structures.
A recent advancement was made when friction stir welding became available for the solid state welding of materials. Reference is made, for example, to U.S. Pat. Nos. 6,168,067 B1 to Waldron et al. and 6,053,391 to Heideman et al. With the use of friction stir welding, a solid state weld could, for the first time, be provided in applications requiring longitudinal welds, ranging from several inches to an unlimited length. As described in more detail in the aforementioned patents, the friction stir weld process uses a rotating shoulder/pin configuration. The shoulder produces frictional heat to bring the material into a plasticized state and forges the welded material with extremely large forces. To accomplish the necessary large forces for the forging effect, a very robust backing anvil is required for support. The welding pin spins inside the workpiece at the same rate as the shoulder. The dependent motion of the welding pin and shoulder restricts the speed of the welding process.
BRIEF SUMMARY OF THE INVENTION
In accordance with the present invention, a welding method and apparatus are provided for forming a weld joint. The method separates the welding process into separate and discrete steps, one providing heating of first and second abutting elements to be welded to form an interface therebetween of plasticized or melted material and a further matrix transformation step for processing the interface material after cooling to a plasticized phase. The heating process may use any conventional fusion welding process such as laser or plasma torch which initially melts the interface material. Subsequently, a separate grinding/extrusion element recrystallizes possible, undesirable dendritic matrix structures while the interface material is in the plasticized temperature state. Advantageously, separate heating sources can be used to plasticize or melt the respective first and second elements forming the weld joint independently. The independent melting feature provides for the joining of dissimilar metals such as copper and aluminum or stainless steel and titanium.
According to one aspect of the present invention, a welding method is provided for joining a workpiece comprising first and second elements in abutting relation along facing surfaces. The method includes heating the first and second element to plasticize or melt the elements at least at the facing surfaces so as to form an interface therebetween of material in a melted state. If the interface material is heated to a melted state, then the interface material is allowed to cool from the melted state to a plasticized state. Next, the interface material is mixed while in the plasticized state.
According to another aspect of the present invention, an apparatus is provided for forming a weld joint in a workpiece between first and second elements in abutting relation along facing surfaces. The apparatus includes a heating device for plasticizing or melting the first and second elements at least at the facing surfaces so as to form interface therebetween of material in a plasticized or melted state respectively. A mixing tool mixes the interface material when in a plasticized state.
Preferably, the apparatus further comprises forming means for exerting force on the elements to control forming thereof. Advantageously, the temperature of the forming means is controlled to provide heating or cooling of the elements.
In one preferred embodiment, the forming means comprises at least one forging plate. Advantageously, the apparatus further comprises control means for sensing the force exerted by the forging plate and for controlling feeding of the first and second elements based thereon. Preferably, the control means controls one of feed rate and travel speed to control feeding of the elements.
In another preferred embodiment, the forming means comprises a plurality of rollers. In this embodiment, the apparatus preferably further comprises control means for controlling the force exerted by the rollers and for controlling feeding of the first and second elements based thereon. Preferably, the control means controls one of feed rate and travel speed to control feeding of said elements.
Preferably, the apparatus further comprises control means for sensing energy input to the heating elements and for controlling one of feed rate or travel speed of the elements based thereon.
In a preferred implementation, the apparatus further comprises a pre-weld tack welding means located upstream of the mixing tool for tack welding the two elements together prior to mixing by the mixing tool.
Advantageously, the mixing tool is retractable so as to enable complete withdrawal thereof from the first and second elements.
Preferably, the apparatus further comprises containment forging plates for containing the first and second elements during mixing by the mixing tool.
According to yet another aspect of the present invention, a joined workpiece has a first element comprising a first metal material having a first plasticized temperature and a second element comprising a second metal material having a second plasticized temperature different from the first plasticized temperature. A longitudinal weld joint is formed between the first metal element and the second metal element. The weld joint has a recrystallized fine grain matrix.
A key feature of the present invention relates to the separation of a heating process to form a plasticized or melted interface material between two elements to be joined and a mixing process for mixing the interface material together while in a plasticized state. This separation enables each of the respective materials being joined to be heated and plasticized/melted independently. One advantage of this feature is that the invention enables dissimilar metals to be welded together which previously were not able to be joined, i.e., metals such as copper/aluminum, stainless steel/copper, and stainless steel/titanium. For example, a copper/aluminum weld can be achieved by providing independent temperature control as each alloy is brought up to its respective plasticized/melted state. A further advantage of separating the heating process from the weld matrix transformation process is that comparatively high workpiece travel rates during welding can be obtained. In this regard, the present invention is not inherently limited with respective to travel rates as is the case with a friction stir welding process.
An additional important feature of the present invention is that the invention provides matrix transformation of the interface material from dendritic to fine grained material. More specifically, the present invention provides for transforming grain structure from the dendritic-type weld microstructure formed as a result of the heating process to a recrystallized fine, non-dendritic grain structure. As a consequence, the resulting final grain structure is typically that of a solid state weld material and thus exhibits excellent mechanical material properties.
A further advantage of the present invention is that the invention can provide long longitudinal welds of varying material thickness.
Yet another advantage of the present invention is that the invention can be used to form longitudinal welds exhibiting a solid state weld material property without a backing anvil such as is required in stir welding.
Further features and advantages of the present invention will be set forth in, or apparent from, the detailed description of preferred embodiments thereof which follows.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a longitudinal cross sectional view of a welding apparatus according to a preferred embodiment of the present invention;
FIG. 2 is an end elevational view of the welding apparatus of FIG. 1 ; and
FIG. 3 is a longitudinal cross sectional view, partially broken away, of a further embodiment of the invention.
DETAILED DESCRIPTION OF THE INVENTION
Referring now to FIG. 1 and FIG. 2 , there is shown a welding device, generally denoted 10 , which is adapted to join together first and second elements 14 and 16 of a workpiece 12 . The welding device 10 includes heating elements 18 and 20 .
Heating element 18 provides sufficient heat to plasticize or melt the material of element 14 and may comprise such conventional heating devices as lasers or plasma torches or other suitable devices known in the art. Similarly, heating element 20 provides sufficient heat to plasticize or melt the material of element 16 . As a result, together, heating elements 18 and 20 transform a portion of the solid material of the workpiece 12 , viz., respective abutting portions of elements 14 , 16 to form an interface 34 (see FIG. 2 ) in a plasticized or melted phase, between the elements 14 , 16 .
The heating elements 18 and 20 can be controlled individually for providing heating at a desired separate temperature. For example, where elements 14 and 16 comprise dissimilar materials having different melting points, heating element 18 , preferably provides heating at the plasticizing or melting temperature of element 14 whereas heating element 20 preferably provides heating at the plasticizing or melting temperature of the material of element 16 .
The material of element 14 and element 16 may be formed of the same or different metal material. For example, element 14 may be copper or stainless steel, and element 16 may be aluminum, copper or titanium, so that when joined together, elements 14 and 16 form a workpiece 12 formed of copper/aluminum, or stainless steel/copper or stainless steel/titanium or another combination.
In an alternative embodiment, additional heating elements (not shown) of the type of heating elements 18 , 20 may be disposed adjacent to the heating elements 18 , 20 and/or below workpiece 12 , to assist in plasticizing/melting the abutting portions of the elements 14 , 16 . An optional tack weld heater 22 , disposed upstream, relative to the heaters 18 and 20 , provides sufficient heat to form an initial tack weld between the elements 14 , 16 .
As shown in FIG. 2 , a pair of clamping elements 36 , 38 apply a respective force on the workpiece 12 towards each other. The force applied maintains elements 14 and 16 in proper alignment with each other.
A mixing tool such as toothed grinding/extruding member 40 is positioned in the path of the interface 34 between elements 14 and 16 and rotates to mix the material of interface 34 when in a plasticized phase. The grinding/extruding member 40 allows plasticized metal of the interface 34 to flow and extrude through the individual teeth, which are indicated at 40 a , of member 40 . The teeth 40 a are angled, thus forcing the plasticized material to flow downwards or upwards depending upon the angle of the teeth 40 a . As a result, the grinding/extruding member 40 will recrystallize the dendritic matrix structure which may have been formed in the material of interface 34 as a result of the melting process. Grinding/extruding member 40 is retractable as indicated by arrow A and can be completely withdrawn from the workpiece formed by elements 14 and 16 .
A plurality of force actuators 42 are located downstream of grinding member 40 and used to apply a force on a pair of forging plates 44 , 46 which are located on opposite sides of workpiece 12 . Force actuators 42 include rollers 42 a which engage and bear against plates 44 , 46 . In an alternative embodiment, plates 44 , 46 can be eliminated and rollers 42 a used to bear directly on the workpiece, i.e., either rollers, or plates, can be used separately to exert the required force to further form the workpiece. Further, the rollers or forging plates can be heated or cooled (e.g., by water cooling) to control the temperature of the workpiece material.
As indicated in the drawings, the heating elements described above and the grinding member 40 extend through forging plates 44 , 46 so as to permit them to perform their respective functions. The force exerted upon the forging plates 44 , 46 by the force actuators 42 is constant for a workpiece having constant thickness, while a variable force is exerted on the forging plates 44 , 46 by the actuators 42 to accommodate workpieces of a tapered thickness.
A pair of motion control devices indicated separately at 48 control the amount of movement of the forging plates 44 , 46 . The motion control devices 48 each may comprise a LVDT, a laser device or other suitable motion control device known in the art.
During the operation of the welding device 10 , the workpiece 12 is inserted into an entrance 50 of a housing 52 which houses the various elements and units described above. As set forth hereinbefore, the heating elements 18 , 20 provide the desired heating of elements 14 and 16 , to form the plasticized or melted phase interface 34 .
During the heating process, undesirable dendritic-type Weld microstructures may be introduced into the matrix of the interface material 34 . Advantageously, the heating process takes place in an inert environment. For example, nitrogen gas can be pumped into housing 52 to provide an inert environment, thereby reducing or eliminating the oxidation of the material of workpiece 12 during the heating process.
The workpiece 12 proceeds through the welding device 10 in a direction denoted by arrow 54 . The material of interface 34 is in a plasticized or melted state while in the area generally indicated by reference numeral 56 . As the workpiece 12 proceeds along direction 54 , if the interface was heated to a melted state, the melted interface is transformed into a plasticized state. The transition point where the melted interface becomes plasticized is denoted by a dashed line 58 . The workpiece 12 transitions from the melted state to the plasticized state due to the absence of applied heat. Alternatively, if the material of interface 34 is merely heated to a plasticized state, the interface material remains in a plasticized state as the workpiece proceeds past dashed line 58 .
The workpiece 12 then proceeds to the location the grinding/extruding member 40 . The interface 34 , now in the plasticized state, is processed by the grinding/extruding teeth 40 a of member 40 and the plasticized material of interface 34 flows and is extruded through the teeth 40 a . As indicated above, this processing of the interface material dramatically recrystallizes the grain structure, thus producing a fine grained weld matrix when fully cooled.
As shown in the drawings, member 40 includes a central mixing portion comprising the grinding/extruding teeth 40 a extending along the length thereof and support portions directly connected to the central portion. Considering, for example, the upper support portion, this portion extends through an opening in forging plate 44 which terminates at a major surface at plate 44 , as illustrated.
The workpiece 12 next travels past the grinding/extruding member 40 to a location where the hot interface material, which is still in a plasticized state, is forged under pressure by the forging plates 44 , 46 .
In an advantageous embodiment, a controller or control system 60 is employed which controls the feed rate or travel speed of the workpiece formed by elements 14 and 16 by controlling the force exerted by either the forging plates 44 , 46 and/or rollers 42 a (whether used separately or in combination, as indicated schematically by the dashed lines in FIG. 1 ). Although a separate controller 60 is shown, the control system could directly control force actuators 42 .
Alternatively, or in addition, a control system or controller 62 is also provided which controls the material feed rate or travel speed by monitoring or sensing the energy input to the heating elements 18 and 20 , or as illustrated, the energy input to a further heating element 64 . The overall control system could also include a sensor 66 for sensing feed rate or travel speed and supplying a corresponding input signal to controller 62 .
Referring to FIG. 3 , in accordance with a further important feature of the invention, separate containment forging plates 68 and 70 are provided closely adjacent to or, in one embodiment, in surrounding relation to, the mixing tool 40 so as to contain the heated material of elements 14 , 16 during rotation of the grinding teeth 40 a of mixing tool 40 .
It should be apparent to those of ordinary skill that the present device and process offers important advantages over previous welding methods. These advantages include the ability to weld together dissimilar alloys which previously could not be joined due to differences in their respective melted and plasticized phase temperatures. Further, the separation of the plasticizing/melting process and interface matrix transformation process results in significantly enhanced welding speeds.
Although the invention has been described above in relation to preferred embodiments thereof, it will be understood by those skilled in the art that variations and modifications can be effected in these preferred embodiments without departing from the scope and spirit of the invention.
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A welding method and apparatus are provided for forming a weld joint between first and second elements of a workpiece. The method includes heating the first and second elements to form an interface of material in a plasticized or melted state interface between the elements. The interface material is then allowed to cool to a plasticized state if previously in a melted state. The interface material, while in the plasticized state, is then mixed, for example, using a grinding/extruding process, to remove any dendritic-type weld microstructures introduced into the interface material during the heating process.
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RELATED APPLICATION(S)
This application is a divisional of U.S. patent application Ser. No. 11/445,025 (now U.S. Pat. No. 7,844,722), filed Jun. 1, 2006, which is a divisional of U.S. patent application Ser. No. 10/142,731 (now U.S. Pat. No. 7,085,845), filed on May 8, 2002, which claims the benefit of U.S. Provisional Application No. 60/289,768, filed on May 9, 2001 and U.S. Provisional Application No. 60/289,772, filed on May 9, 2001. The entire teachings of the above applications are incorporated herein by reference.
BACKGROUND OF THE INVENTION
This invention relates generally to tracking user preferences, and more specifically to acquiring user preference data relating to media recordings.
SUMMARY OF THE INVENTION
Collecting user preference information related to a playing media recording is accomplished by gathering descriptive information related to the playing media recording from a media player program presenting the playing media recording and determining if tags are embedded in the media recording and gathering descriptive information related to the playing media recording from the tags embedded in the playing media recording, if the tags exist. Further, the invention determines if a table of contents exists on the media recording, or gathers table of contents information for a collection containing the playing media recording by identifying the collection using a technique that concatenates track lengths to generate an identifier. Next, the invention method and apparatus assembles the descriptive information into a media recording information packet and sends the media recording information packet to a server computer, resulting in a collection of user preference information related to the playing media recording.
In an embodiment of the present invention the descriptive information comprises a user identifier; at least one of: a name of the playing media recording, a name of a collection containing the playing media recording, a name of an artist performing the playing media recording; and a sequence number of the playing media recording within the collection. Additionally, tags can be MPEG Layer 3 tags.
The present invention records a subject user's audio listening history by receiving a media recording information packet from a client computer and cross-referencing the media recording information packet with a media recording description database and returning a unique serial number for the entry in the media recording description database. A user identifier is recorded together with the unique serial number into a user preference database, such that the user preference database provides the subject user's media listening history.
Cross-referencing may include identifying an exact match in the media recording description database for a non-empty element in the media recording information packet. Cross-referencing may also include identifying a match in the media recording description database using a fuzzy-logic algorithm and determining the match based upon a highest probability computed. Cross-referencing may further include identifying an associated domain-specific element in the media recording description database for a non-empty element in the media recording information packet. Cross-referencing may further include identifying a metaphone-associated element in the media recording description database for a non-empty element in the media recording information packet.
The present invention identifies users listed in the user preference database as those who listen to the same media recording, as identified by the same unique serial number, as that listened to by the subject user. Identified users can be sent a message. The identified users can be sent a message while they are listening to the same media recording. User's preferences are inferred based upon analysis of the user's audio listening history or directly solicited from the a user. Preference may include: specific media recording, collection, artist or genre. Users with similar preferences based upon analyzing the user preference database can be identified and introduced to each other.
A user community can be created by transferring information from the user preference database into an automated collaborative filtering engine to generate a list of users having similar preferences. Lists of preferred media recordings of the user community can be created. Identified users can message each other based upon being identified as having a particular user preference for the media recording.
BRIEF DESCRIPTION OF THE DRAWINGS
The foregoing and other objects, features and advantages of the invention will be apparent from the following more particular description of preferred embodiments of the invention, as illustrated in the accompanying drawings in which like reference characters refer to the same parts throughout the different views. The drawings are not necessarily to scale, emphasis instead being placed upon illustrating the principles of the invention.
FIG. 1 illustrates a digital music network on which an embodiment of the present invention is implemented.
FIG. 2 is a diagram of the internal structure of a node on the digital music network of FIG. 1 configured according to an embodiment of the present invention.
FIG. 3 is a flow diagram showing client-side processing and server-side processing in the embodiment of FIG. 1 and FIG. 2 .
DETAILED DESCRIPTION OF THE INVENTION
A description of preferred embodiments of the invention follows. In support of creating an online music community service, the present invention utilizes a unique combination of technologies. The first aspect of the present invention is implemented as client program, made available to the general public free of charge for downloading from the Internet. The second aspect is a database system and server program. The downloadable program products running on behalf of many different users simultaneously, and the server software, work together to create an online experience for users which identifies fans of the same and similar music to each other creating a dynamic collection of online communities.
FIG. 1 is a diagram of a computer system on which an embodiment of the present invention is implemented. Client computer 50 provides processing, storage, and input/output devices playing recorded media. The client computers 50 can also be linked through a digital music network 100 to other computing devices, including other client computers 50 and server computers 60 . The digital music network 100 can be part of the Internet, a worldwide collection of computers, networks and gateways that currently use the TCP/IP suite of protocols to communicate with one another. The Internet provides a backbone of high-speed data communication lines between major nodes or host computers, consisting of thousands of commercial, government, educational, and other computer networks, that route data and messages. In one embodiment of the present invention, user preference information is collected and recorded in a user preferences database 130 . Additionally, audio listening history is collected and recorded in an audio recordings description database 120 .
FIG. 2 is a diagram of the internal structure of a computer (e.g., 50 , 60 ) in the computer system of FIG. 1 . Each computer contains a system bus 200 , where a bus is a set of hardware lines used for data transfer among the components of a computer. A bus 200 is essentially a shared conduit that connects different elements of a computer system (e.g., processor, disk storage, memory, input/output ports, network ports, etc.) that enables the transfer of information between the elements. Attached to system bus 200 is an I/O device interface 202 for connecting various input and output devices (e.g., displays, printers, speakers, etc.) to the computer. A network interface 206 allows the computer to connect to various other devices attached to a network (e.g., network 70 ). A memory 208 provides volatile storage for computer software instructions (e.g., media preference software 250 ) and data structures (e.g., user preferences database 130 and audio recordings description database 120 ) used to implement an embodiment of the present invention. Disk storage 210 provides non-volatile storage for computer software instructions (e.g., media preference software 250 ) and data structures (e.g., user preferences database 130 and audio recordings description database 120 ) used to implement an embodiment of the present invention. A central processor unit 204 is also attached to the system bus 200 and provides for the execution of computer instructions (e.g., media preference software 250 ), thus allowing for the collection of user preference information and audio listening history information to provide a digital music network.
The present invention client program, when installed on a multimedia-capable personal computer, interacts with the server software and data base system to provide the following functions as illustrated in FIG. 3 .
Plug-in technology is used to sense activity. The present invention client program uses plug-in technology to sense activity in a wide variety of other program products from various sources called Media Players. These Media Player program products are used to play recorded sounds—usually prerecorded music—through the PC's speakers to the user of the PC. Media Players include Winamp, the Real Player, the Microsoft Media Player, Lycos's Sonique player, and others. Each distinct player has activity sensed by a software component compatible both with the present invention client program and the particular player. Those skilled in the art of programming for personal computers with Microsoft Windows will appreciate that it is straightforward to develop and test such software components, known as dynamic link libraries or DLLs. Those skilled in the art will also appreciate that some media player vendors publish specifications for the development of plug-in components, and others do not. The plug-in component for each player senses when a new piece of music, sound file, or track begins to play, and relays whatever information it can determine about the music, track, or sound file being played. Specifically when players play music, they ordinarily display information about that music, such as the name of the artist, the name of the album, the name of the track or song, and the number of the track or song being played. They may also display the year the music was published, a genre (such as “funk,” “classical,” or “jazz”). In one embodiment the present invention client program is implemented as a plugin that gathers and relays whichever of these displayed items of data it has available (Step 31 , FIG. 3 ).
CD Table of Contents sensing is a component of the present invention. It senses the insertion of a compact disc into the compact disc player of a personal computer. Using the retrieval techniques, it retrieves descriptive information for the CD as a whole, and for the individual tracks of the CD, from a server on the Internet. It then transmits that information (Step 31 of FIG. 3 is illustrative).
Audio file information retrieval is performed when a plugin (as described above) detects that a media player is playing an audio file, commonly a file in MPEG Layer 3 sound format (commonly known as MP3). A component 31 of the present invention client program looks for and retrieves descriptive information from within the sound file. The means for storing and retrieving such information from sound files is well known in the art. Those skilled in the art will appreciate that this sought and/or retrieved information may be present or absent, may be complete or incomplete, and may be correct, misspelled, or just plain wrong.
Assembly of information from various sources is performed within the present invention client program. A collection of (i) descriptive information about each track, coming from various sources including the player, (ii) CD contents data, (iii) type of media (compact disc, audio file, etc) and (iv) audio file tag data is assembled. Each item in the collection of information may be absent, present, or present from multiple sources. It may be complete or incomplete, and it may be wrong or right.
Collected information from the present invention client program product is relayed to the present invention server as shown at 32 in FIG. 3 . The information, in the state gathered by the present invention client program as shown at 31 in FIG. 3 , is transmitted to a present invention server program containing a server software package and database system. The server software makes a record of this information as shown at 35 in FIG. 3 .
A lookup of a particular song is performed on the server software package using the collected information to locate the best match—the most likely song—within a database 120 structured as a sequence of records for each published compact disc or other music collection and another sequence of records for each published track (song) within the published compact discs or other music collections. The sequences of records for published compact discs are furnished by a commercial data service, and are augmented by sequences of records for other collections not made available on compact disc. The present invention server program assigns a unique serial number to each compact disc or collection, and another unique serial number to each track or song occurring within any collection. The lookup process retrieves, if possible, the unique CD serial number and the unique track serial number of the best possible matching item.
The search process 37 first looks for an exact match in each data item (performer, collection title, track title, track number, and publication year) between the data base and the information about the particular song relayed from the present invention client program. Finding a match, it yields the appropriate serial numbers. If an exact match is not found, the database system and server software performs a match using commonly known text-search techniques such as preposition removal, case-insensitive matching and number spelling. Those skilled in the art will appreciate that such techniques must be used in domain-specific ways, correctly to handle cases such as, for example, the rock-and-roll act called “The The”. Finding a match in this way, the software yields appropriate serial numbers. If a match is still not found, the database system 120 and server software attempts to perform a match using sound-alike techniques as taught (e.g., metaphone and double metaphone search algorithms). As persons skilled in the art will appreciate, such techniques ordinarily yield multiple ambiguous matches, so the server software applies rules to determine the probability of correctness of each match, and chooses the most probable. If a particular match has a distinguished high probability, appropriate serial numbers are yielded. If the data base server matches tracks that appear on multiple compact discs or other collections, and cannot differentiate which compact disc or other collection the track might appear on, it removes the ambiguity by choosing the compact disc or collection with the earliest date of publication. Notice that if one user of the present invention plays a sound file of “Every Breath You Take” by The Police, and another plays the same song on a compact disc, the present invention database and server software will yield the same serial number for both cases.
The present invention records current user behavior. The searched serial numbers, and the data items gathered by the present invention server software 37 , are stored in a data base system 130 in a form suitable for the applications described in the following paragraphs.
The present invention server software searches, using the serial numbers, for all the users of the present invention client program at a point in time playing the same music, and using Web information display techniques, identifies 39 and introduces 34 these users to one another, so that they may interact with each other. This is possible because all the users' program products report to a centrally organized server on the Internet.
The unique matched serial number codes are used to detect behavioral actions and infer user preferences 38 . If a user plays a particular track on a compact disc frequently, it is valid to infer that the user likes the music on that track. If a user plays a particular sound file frequently, it is also valid to infer that the user likes the music on that sound file. However, it is also valid to infer that the user who possesses a physical compact disc or other media has a somewhat stronger preference for the music. The present invention server software system (at 38 ) keeps track of repeated behavior by each user, and infers users preferences from that repeated behavior.
The present invention also solicits explicit user preferences. Using World-wide-web information systems techniques well known to those skilled in the art, such as HTML forms, the present invention client program solicits its users explicitly to identify their preferences for particular music tracks. The present invention server product 38 then records those explicit preferences, discontinuing the use of inferred preferences for the particular tracks the user gave ratings for.
The present invention server software searches, using the serial numbers, for all the users who have rated the same music highly, and using Web information display techniques, identifies 39 and introduces 34 these users to one another, so that they may interact with each other.
The present invention server software at 40 a,b forms clusters of users with similar tastes using Automated Collaborative Filtering (ACF) technology furnished by NetPerceptions, Inc., and based on user preferences both inferred from user behavior and explicit. Automated Collaborative Filtering, in general, uses accumulated rating data furnished by a large number users to determine which users are likely to have similar tastes. For example, many different users might each rate a hundred or so movies from a collection of several thousand, specifying how much they like each movie on a scale of 1 (hate it) to 5 (love it). Once this ratings data is in place, such a typical ACF application would present each user with recommendations of other movies they might like, based on a comparison of that user's preferences with other users.
The present invention exploits this ACF technology in an innovative fashion by entering ratings into the system 40 a,b based on the behavioral detection of user preference 38 . This sort of innovation is important because it ensures that larger numbers of ratings, and more accurate ratings, go into the ACF system 40 a,b , which yields more accurate and interesting recommendations.
The present invention server software is capable of delivering messages—termed “Alerts” within a system employing the present invention—to end users. These messages are delivered to a user after the present invention server software records current user behavior. The choice of which users should see each message is based upon the users' individual behavior. The timing of message delivery is based upon the user's behavior in real time—that is, the message can be delivered precisely when the user chooses to listen to particular music.
A music identification subsystem of the present invention determines which piece of music is being played by a particular client. A piece of music is characterized by particular artist, title, and song. The present invention client program reports what's playing by passing in several different kinds of parameters. The client program gleans these parameters from the music player and/or the MP3 file tags. In some cases, these parameters may be complete, well-formed, and spelled correctly. In other cases the parameters may be misspelled or incomplete. In the worst case the player may report back nothing but a CD hash code or a MP3 file pathname.
The music identification subsystem takes the parameters, looks them up, and reports back the three identifying items: the artist, title and song being played. The identifiers point out the particular artist, title, or work uniquely within the set of known artists, titles, and works.
The music identification subsystem can be implemented in a way which allows several web server instances running on each of several machines to access it. It is acceptable to implement the system in a replicated fashion, with the same code running on each of several servers, or as a single server.
In one embodiment, the web servers are Apache 1.3.12, with mod_php 4.0.0 built in. They run on Linux (Red Hat 6.1/Intel, kernel 2.2.12, glibc 2.1). The development environment is that provided with Red Hat 6.1. Additionally, an Oracle 8i data base version 8.1.5 is employed, running on Solaris 2.7/SPARC. The music ID subsystem could be implemented to run on Linux servers, with a view towards porting it easily to run on Solaris.
Each piece of music is identified with three codes: the artist, title, and song being played. The first identifier is the title of the CD from which the music comes. The present invention uses a code (the domain DOT_TITLE in our data dictionary) to identify this title. Most of our DOT_TITLE unique identifiers are the same as Muze Numbers (MUZENBR, see www.muze.com), although DOT_TITLE codes are assigned to titles which aren't cataloged by Muze. Another identifier is the artist responsible for the CD. In the case of most popular music, the CD is identified by a single artist. The present invention uses a code (the domain DOT_ARTIST in our data dictionary) to uniquely identify an artist. Most of the values of this code relate directly to the PERFORMER2 column from MUZENBR. Again, the present invention can assign codes for artists which aren't cataloged by Muze. The third identifier is the song (or track) for the music. The present invention uses a code (the domain DOT_TRACK in our data dictionary) to identify the individual track being played. This identifier is constructed by appending the disc number and track number to the appropriate DOT_TITLE code for the track. The DOT_TRACK uniquely identifies a song being played. In the Muze database, each title has an associated genre and sub-genre.
The information sent from the player may be ambiguous in the way it identifies tracks. Our music identification system does its best to find a “canonical” track for each batch of track information sent from a client. For example, consider these three sets of track information:
Grateful Dead “Sugar Magnolia” American Beauty, 1969 4:10 Grateful Dead “Sugar Magnolia (Jam) Orpheum” bootleg, 1994, 34:20 Greateful Dead “Sugar Megnolia” American Beauty
The first of these is a track from a CD. The second is a recording made by a fan at a concert and put on an MP3 file. No record exists in the title database for this specific recording. In this case, the closest match for the second item in the data base may be the first item. The third item illustrates misspellings. In this case the closest match is also the first item.
The DOT_TRACK, DOT_TITLE, and DOT_ARTIST codes must remain permanently unchanging, as they will be used to record user activity and preferences throughout the system. The MUZENBRs from which the DOT_TITLE and DOT_TRACK codes are derived are permanently assigned. The present invention assigns the DOT_ARTIST code, and must make it a permanent assignment.
The music ID system, externally, offers three basic functions, and some extra service functions. The basic functions are these:
song=lookup_song (<input parameters>)
title=lookup_title (<input parameters>)
artist=lookup_artist (<input parameters>)
Because of the structure of the reference database used, the song's identity (the DOT_TRACK) also identifies the artist and title. However, for our purposes it makes sense sometimes to look up just the title or just the artist. In some situations, including misspellings in the input parameters, we may be able to search the data base 120 in a way which would yield an ambiguous result if we were searching for the precise song, but an unambiguous result if we were searching just for the artist who created the song.
Each of these basic functions starts with the input parameters offered by the Present invention client. Each function matches those parameters to the music data base 120 and returns the single most likely choice of song, title, or artist. The music ID system also offers some simple service functions to navigate the artist/title/song hierarchy.
title=get_title_from_song (song)
artist=get_artist_from_song (song)
artist=get_artist_from_title (title)
Finally, the music ID system offers some simple service functions to retrieve genre information from the data base 120 . Genre information, both general and specific, is provided for each title in our data base.
genre=get_genre (song)
genre=get_genre (title)
The basic music identification process flow must take into consideration many situations while attempting to identify MP3 files. It is acknowledged that the identification may not always be perfect. The following is a description of a music identification process flow for identifying MP3 files according to an embodiment of the present invention.
Transmit the contents of the MP3 file's ID3 tag to the server, if an ID3 tag is available and populated with information. Most MP3 files have at least some information in the ID3 tag. This information is put there by the “ripper”—the program which created the MP3 file from the CD. In many cases the ripper fetched that information from the CDDB version 1 data base. In other cases the user of the ripper keyed in the information. ID3 tags are often lost or incomplete (e.g., Napster often truncates files, and the ID3 tags are at the ends of the files).
Transmit each MP3 file's path and file name. These are often named after the track, CD, and artist.
Match the incoming textual data to the MUZE track list data base using the multi-step search algorithm. This algorithm is fairly accurate at identifying the appropriate artist—a very important key to the operation of the system. It is also accurate at identifying the CD and track, but less so.
Display the appropriate information from the Muze database (and elsewhere) when the artist and CD are known.
The basic music identification process flow must take into consideration many situations while attempting to identify CDs. It is acknowledged that the identification may not always be perfect. The following is a description of a music identification process flow for identifying CDs files according to an embodiment of the present invention. Identifying CDs.
Compute two TOC hash codes including the Microsoft hash code and the open-source “XCMD” hash-code (the one used by CDDB version 1) from the CD's TOC. The present invention uses proprietary technology allowing it to do this without interfering with the CD player operation.
Retrieving information from CDDB version 1 based on the hash codes. This is an optional step, that may be substituted with other retrievals.
Transmit textual descriptive information if available within the player describing the track (similar to the above). This information may exist within the Microsoft-furnished CDPLAYER.INI file, or may be within some kind of play list within the player. This textual information can come either indirectly from CDDB, or can come from users indexing their own CD products.
Augment the track-list data base we propose to purchase from MUZE with a collection of freely-available TOC data on the internet. The TOC data we have assembled to date includes over 45,000 unique TOC hash codes. The quality of this freely available track list data may vary, but the cross-correlation between Microsoft CD player hash codes and Artist/Title/Track data is sufficient.
Ensure that the top 100 CDs are indexed correctly with the Microsoft hash code in our data base, by doing so manually.
Match the data coming in from the user with the Muze tracklist using purely textual techniques, if possible.
If there is a good match and there is an incoming TOC hash code there is no hash code in our data base, we put the incoming hash code into our data base, associating it with the Title identifier (derived from the MUZENBR).
If there is a good match and the hash code is different from what is stored in the database, we make an assumption of multiple TOC hash codes, and record an alternate hash code.
If the incoming data contains a hash code, but no useable textual data, it is looked up. If it matches something on file, the present invention matches the title being played. If it isn't on file, no match to that music is made. It is also possible for a hash code to match more than one title.
Display appropriate information from the Muze database (and elsewhere) when the artist and CD are known.
CD identification involves various methods. One is the sample data kit from MUZE.COM. Additionally, freely available CD tracklists from around the web (e.g., www.hizen.de/cdplayer/index.html). Muze offers a unique Muze number (MUZENBR) for each unique published CD. CDs which haven't been published (such as those created by independent artists and personal compilations written onto CD-R media) don't have MUZENBRs. Tracklists offer a Microsoft-define hash-code. Any particular published CD will have a single MUZENBR and possibly multiple different hash codes.
CDDB (originally the open-source XCMD project) uses a different hash code. These hash codes are derived from the table of contents of the CD. The CD table of contents consists of information describing the number of music tracks on the CD, the overall length of the music on the CD, and the length of each track (see www.disctron.ics.co.uk for further information). The impact of this method of computing hash codes is that two short CDs—CDs with a small number of tracks on them—are statistically much more likely to have identical tables of contents and therefore identical hash code values than longer CDs. CDs of any length can have this problem of TOC hash-code collision. Usually this TOC hash-code collision isn't due to imperfections in the hash function, but rather identity in the underlying TOCs.
The present invention provides performance benefits, including lookup performance. Assuming that a typical song is three minutes in length, for each 1000 users online, the music ID system will have to handle approximately 5.6 queries a second. Assuming 500,000 users, of which about 15% (75,000) will be active, this will require, if the active members are all listening at the same time, about 500 lookups per second (2 ms of processing per lookup). The system is designed for 1000 lookups per second, to give room for growth. Notice that the music lookup subsystem works from basically static reference data. This means it's possible to provide several parallel servers to perform this task.
Muze provides updated data weekly, and the present invention may add data from other sources. It must be possible to load the updated data into our operational lookup system in a convenient amount of processing wall-clock time (an hour or less), in a way which interrupts the lookup process for no more than a second or two.
These lookup algorithms assume that the taking of input data items and the mapping of each of them to a single particular track, title, and artist from within our predetermined set of tracks, titles, and artists. These algorithms have two closely related phases. The first phase is obtaining and preprocessing reference data (the MUZE tracklist, augmented with data from other sources) to build reference index tables. This phase can be performed in batch each time the reference data is updated. The second phase is taking information from clients and matching it to the reference data base, then ordering the match results by relevance. The heart of such lookup algorithms lies in the structure of the reference tables, and their representation of the reference data set. Incoming reference data has these fields (table and column from MUZE data).
Table and column Spelling Description ZTITLE.MUZENBR Title identification number (DOT_TITLE) ZTITLE.PERFORMER Authoritative Artist name, suitable for display ZTITLE.PERFORMER2 Authoritative Artist name (indexed to DOT_ARTIST) ZTITLE.TITLE Authoritative Title name ZTITLE.CAT3 Authoritative Major Genre ZTITLE.CAT4 Authoritative Sub Genre ZSONG.MUZENBR DOT_TITLE (join index to ZTITLE table) ZSONG.DISC Which disc in a multiple disc set ZSONG.TRK Which track on the disc ZSONG.SONG Authoritative Song title
The present invention provides information for CDs we add to the MUZE data base in a form similar to this, with a separate distinguishable set of MUZE numbers. The present invention also has incoming reference data from CDPLAYER.INI files we gather from around the net, and from the machines used, with MusicMatch Jukebox, to index new CDs.
hashcode Microsoft Hash code for CD artist Questionable Artist genre Accurate Genre title Questionable Title name song Questionable One entry for each song.
The first phase of the search takes this input data and builds reference tables. In one embodiment the form for the reference tables is:
String Table:
Key: Each distinct authoritative text string (title, song, artist), case folded to lower case, with frequently repeated words (a, the) and all punctuation removed. Value: a list of (DOT_ARTIST, DOT_TITLE, DOT_TRACK) triples, one entry for each item the key appears in.
Word-Triple Table:
Key: Each set of consecutive three words from the string table. Value: a list of (DOT_ARTIST, DOT TITLE, DOT_TRACK) triples, one entry for each item the key appears in.
Word Table:
Key: Each individual word from the string table. Value: a list of (DOT_ARTIST, DOT TITLE, DOT_TRACK) triples, one entry for each item the key appears in.
Metaphone-Triple Table:
Key: Metaphone keys for each set of consecutive three words from the string table. Value: a list of (DOT_ARTIST, DOT_TITLE, DOT_TRACK) triples, one entry for each item the key appears in.
Metaphone Word Table:
Key: Metaphone keys for individual word from the string table. Value: a list of (DOT_ARTIST, DOT_TITLE, DOT TRACK) triples, one entry for each item the key appears in.
Phase 2 of the lookup algorithm works as follows. In Step 1 , for each text string in the input data, look for matches in the string table. Retrieve the list of DOT_ARTIST, DOT TITLE, DOT_TRACK triples, and assign each item in the retrieved list a relatively high weight. The weight should be a constant times the number of words matched in the string. Step 2 , for each triplet of words in each distinct string in the input data, look for matches in the string table. Again, retrieve the list of DOT_ARTIST, DOT_TITLE, DOT_TRACK triples, and assign each item in the retrieved list a lower weight. Step 3 , for each word, look for matches in the word table. Assign a modest weight to each word. Step 4 , for each triplet of words (as in step 2 ), compute the metaphone keys and match to the metaphone-triple table. Assign a small weight to each matched item. Step 5 , for each individual word, compute the metaphone key and match it to the metaphone word table. Assign a very small weight to each matched item. Step 6 , order the matched items by total weight matched. If looking for artist, order the artists. If looking for title, order the titles, and if you're looking for track, order the tracks. The highest weight wins. Note that it's very important to do the ordering depending on what you're looking for. Step 7 , (optional) if two or more different items have a tie for top weight, get help from the user in disambiguating the results.
When constructing word triples, we include placeholders at the beginning and end of phrases (indicated by zzz in this specification).
“Love in an elevator” turns into:
zzz love in
love in an
in an elevator
an elevator zzz
“Aerosmith” turns into:
zzz aerosmith zzz
“The Boston Symphony Orchestra” turns into, after stripping the common word:
zzz boston symphony
boston symphony orchestra
symphony orchestra zzz
The following is an example CDPLAYER.INI entry:
[1081d72]
EntryType=1
artist=Jimmie's Chicken Shack
title=Bring Your Own Stereo
genre=rock
numtracks=13
0=Spiraling
1=Lazy Boy Dash
2=Do Right
3=String Of Pearls
4=Ooh
5=Let's Get Flat
6=Trash
7=Fill In The Blank
8=Face It
9=Silence Again
10=Pure
11 Waiting
12=30 Days
Each major record label currently spends as much as $100 million yearly on radio promotion and marketing. There are over 300 new songs being promoted to radio stations each week, but only 10% of these will ever see significant airtime. Thus a considerable amount of a record label's promotional budget is wasted on songs that will not be heard by listeners. Meanwhile, radio stations currently do some testing in order to figure which songs will perform best, but most of this testing is conducted via telephone outcall—by placing survey calls to fans.
DotClick tests individual songs over the Internet before their release, via alliances with radio station Web sites. This will dramatically improve record labels' efficiency in determining song-release strategies, and will improve the information radio station programmers use to determine what their listeners most want to hear. Individual radio station Web sites (collectively, the “Radio Station Group”) will distribute DotClick to their member bases, establishing an expanding network of users, many of whom are ready to listen to pre-release songs and provide feedback.
The benefits of testing with DotClick are clear: the DotClick technology, which uses both passively gathered and actively provided user preferences from a large population of users allows highly precise control over targeting. Because the DotClick service can control the testing audience via our powerful targeting technology, a record label can be sure the testers are fans of a certain artist or a certain music genre. DotClick's reporting mechanism is built-in and on-demand, so record labels receive timely, sortable reports that indicate how well a song performs before labels have to sink significant promotional dollars into that song.
The concert touring industry is a multi-billion-dollar-per-year business. Concert promoters spend up to $75,000 per concert, advertising on local radio, print and television for shows in amphitheatres, large arenas and stadiums. A single such ad typically costs $500 to $1,000, and also often requires a free ticket giveaway. Therefore large promoters like SFX and smaller promoters such as Universal Concerts, House Of Blues Concerts, Hard Rock Chains, Golden Voice and JAM are all accustomed to spending large amounts of money, using their promotional dollars on marketing channels that are off-line, and aren't nearly as targeted as DotClick's service.
DotClick's powerful tools allow concert promoters to identify fans in 460 different Designated Marketing Areas (DMAs) across the country, and reach them with concert information and enticements to purchase tickets. On an event-by-event and market-by-market basis, DotClick will deliver information and one-click-shopping for concert tickets to DotClick users who, based upon their listening profiles, would be interested in attending a given event/concert. This is a powerful concept: as a DotClick member plays an artist's music, they are told about a concert coming to their area. It's a focused and Efficient way to fill concert seats.
The Process. The Tour Marketing & Promotion program is sold to a promoter by DotClick (or by a DotClick-designated consultant) for $500 per event, quite a reasonable amount considering how much promoters currently pay for a single radio, print or TV spot. That promoter creates Alerts, along with links to Web sites where tickets to the event may be purchased, and then targets these Alerts using DotClick's behind-the-scenes geography and preferred-genre targeting mechanism. DotClick members receive these Alerts instantly when they've indicated that they're interested in the artist(s) in question, or, even more powerfully, the moment they play music by that artist(s).
The Radio Research & Testing program is sold to a record label by the Radio Station Group (or by a designated consultant). In concert with the Radio Station Group, DotClick arranges for the hosting of songs or song clips to be tested. Over the course of a one-week period, DotClick sends an Alert to the appropriate Digital Music Network members (i.e., those members that are fans of artists or music genres requested by the record label); this Alert contains a hyperlink to one or more of the songs or song clips. After listening to the songs, members are asked to “Play It or Slay It,” thereby contributing to ratings data DotClick collects.
Data is compiled into a report with full demographic breakdown; this report is available online, on-demand. The business of promoting new releases is extremely expensive. The cost to a record label of retail promotion programs can range from $25,000 for an end cap display at a national retailer to over $50,000 for an artist wall. Smaller programs include hundreds of dollars for a shelf marker and a few thousand dollars for listening stations. Considering the fact that there are at least 1,100 new records debuting at retail in any given month, record labels must spend a huge amount of money to get any attention for their releases.
In conjunction with large music retailers, DotClick will provide a targeted, lower cost alternative for record labels to promote their recorded music. Individual retail chains will distribute DotClick via their Web sites, establishing a network of their users who can be predicted to be especially receptive to receiving promotional offers from record labels to buy particular types music online. Because DotClick's system gathers detail on members' listening preferences due to our combination of gathering preferences both passively and actively, the DotClick service is uniquely capable of identifying interesting members when a newly released music product or music-related product will appeal to them.
The Retail Marketing & Promotion program is sold to record labels by an individual retailer's retail marketing and sales department. (Record labels may choose to run pre-release and/or post-release programs, depending on their needs.) Each retailer's online division subsequently coordinates the implementation of the program, with V.I.P. customer support from DotClick. The retailer's online division creates Alerts for that retailer's DotClick member base; these Alerts contain information about new releases, direct links to purchase that music from that retailer's Web site, and (optionally) links to streaming audio and music video clips.
While DotClick establishes its initial member base, some key Charter Affiliated Partners do not have to “pay for play” on the Digital Music Network. In other words, Charter Partners distribute a co-branded DotClick, the ability to send targeted Alerts and emails, and the ability to view demographic reports about select members on the Digital Music Network. After DotClick's first year, however, this will change. Once DotClick's member base is large enough to warrant a change, new Affiliates will pay annual subscriptions to participate in the Digital Music Network.
For $5,000 per year per artist, an artist, label, management company and any other potential Affiliate receives unlimited access to DotClick's basic Affiliate services: co-branded download, Alerts, emails and reports. Emerging-Artist Affiliate Subscriptions are also available at a cost of $1,000 per year. Emerging-Artist Subscriptions offer the same services as established-artist services but are limited to artists who do not have any gold- or platinum-selling records.
While this invention has been particularly shown and described with references to preferred embodiments thereof, it will be understood by those skilled in the art that various changes in form and details may be made therein without departing from the scope of the invention encompassed by the appended claims. For example a “piece of music” is meant to encompass any recorded media, including audio, video and multimedia (e.g., a single, or multi-media recording on CD, a video recording on DVD, etc.).
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Collecting user preference information related to a playing media recording is accomplished by gathering descriptive information related to the playing media recording from a media player program presenting the playing media recording and determining if tags are embedded in the media recording and gathering descriptive information related to the playing media recording from the tags embedded in the playing media recording, if the tags exist. Further, determining if a table of contents exists on the media recording and gathering a table of contents for a collection containing the playing media recording by identifying the collection using a concatenation of track lengths identifier generation technique, the table of contents exists. Then assembling the descriptive information into a media recording information packet and sending the media recording information packet to a server computer, resulting in a collection of user preference information related to the playing media recording.
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RELATED APPLICATIONS
[0001] This disclosure includes material related to the disclosure of the following commonly-owned US Patent Applications: U.S. patent application Ser. No. 13/136,402; filed Jul. 29. 2011, now U.S. Pat. No. 8,485,147; U.S. patent application Ser. No. 13/385,127, filed Feb. 2, 2012, now U.S. Pat. No. 8,851,029; U.S. patent application Ser. No. 14/255,756, filed Apr. 7, 2014, now U.S. Pat. No. 9,121,365; pending U.S. patent application Ser. No. 14/675,340, filed Mar. 31, 2015; and pending U.S. patent application Ser. No. 14/732,496, filed Jun. 5, 2015.
FIELD
[0002] The field includes opposed-piston engines. More particularly, the field relates to a barrier assembly, which includes a barrier ring, for a cylinder assembly constructed to reduce heat rejection from the cylinder assembly in an opposed-piston engine.
BACKGROUND
[0003] Construction of an opposed-piston engine cylinder assembly is well understood. The cylinder assembly includes a liner (sometimes called a “sleeve”) retained in a cylinder tunnel formed in a cylinder block. The liner includes a bore and longitudinally displaced intake and exhaust ports, machined or formed in the liner near respective ends thereof. Each of the intake and exhaust ports includes one or more circumferential arrays of openings in which adjacent openings are separated by a solid portion of the cylinder wall (also called a “bridge”). An intermediate portion of the liner exists between the intake and exhaust ports. In an opposed-piston engine, two opposed, counter-moving pistons are disposed in the bore of a liner with their end surfaces facing each other. At the beginning of a power stroke, the opposed pistons reach respective top dead center (TDC) locations in the intermediate portion of the liner where they are in closest mutual proximity to one another in the cylinder. During a power stroke, the pistons move away from each other until they approach respective bottom dead center (BDC) locations in the end portions of the liner at which they are furthest apart from each other. In a compression stroke, the pistons reverse direction and move from BDC toward TDC.
[0004] The intermediate portion of the cylinder lying between the intake and exhaust ports bounds a combustion chamber defined between the end surfaces of the pistons when the pistons are near their TDC locations. This intermediate portion bears the highest levels of combustion temperature and pressure that occur during engine operation. The presence of openings for engine components such as fuel injectors, valves, and/or sensors in the intermediate portion diminishes the cylinder assembly's strength and makes the cylinder liner vulnerable to cracking, particularly through the fuel injector and valve openings.
[0005] Heat loss through the cylinder liner is a factor that degrades engine performance throughout the operating cycle of an opposed-piston engine. Combustion occurs as fuel is injected into air compressed between the piston end surfaces when the pistons are in close mutual proximity, forming the combustion chamber. Loss of the heat of combustion through the liner reduces the amount of energy available to drive the pistons apart in the power stroke. By limiting this heat loss, fuel efficiency would be improved, heat rejection to coolant would be reduced, and higher exhaust temperatures can be realized. Smaller cooling systems and lower pumping losses are just some of the benefits of limiting heat loss through the cylinder assembly. It is therefore desirable to retain as much of the heat of combustion as possible within the cylinder assembly.
[0006] An opposed-piston cylinder assembly construction according to the present disclosure satisfies the objective of heat containment, thereby allowing opposed-piston engines to operate higher heat retention than opposed-piston engines of the prior art.
SUMMARY
[0007] The highest concentration of heat in an opposed-piston engine cylinder assembly occurs in the annular portion of the cylinder liner between the top dead center (TDC) locations of the pistons, where combustion takes place. Nearly half of the total heat flux into the liner occurs in this annular portion. Accordingly, construction of a barrier ring for insertion into the cylinder liner in such a manner as to yield a high thermal resistance will reduce heat flux through the annular liner portion.
[0008] In some implementations, provided herein is a barrier assembly that includes a barrier ring, a groove adjacent to the portion of the cylinder liner near the combustion chamber, and a space or gap between the barrier ring and the back wall of the groove. The combustion chamber is partially defined by a first end surface on a first piston and a second end surface on a second piston when the first and second pistons are near their top dead center positions in the cylinder assembly. In a related aspect, provided herein is a barrier ring for use in the barrier assembly. The barrier ring includes an open-ended tube with a wall defining a volume inside the tube. The tube includes a first and a second set of openings in the wall, in which the first set of openings allows for communication between engine hardware and the combustion chamber, and the second set of openings allows for pressure equalization between two volumes separated by the barrier ring. Methods of making and using the barrier ring and barrier assembly are also provided herein.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] FIG. 1A shows a cross-section of a portion of a cylinder assembly from an opposed-piston engine with a compression sleeve and pistons received in a liner.
[0010] FIG. 1B shows the outer portion of the cylinder assembly of FIG. 1A .
[0011] FIG. 2A is a three dimensional view of a portion of a cylinder liner with an installed barrier ring shown in shadow.
[0012] FIG. 2B is a schematic drawing of an opposed-piston engine with one or more cylinder assemblies according to this specification.
[0013] FIG. 3 is a three-dimensional drawing of the barrier ring prior to installation into the cylinder bore.
[0014] FIG. 4A is a cross sectional view of a portion of the cylinder assembly and engine block with the opposing pistons at TDC and the barrier assembly.
[0015] FIG. 4B is an exploded partial view of the cylinder assembly and pistons of FIG. 4A .
[0016] FIG. 4C is a variation of the cylinder assembly and barrier assembly shown in FIG. 4B .
[0017] FIGS. 5A-5C are three exemplary configurations of a barrier ring, with the ring laid out flat prior to installation in the cylinder bore.
[0018] FIG. 6 shows an exemplary barrier ring for use in a cylinder assembly.
DETAILED DESCRIPTION
[0019] FIGS. 1A and 1B show an exemplary cylinder assembly for use in an opposed-piston engine. The cylinder assembly 16 includes a liner 20 , intake ports 25 , exhaust ports 29 , an external surface of the liner 42 , a compression sleeve 40 , and a bore 37 . Two pistons 35 and 36 are disposed within the bore 37 . The pistons 35 and 36 have end surfaces, 35 e and 36 e, respectively, that partially define the combustion chamber 41 when the pistons 35 , 36 are at or near their respective top dead center (TDC) positions. The combustion chamber 41 is also partially defined by the cylinder liner 20 in the intermediate portion 34 of the cylinder. The intermediate portion 34 is located between the intake ports 25 and the exhaust ports 29 . Located in the intermediate portion 34 , at the periphery of the combustion chamber 41 , are openings 46 into which fuel injection components 45 and other engine components can fit. This exemplary cylinder assembly is described in detail in related U.S. patent application Ser. No. 14/675,340.
[0020] The compression sleeve 40 is formed to define generally cylindrical space between itself and the external surface 42 of the liner through which a liquid coolant may flow in an axial direction from near the intake ports toward the exhaust ports. The intermediate portion 34 is reinforced by the compression sleeve 40 , as described in greater detail in U.S. patent application Ser. No. 14/675,340, and cooling fluid is circulated in the compression sleeve 40 in generally annular spaces 55 and 59 . The cooling fluid that circulates in these generally annular spaces 55 , 59 flows to other components of the opposed-piston engine, not shown in FIGS. 1A and 1B , that allow for heat to dissipate from the cooling fluid to the surrounding environment, such as a radiator.
[0021] FIG. 2A is a three dimensional view of a portion of a cylinder liner 20 with a barrier ring 200 installed. The barrier ring 200 is shown in shadow. The barrier ring 200 is located in the intermediate portion 34 , overlapping with the portion of the intermediate portion that includes one or more openings 46 for injection components, as well as the portion of the intermediate portion that encircles the combustion chamber. FIG. 2B illustrates an opposed-piston engine 100 with three cylinder assemblies 101 , in which each cylinder comprises a cylinder tunnel 103 in a cylinder block 105 and a cylinder liner 107 (reference number 20 in FIGS. 1A-1C ) according to this specification seated in the cylinder tunnel. Of course, the number of cylinders is not meant to be limiting. In fact, the engine 100 may have fewer, or more, than three cylinders. Each cylinder assembly 101 has a barrier ring 200 installed in the intermediate portion of the cylinder assembly 101 . The barrier ring 200 is shown in shadow, as in FIG. 2A .
[0022] The barrier ring 200 discussed herein is a part of a barrier assembly (e.g., a heat barrier assembly) that is inserted into, or located in, the bore of a cylinder assembly and that prevents heat incident upon the barrier ring from the combustion chamber from passing to other parts of the opposed-piston engine. The barrier ring can be thin compared to the walls of the cylinder assembly, and numerous openings, perforations, or holes, can be present in the ring. The materials of the barrier ring, barrier ring shape, openings in the barrier ring, and combination of the barrier ring with insulation or air gaps influence the ability of the barrier assembly to keep heat from escaping to other volumes in the engine.
[0023] FIG. 3 is a three-dimensional drawing of an exemplary barrier ring 200 (e.g., heat screening ring) prior to installation into the cylinder bore. The barrier ring 200 is a thin-walled tube or ring with folded edges 210 , openings 220 for communication between injection/combustion hardware and the combustion chamber, and openings 215 to allow for pressure equalization between the space inside and the cylinder environment outside of the barrier ring 200 . The barrier ring 200 sits in a circumferential groove on the inside of the cylinder liner. The groove is located at, or adjacent to, the combustion chamber. The barrier ring 200 is formed so that the folded edges 210 allow the inside surface of the barrier ring 200 to lie substantially flush with inside wall of the cylinder liner when inserted into the groove. The barrier ring 200 and the circumferential groove, along with a gap between the ring and groove back wall, are part of a barrier assembly.
[0024] FIG. 4A is a cross sectional view of a portion of the cylinder assembly 16 and engine block with the opposing pistons 35 , 36 at TDC, forming the combustion chamber 41 , and with the barrier ring 200 installed into a groove 225 , as described above. The barrier ring 200 has a width that is approximately the height of the combustion chamber 41 , as measured along the central axis of the cylinder, from one piston end surface 36 e to another piston end surface 35 e. FIG. 4B is an exploded partial view of the cylinder sleeve and pistons of FIG. 4A that shows the barrier assembly, including the groove 225 and the barrier ring 200 , in greater detail. The openings 215 in the barrier ring for equalizing pressure between the gap 230 in the groove 225 and the combustion chamber 41 are also shown in FIG. 4B . The gap 230 helps to prevent the flow of heat away from the combustion chamber 41 . In FIG. 4B , the barrier ring 200 is situated in the groove 225 and is shown as flush with the sides 226 of the groove; the folded edges 210 of the barrier ring 200 are up against the groove sides 226 . The main portion of the barrier ring, the barrier ring wall that includes the openings 215 , is spaced away from the back wall 227 of the groove 225 by the folded edges 210 of the barrier ring. The barrier ring 200 may have the configuration shown in FIG. 4B after the engine has warmed up and the barrier ring 200 has expanded. When the engine is cold, there can be a clearance of between 10 microns and 100 microns in the interface 240 between the groove sides 226 and the folded edges 210 of the barrier ring. In some implementations, the clearance in a cold engine between the groove sides 226 and the edges 210 of the barrier ring can be less than 10 microns, or alternatively, the clearance can be 100 microns or greater. Alternatively, or additionally, the material at or around the groove sides 226 can be compliant enough or be constructed to accommodate any expansion of the barrier ring 200 in the axial direction of the cylinder assembly 16 .
[0025] In most engines, a circumferential clearance space between pistons and the inner wall of the cylinder liner is provided to allow for thermal expansion. After long hours of operation carbon builds up in this clearance space, on the top land of a piston, which can result in increased friction and ring wear; at worst it can cause ring jacking. It is preferable that carbon removal not occur where the ports are located. Carbon debris near the ports can contaminate charge air entering the bore or be swept into the gas stream exiting the cylinder assembly after combustion, degrading the performance of the engine.
[0026] In the configuration shown in FIG. 4A , the barrier ring 200 is shown as contacting the pistons 35 , 36 and bridging the gap 450 between the cylinder bore and the sides of the pistons 35 , 36 . By protruding beyond the groove 225 , the barrier ring 200 can contact and scrape the sidewalls of the pistons 35 , 36 as the pistons approach and/or leave TDC in the cylinder. This contacting and scraping can remove carbon buildup on the sidewalls of the pistons 35 , 36 while avoiding the possibility of fouling incoming air with the scraped carbon or adding to exhaust emissions.
[0027] Alternatively, in some implementations, the barrier ring 200 may be flush with the sides 226 of the groove when the engine is cool. When the engine warms up, the barrier ring 200 can bow away from the cylinder liner, into the combustion chamber. The bowing portion of the barrier ring can rub against the sidewalls of the pistons 35 , 36 as the pistons move through the cylinder, toward or away from TDC. In such implementations, the clearance in the interface 240 between the barrier ring edge and groove sidewall when the engine is cold, discussed above, may or may not be present.
[0028] FIG. 4C shows an alternate configuration for the barrier ring 200 and groove 225 . The barrier ring 200 shown in FIG. 4C lacks folded edges, and the barrier ring 200 and back wall 227 of the groove 225 are separated by a spacer 228 . The spacer 228 is shown as a pair of ledges that protrude from the groove sidewalls 226 and back wall 227 . This spacer 228 replaces the folded edges 210 of the barrier ring shown in FIG. 4B . The clearance between the barrier ring 200 and the groove sidewall 226 at the interface between the two 240 , when the engine is cold, could have the characteristics of the clearance discussed with respect to the configuration shown in FIG. 4B . A barrier ring 200 with folded edges 210 could be used with a liner whose groove 225 includes a spacer 228 , however, doing so may lead to a configuration in which the barrier ring 200 protrudes too far into the volume of the cylinder, and not only scrapes the top lands of the pistons, but may in fact hinder the movement of the pistons.
[0029] In any case, whether the spacer 228 is present as a ledge, as in FIG. 4C , or as folded edges 210 of the barrier ring, or in some other fashion, the barrier ring 200 is separated from the back wall 227 of the groove 225 by a distance ranging from about 0.5 mm to about 3 mm. In some implementations, the gap separating the barrier ring from the back wall of the groove can be about 0.5 mm to about 2.5 mm, such as about 0.75 mm to about 2 mm, including about 1.0 mm to about 1.5 mm.
[0030] The barrier ring 200 can be made from any suitable material that can withstand repeated exposure to the temperatures and pressures experienced in the combustion chamber, as well as that can quickly dissipate heat. In some implementations, the material used to make the barrier ring will be different from the material used to form the cylinder liner or bore. Suitable materials for the barrier ring include high temperature nickel-chromium-based alloys such as Inconel®, a cobalt-chromium alloy such as Stellite® Alloy 6, stainless steel, and the like. The thickness of the barrier ring 200 is selected, along with the material used to fabricate the barrier ring and the pattern of openings made in the barrier ring, so that the barrier ring 200 is robust enough to withstand mechanical failure when exposed to the temperatures and pressures of the cylinder assembly interior while the engine is running. The thickness of the barrier ring can range from about 0.5 mm to about 3.0 mm, such as from about 1.0 mm to about 2.5 mm, including from about 1.0 mm to about 2.0 mm.
[0031] As described above, openings in the barrier ring can allow engine components to contact the interior of the combustion chamber and/or allow for equalization in pressure between the volumes in the cylinder that are separated by the barrier ring. The barrier ring is sized to fit into a groove in the bore of a cylinder liner where the combustion chamber is formed when the pistons are near their TDC positions. Together the barrier ring and the groove, including the space between the barrier ring and back wall of the groove, form the barrier assembly that prevents heat loss from the combustion chamber to the surrounding cylinder assembly and engine.
[0032] The openings in the barrier ring that allow engine components to reach into the combustion chamber can be located where fuel injection nozzles, compression release engine breaking valves, and sensors project from the cylinder into the combustion chamber (e.g., 46 in FIG. 2 ). These pressure-equalizing openings (e.g., 220 in FIG. 3 ) are sized to just allow engine components (e.g., nozzles and sensors) through; openings that are too large are undesirable, as will be explained further below. The barrier ring is then about 2 mm-20 mm wider (taller) than the diameter of the largest opening. In some implementations, the barrier ring has a height about 4.0 mm to about 20.0 mm wider than the diameter of the largest opening in the barrier ring wall, including a height about 2.0 mm to 4.0 mm wider than the diameter of the largest opening, about 5.0 mm to about 20.0 mm wider than the diameter of the largest opening, about 6.0 mm to about 19.0 mm, about 7.0 mm to about 18.0 mm, and about 8.0 mm to about 16.0 mm wider than the diameter of the largest opening in the barrier ring wall.
[0033] There are various possible configurations for the openings in the barrier ring that are meant to allow for equalization in pressure between the spaces on either side of the barrier ring (e.g., 215 in FIG. 3 ). These openings allow for movement of gas between the space in the combustion chamber enclosed by the barrier ring and the gap between the barrier ring and the cylinder liner in the groove. This allows for equalization of pressure, which in turn prevents excessive deformation of the barrier ring due to high mechanical stresses. While larger openings will allow for rapid equalization of pressure across the barrier ring, openings that are too large will not provide the heat screening properties that are desired. Openings that are too large will allow heat to escape through the cylinder liner and the rest of the cylinder assembly, while openings that are too small will lead to inequality in pressure across the ring and in turn mechanical stresses in, and deformation of, the barrier ring.
[0034] The size and shape of all of the openings in the barrier ring are optimized to achieve maximum heat-loss reduction while maintaining an acceptable pressure difference across the barrier ring. Pressure-equalizing openings can have any shape, such as circular, elliptical, triangular, rectangular, square, slit-like, and the like. Fillets can be used to eliminate stress concentration in the barrier ring. The arrangement of pressure-equalizing openings can vary to maximize heat-loss reduction and pressure equalization across the barrier ring. Groupings of pressure-equalizing openings can be used to vary the density of the openings. In some implementations, the selected opening locations can produce a ring with no pressure-equalizing openings along the center, or midline, of the barrier ring. Alternatively, the selected opening locations can produce a barrier ring with openings exclusively along the midline of the ring, or a barrier ring with openings along the midline and off the midline of the ring. Also, the location of the openings can be targeted to a particular angular pitch (e.g., frequency of openings along the ring). The angular pitch of the pressure-equalizing openings can be between 30° and 45°. Pressure-equalizing openings can be located randomly or have a definite pattern. These openings can all have similar sizes and shapes, or the sizes and shapes of the pressure-equalizing openings can vary, so long as the barrier ring maximizes the heat-loss reduction of the cylinder while minimizing mechanical stresses in the ring that can cause failure.
[0035] In general, the total surface area of the barrier ring can be made up of between 1% and 5% openings. In some implementations, the barrier ring can have a surface area that is less than 1% openings. In some implementations, openings can make up 5% or more of the surface area of the barrier ring.
[0036] FIGS. 5A-5C show exemplary barrier ring configurations with the barrier ring laid out flat prior to installation in the cylinder bore. FIG. 5A is a barrier ring 200 with folded edges 210 , openings for injection nozzles and other components 220 , and pressure-equalizing openings 215 . In the barrier ring shown in FIG. 5A , the pressure-equalizing openings 215 are circular and are grouped so that these types of openings are not located along the midline 260 a of the ring. FIG. 5B shows a barrier ring 200 b with folded edges 210 b, openings for injection nozzles and other components 220 b, and slit-like pressure-equalizing openings 215 b. The slit-like openings 215 b are spaced evenly in pairs on either side of the midline 260 b of the ring. FIG. 5C shows a barrier ring 200 c with folded edges 210 c, openings for engine components 220 c, and circular pressure-equalizing openings 215 c. Like the slit-like openings 215 b, the circular openings 215 c are located in a pattern that avoids placing any openings 215 c along the midline 260 c of the barrier ring. The openings 215 c are grouped in alternating pairs and single openings. As described above, though the barrier ring configurations shown in FIGS. 5A-5C do not have openings along the midline of the rings, in some implementations, the barrier rings can include openings along the midline.
[0037] Though FIG. 2 shows the barrier ring 200 as a continuous ring, with the ends, as shown in FIGS. 5A-5C , adhered to each other, the ends may actually not be sealed or adhered. This can facilitate installation of the barrier ring 200 into the cylinder liner, as well as to allow for changes in the dimensions of the ring with changes in temperature in the cylinder assembly. The barrier ring 200 can be fabricated as a strip of material, as shown in FIGS. 5A-5C , with the openings and folded edges machined or cast into the material. The strip of material can then be worked to conform to a certain radius of curvature. The radius of curvature can be equal to that of the groove or slightly larger, to that when the barrier ring 200 is placed into the groove 225 , the barrier ring 200 pushes against the edges of the groove and is secured into place. Alternatively, the barrier ring 200 can be fabricated without folded edges, and the barrier ring can hold a radius of curvature worked into it because the ring is sufficiently thick. Barrier rings without folded edges can maintain a gap in the groove, between the ring and the cylinder liner, by using a spacer, such as a lip or step (i.e., a ledge 228 in FIG. 4C ) in the groove that supports the edges of the barrier ring and keeps the edges away from the back wall of the groove.
[0038] Additionally, or alternatively, cylinder assemblies for opposed-piston engines that use liners with a barrier ring can be used in conjunction with pistons that each have a barrier layer at their end surface. The barrier layer at the end surface of such pistons can allow for higher temperatures to be reached in the combustion chamber without diminishing performance. Such a combination of pistons with a heat-loss preventing barrier layer and the cylinder assemblies described herein can allow for reductions in conventional thermal management systems, better engine efficiency, and/or reductions in emission levels.
[0039] During a combustion event in an opposed-piston engine, a first piston and a second piston will move in a cylinder assembly, through the bore of an annular cylinder liner, in a direction along the long axis of the cylinder liner, from bottom dead center (BDC) towards top dead center (TDC). As the first and second pistons move axially, and both pistons are near their top dead center locations, they will eventually create a combustion chamber between their end surfaces. The air that is in the cylinder assembly between the end surfaces of the pistons heats up as the pistons move towards each other to form the combustion chamber. Fuel is injected into the combustion chamber, and the fuel mixes with the heated air. Combustion takes place between the end surfaces of the first and second pistons, releasing heat and creating pressure. The pressure pushes the first and second pistons apart. A barrier assembly, including a barrier ring as described herein and a groove in the cylinder liner, that is located inside the bore of the annular cylinder liner, on the periphery of the combustion chamber (e.g., between the TDC locations in the bore for the first and second pistons) prevents some of the combustion heat from reaching the outside of the cylinder assembly.
[0040] Cylinder assemblies for opposed-piston engines that use liners with barrier ring, as described herein, can be used with conventional thermal management systems to dissipate heat lost through the cylinder walls. By using cylinder liners with a barrier ring, as described above, the conventional cooling systems may not have to dissipate as much heat from cylinder assembly, around the combustion chamber. As a result of this, the cooling systems can be smaller in size, resulting in an overall more compact and efficient engine.
EXAMPLE 1
[0041] FIG. 6 shows an exemplary barrier ring 600 for a cylinder liner of an opposed piston engine. The barrier ring 600 fits into a groove in a cylinder liner. The cylinder liner for which the barrier ring is made has a 98.25 cm internal diameter. The barrier ring 600 has pressure-equalizing openings 615 of 2.5 mm diameter and 45° angular pitch that are formed along the centerline of the barrier ring. The barrier ring 600 also has folded edges 610 and has openings 620 to allow for nozzles injecting fuel into the combustion chamber that is surrounded by the barrier ring 600 .
[0042] The scope of patent protection afforded these and other barrier ring embodiments that accomplish one or more of the objectives of durability and thermal resistance of an opposed-piston engine according to this disclosure are limited only by the scope of any ultimately-allowed patent claims.
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A barrier ring for a cylinder assembly for an opposed-piston engine fits into a groove fashioned into a portion of the cylinder liner that is adjacent to the top dead center location of the end surfaces of the pistons, in a volume of the cylinder liner that defines the combustion chamber. The barrier ring and groove are part of a barrier assembly that prevents heat generated during combustion from reaching the outer wall of the cylinder assembly, reducing the need for conventional cooling systems and increasing the amount of heat retained in the combustion chamber. The barrier assembly allows for increased engine efficiency because of the combustion heat retained in the combustion chamber, as well as a reduction in the overall size of the engine because of the reduction in engine cooling needed.
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CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims priority to and the benefit of U.S. Provisional Application Ser. No. 61/877,425, filed Sep. 13, 2013, the disclosure of which is hereby incorporated by reference herein in its entirety.
INTRODUCTION
[0002] Electrochromic devices may be used in a variety of applications where it is desired to control the opacity of an object. For example, an electrochromic device may be used in conjunction with a window to create a so-called “smart window.” Some smart windows may be constructed by first depositing the electrochromic device on a flexible original superstrate. Additionally, the electrochromic device may then be oriented such that light traveling through the window pane passes through the electrochromic device. A voltage applied to the electrochromic device changes the opacity of the electrochromic device. Controlling this voltage results in controlling the amount of light that passes through the window.
[0003] Smart windows may be used for privacy purposes or for energy efficiency purposes. Energy efficiency may be realized by controlling the amount of light entering a building through the window. For example, when it is desired to heat a space, such as an office building, the smart window may be controlled to allow more light to pass through the window. This light may heat the interior space and reduce the amount of additional energy required to heat the space to a desired temperature. Alternatively, the smart window may be used to allow less light to pass through a window, thus keeping the space cool.
[0004] It is with respect to these and other considerations that embodiments have been made. Also, although relatively specific problems have been discussed, it should be understood that the embodiments should not be limited to solving the specific problems identified herein.
Electrochromic Window Insert Assembly and Methods Of Manufacture
[0005] An electrochromic insert adapted to be fitted into an existing window frame allowing an existing window to be retrofit to have the benefits of electrochromics. The insert may have a scaffold that fits into a window frame. Securing the insert to the frame may occur through a variety of ways including a bracket, a flexible tab, a brace, a screw, a bolt, a projection, a detent, and an adhesive. The technology allows for the electrochromic insert to include an electrochromic device, energy collection device, an energy storage device, and an electrochromic device controller. Such a configuration may be considered autonoumous such that it need not draw power from another source.
[0006] In one aspect, the technology relates to a system including a rigid scaffolding adapted to be fixed to a pre-existing window. The system also includes an electrochromic device spanning the rigid scaffolding.
[0007] In an additional aspect, the technology relates to a system including a superstrate, an electrochomic device fixed to the superstrate, and a securement system connected to the superstrate for securing the superstrate to a window frame.
[0008] Additionally, one aspect of the technology relates to a method including affixing an electrochromic device to a superstrate to form a sheet comprising a plurality of edges and a plurality of outer corners joining adjacent edges of the plurality of edges. The method also includes removing each of the plurality of outer corners so as to form a plurality of inner corners. Additionally, the method includes folding each of the plurality of edges such that adjacent inner corners contact each other, so as to form a box structure.
[0009] This summary is provided to introduce a selection of concepts in a simplified form that are further described below in the Detailed Description. This summary is not intended to identify key features or essential features of the claimed subject matter, nor is it intended to be used to limit the scope of the claimed subject matter.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] The same number represents the same element or same type of element in all drawings.
[0011] FIG. 1 depicts a side sectional view of one embodiment of an electrochromic assembly.
[0012] FIG. 2 depicts a side sectional view of another embodiment of an electrochromic assembly.
[0013] FIG. 3 depicts a side sectional view of another embodiment of an electrochromic assembly.
[0014] FIG. 4 depicts a side sectional view of another embodiment of an electrochromic assembly.
[0015] FIGS. 5A-5H depict views of embodiments of securement systems for an electrochromic assembly.
[0016] FIG. 6 depicts a method of installing a electrochromic insert into a window frame.
[0017] FIGS. 7A and 7B depict a system for manufacturing an electrochromic assembly.
[0018] FIG. 8 depicts a method of manufacturing an electrochromic assembly utilizing the system of FIGS. 7A and 7B .
[0019] FIG. 9 depicts one example of a suitable operating environment in which one or more of the present examples may be implemented.
[0020] FIG. 10 is an embodiment of a network in which the various systems and methods disclosed herein may operate.
DETAILED DESCRIPTION
[0021] It should be noted that this application uses the terms “transparent,” “translucent,” “opaque,” and “opacity.” As used in this application, the word “transparent” describes the property of allowing substantially all light, or a large portion thereof, of a given electromagnetic range (e.g., the visible range or a portion thereof) to pass through the material. As such, it is possible that a material may be “transparent” with respect to a certain portion of the electromagnetic spectrum, but be opaque or translucent with respect to other portions of the electromagnetic spectrum. Additionally, a device may be considered transparent even if some small amount of light within the given electromagnetic range is scattered or reflected. As used, “transparent” is best understood as a relative term to distinguish a state of an electrochromic device from an “opaque” state in which less light passes through the device. Translucent describes the property of scattering light as the light passes through an object. Translucent and transparent are not exclusive terms; that is, it is possible for a material to be both highly translucent and highly transparent or, alternatively, highly translucent but not very transparent. Opacity describes the degree to which a material prevents light or a portion of the electromagnetic spectrum from passing through the material, such degree ranging from highly transparent to perfectly opaque. A material may have multiple opacity states and may change between these opacity states. Unless explicitly stated, these terms refer at least to the visible spectrum, although one of skill in the art will understand that the affected spectrum may be expanded or changed depending on the end goal (e.g., if the goal is to manage temperature in the interior space, then increasing the opacity of non-visible portions of the electromagnetic spectrum may be beneficial).
[0022] As discussed above, in an embodiment, an autonomous electrochromic assembly may include an electrochromic device, an energy collection device, an energy storage unit, and an electrochromic device controller. This autonomous electrochromic assembly may be used in conjunction with or incorporated into a window to control the amount of light passing through the window. Because the autonomous electrochromic assembly is autonomous in the sense that it receives its power from ambient light (i.e., it may be considered self-powered or passively powered), it may be easily retrofitted into existing construction without the need to provide wired or active wireless power to the window. Thus, by simply replacing traditional windows or exterior (or interior) panels with the windows described herein, a structure may be upgraded to allow active control of the light energy passing into the structure. Alternatively, the electrochromic assembly need not be autonomous, but may be powered and/or controlled from a central building location.
[0023] FIG. 1 depicts a side sectional view of one embodiment of an electrochromic assembly 100 . In embodiments, an autonomous electrochromic assembly 100 includes an electrochromic device 102 , a superstrate 104 , an energy collection device 106 , an energy storage device 108 , and an electrochromic device controller 110 .
[0024] In embodiments presented herein, the electrochromic device 102 is described as a thin film electrochromic device, although other types of electrochromic devices may be used. The electrochromic device 102 may have multiple layers including a substrate layer, a counter electrode layer, an electrolyte layer, and an electrochromic layer. The substrate layer may be flexible or rigid. The substrate layer may be indium tin oxide (“ITO”) coated polyethylene terephthalate (“PET”). Alternatively, the substrate layer may be glass, or another substantially transparent or translucent material. Additionally, the counter electrode layer may be a lithiated metal oxide or a lithiated mixed metal oxide. For example, lithium vanadium oxide, lithium nickel oxide, and lithium nickel tungsten oxide (where the ratio of W to Ni is less than 1 to 1) may be used. The electrochromic layer may be a similarly mixed oxide, such as molybdenum tungsten oxide (where the Mo to W ratio is less than 1 to 1). These layers may be formed using a variety of processes such as physical vapor deposition, chemical vapor deposition, thermal evaporation, pulsed laser deposition, sputter deposition, and sol-gel processes. A roll-to-roll manufacturing process may be used for flexible electrochromic film. This process may achieve cost reduction with high-yield manufacturing, and is described in more detail herein.
[0025] A voltage may be applied to an electrochromic device 102 to cause the electrochromic device 102 to change its opacity state. For example, the electrochromic device 102 may change from substantially transparent with respect to the visible light range to an opacity state that reflects or otherwise prevents blue light from passing through the device. Other opacity changes are possible and may be selected by the manufacturer to achieve desired performance criteria. The electrochromic device 102 may become more or less reflective or opaque when voltage is applied.
[0026] Additionally, the electrochromic device 102 may be temperature controlled. A cooling device may be used to remove excess heat from the electrochromic device 102 . Cooling the electrochromic device 102 may reduce heat transfer into a confined space, such as an interior of a building. Alternatively, heating the electrochromic device 102 may allow for a faster conversion of the electrochromic device 102 from one opacity state to another opacity state. The device used to control temperature may be a thermoelectric device that may provide either an active heating or cooling solution by reversing the polarity of the applied voltage. Depending on the embodiment, the power supplied to the thermoelectric device may be supplied by either or both of the energy collection device 106 or the energy storage device 108 .
[0027] In rigid embodiments, the superstrate 104 may be a rigid plastic such as acrylic or PLEXIGLASS. The superstrate 104 may be affixed to the electrochromic device 102 by lamination or by any other suitable method. By adhering the material directly to the rigid superstrate 104 immediately after the manufacturing of the electrochromic device 102 , wrinkling and creasing of the electrochromic device 102 may be mitigated. Alternatively the electrochromic device 102 may be mechanically attached to the superstrate 104 . Additionally, direct deposition of the electrochromic device 102 onto the superstrate 104 may be utilized. This may also prevent wrinkling of the electrochromic device 102 . The superstrate 104 may be substantially transparent with respect to the visible light range or translucent with respect to the visible light range.
[0028] The superstrate 104 may have additional integrated functionality. For example, resistive heaters may be used to heat the superstrate. This may be accomplished by running current through a slightly conductive superstrate. Electrical connections may be fed to a controller to control the power to a superstrate 104 . This controller may be integrated within a device controller 110 . Alternatively, the controller may be a separate controller. Heating a superstrate 104 may cause an electrochromic device 102 to be heated. This may reduce the time it takes an electrochromic device 102 to switch from one opacity state to another opacity state. This may occur because ion conductivities are poor at low temperatures, and heating the superstrate may heat an electrochromic device 102 .
[0029] An energy collection device 106 may be used in the autonomous electrochromic assembly 100 , and may be used to capture energy. The energy collection device 106 may be a thin film photovoltaic device or any other suitable construction. In embodiments, the energy collection device 106 may be a thin film photovoltaic and have a surface area such that the device need only collect a small portion of the light incident on the surface of the energy collection device 106 . This may result in the energy collection device 106 being substantially transparent with respect to the visible light range. In an embodiment, the energy collection device 106 is substantially or entirely co-extensive with the electrochromic device 102 such that all or nearly all light passing through the assembly 100 passes through both the energy collection device 106 and the electrochromic device 102 .
[0030] In other embodiments, the energy collection device 106 may be a wireless power beam devices (such as radio frequency, e.g., ZIGBEE or IR), a magnetic induction device, or a thermoelectric device. Any combination of energy collection devices may be used.
[0031] In alternative embodiments, the energy collection device 106 need not be substantially transparent, but may instead be substantially opaque. In one embodiment, the opaque energy collection device 106 may be integrated into an edge of the assembly 100 , such as in the location of the window frame, or inside the window spacer. The energy collection device 106 may be oriented with respect to the window pane area such that it does not significantly reduce the line of sight. Thus, in this embodiment, the energy collection device 106 is not co-extensive with the electrochromic device 102 .
[0032] The energy collection device 106 may be laminated or otherwise adhered to the superstrate 104 . Alternatively, the energy collection device 106 may be deposited using similar or the same methods described with reference to depositing the electrochromic device 102 . Deposition of the energy collection device 106 may occur concurrently with the electrochromic device 102 as part of a continuous manufacturing process.
[0033] The energy storage device 108 may be used in the electrochromic assembly 100 . In embodiments, very thin metals and dielectrics may be used to form a thin film capacitor to store energy generated from the energy collection device 106 . In embodiments, the capacitor may be a part of an infrared filter that rejects some infrared light or, alternatively, some other portion of the electromagnetic spectrum. This may reduce the need for other layers or coatings that perform similar infrared filter functions. In an embodiment, the energy storage device 108 may be substantially transparent with respect to the visible light range and may be substantially or entirely co-extensive with the electrochromic device 102 such that all or nearly all light passing through the assembly 100 passes through both the energy storage device 108 and the electrochromic device 102 . In yet another embodiment, both the energy storage device 108 and the energy collection device 106 may be substantially transparent with respect to the visible light range and both may be substantially or entirely co-extensive with the electrochromic device 102 such that all or nearly all light passing through the assembly 100 passes through all three components of the assembly 100 . Additionally, a capacitor or battery may be located at the edge of the window pane area outside of the sightline.
[0034] Alternatively, in an embodiment of the assembly 100 , a battery could be employed as the energy storage device 108 to store energy. Such a battery could be a thin film lithium ion battery or similar construction. In an embodiment, the battery could be solid state or have a liquid or semiliquid electrolyte. The energy storage device 108 may be substantially transparent with respect to the visible light range. In an embodiment, the energy storage device 108 is substantially or entirely co-extensive with the electrochromic device 102 such that all or nearly all light passing through the assembly 100 passes through both the energy storage device 108 and the electrochromic device 102 . Because the assembly 100 may be confined in a controlled and protected environment within a window or panel structure, some battery designs which would not be suitable for use under exposed conditions may be suitable in applications described herein. For example, the gas environment within the window volume (e.g., the selection of gas between the panes of the window) may be selected to allow the use of specific device designs that would not be suitable for use in an ambient environment.
[0035] The electrochromic device 102 may be controlled by the electrochromic device controller 110 . In an embodiment, the electrochromic controller 110 may be a microchip controller. The electrochromic device controller 110 may be hidden from view, and may communicate wirelessly to a central control system or user interface using various communication protocols such as but not limited to BLUETOOTH, ZIGBEE, IR, and RF telemetry. Additionally, the electrochromic controller 110 may be integrated in the frame of the window. Power to the electrochromic device controller 110 may be supplied directly by the energy collection device 106 , or it may be supplied by the energy storage device 108 which, in turn, may be supplied by the energy collection device 106 . In an alternative embodiment, the electrochromic device controller 110 may be substantially transparent with respect to the visible light range. In an embodiment, the electrochromic device controller 110 is substantially or entirely co-extensive with the electrochromic device 102 such that all or nearly all light passing through the assembly 100 passes through both the electrochromic device controller 110 and the electrochromic device 102 .
[0036] Although the autonomous electrochromic assembly 100 is illustrated as a series of layered, transparent thin film devices (which may be referred to as a unitary electrochromic insert assembly) with an attached electrochromic device controller 110 , it need not be. In other embodiments, certain devices may be physically separated from the other devices of the assembly. For example, the electrochromic device 102 may be attached to a flexible superstrate 104 . An electrochromic device 102 and a flexible superstrate 104 may then be attached to a transparent or translucent area of an object such as a window pane. An energy collection device 106 may be affixed to a different area that is exposed to a light source disposed outside of the window frame. The electrochromic device 102 may then be electrically coupled to the energy collection device 106 . The energy storage device 108 may be electrically coupled to the energy collection device 106 and the electrochromic device 102 . The electrochromic controller 110 may then be electrically coupled to the electrochromic device 102 . The configuration may be such that the electrochromic device controller 110 controls the voltage and current delivered to the electrochromic device 102 .
[0037] Additionally, although FIG. 1 illustrates the use of only one each of the electrochromic device 102 , the superstrate 104 , an energy collection device 106 , the energy storage device 108 , and the electrochromic device controller 110 , multiple devices may be used in other embodiments.
[0038] The electrochomic assembly 100 can also include an adhesive layer 112 disposed on, for example the electrochromic device 102 . By including the adhesive layer 112 , which may be covered by a contact paper after manufacturing and during transit, the electrochromic assembly 100 can be applied to an existing window glass pane, either at a window manufacturer facility or at a site where an existing window is installed. Thus, the autonomous electrochromic assembly 100 can be utilized in retrofit installations so as to change functionality of a standard pane of glass.
[0039] FIG. 2 depicts a side sectional view of another embodiment of an electrochromic assembly 200 . Components common with the electrochromic assembly of FIG. 1 are numbered similarly and are generally not described further. In this embodiment, the electrochromic assembly 200 can be applied directly to a pane of window glass 214 during manufacture of a window. In such an embodiment, the superstrate 204 need not be utilized. However, utilization of the superstrate 204 may provide a robust base upon which to apply the energy collection device 206 and energy storage device 208 .
[0040] FIG. 3 depicts a side sectional view of another embodiment of an electrochromic assembly 300 . Components common with the electrochromic assembly of FIG. 1 are numbered similarly and are generally not described further. In this embodiment, the electrochromic assembly 300 includes a rigid scaffolding system 316 between which the various layers of the electrochromic assembly 300 are stretched or spanned. The rigid scaffolding system 316 is generally disposed about two or more edges of the electrochromic assembly 300 and can be used to secure the electrochomic assembly 300 into an in situ window frame, without removal of the pane of glass of the window. Thus, the electrochromic system 300 is well-suited for retrofit applications without requiring removal of a window pane. The scaffold may be secured directly to the window frame, as described in more detail below. In certain embodiments, the controller 310 may be secured to the scaffolding system 316 , which can conceal or integrate additional wiring, buses, electrical connections, etc.
[0041] FIG. 4 depicts a side sectional view of another embodiment of an electrochromic assembly 400 . Components common with the electrochromic assembly of FIG. 1 are numbered similarly and are generally not described further. In the depicted embodiment, after assembly of the electrochromic assembly 400 , the finished assembly 400 can be folded to as to form a framed structure having at least a first leg 418 and a second leg 420 . Indeed, similar to the embodiment of FIG. 3 that utilizes a scaffold, the first leg 418 and the second leg 420 can be used to secure the electrochromic assembly 400 into an existing window frame. Of course, all edges of the electrochromic assembly 400 can be folded to form a full-perimeter frame. In another embodiment, the frame may be formed of a discrete metal or plastic structure, and the edges of the electrochromic assembly 400 can be folded over the frame structure to provide additional rigidity at the edges.
[0042] FIGS. 5A-5H depict views of embodiments of securement systems for an electrochromic assembly 500 . In each figure, an electrochromic assembly 500 is depicted, which assembly may be the same as or similar to the embodiments of the electrochromic assembly depicted above in FIGS. 1-4 . In FIG. 5A , the securement system is a bracket 502 secured to one or more edges of the electrochromic assembly 500 having a frame structure, as depicted in FIG. 4 . The bracket 502 may define one or more openings 504 for receiving a screw, bolt, or other fastener. In FIG. 5B , the electrochromic assembly 500 includes a frame or scaffolding u 506 that protects the edges of the assembly 500 . The frame 506 can include a flexible tab 508 that deflects during installation of the electrochromic assembly 500 into an existing window frame, so as to hold the assembly 500 in place. FIG. 5C depicts an electrochromic assembly 500 that may be held in place with a discrete brace 510 . Once the assembly 500 is placed against a pane of glass in an existing window, the brace 510 may be placed in contact with the assembly 500 and secured in place with, e.g., a fastener installed through an opening 512 defined by the brace 510 . FIG. 5D depicts an embodiment where the electrochromic assembly 500 is directly secured to a window frame via a screw installed through the assembly 500 itself. A cover plate 516 may cover the screw head for aesthetic or security purposes (e.g., to prevent tampering with the screws).
[0043] Another embodiment of a securement system is depicted in FIG. 5E . Here, an electrochromic assembly 500 , such as the embodiment depicted in FIG. 4 defines an opening configured to receive a bolt 518 that may be secured directly to a window frame. FIG. 5F depicts a securement system in the form of a projection having a rigid base 520 secured about the outer perimeter of the electrochromic assembly 500 . A resilient element 522 (e.g., a rubber or silicone strip) is secured to the rigid base 520 and helps secure, via friction-fit engagement, with a window frame. The securement system of FIG. 5G also includes a projection 524 that includes a detent 526 configured to mate with a matching projection 528 on a window frame 530 . FIG. 5H depicts an electrochromic assembly 500 having an adhesive 532 disposed about the outer edge surface thereof. The adhesive 532 may be any factory- or field-applied adhesive that may be used to secure the assembly 500 to the window frame. Of course, other securement systems are contemplated. Additionally, various securement systems may be used with various configurations of electrochromic assembly (e.g., in the securement system depicted in FIG. 5E , a screw may be utilized instead of a bolt as depicted). Modifications to various securement systems will be apparent to a person of skill in the art.
[0044] FIG. 6 depicts a method of installing an electrochromic assembly 600 into a window frame 602 . The assembly 600 can include a frame 604 and flexible or resilient tabs 606 , as described in the embodiment depicted in FIG. 5B . The tabs 606 are electrically conductive and may be aligned with corresponding contacts 608 on the outer frame structure 602 . In this embodiment, the frame 604 is configured to protect the edges of the electrochromic assembly 600 , while the outer frame structure 602 is configured to be secured to a building structure once installed. One or more of the contacts 608 in the outer frame structure 602 are connected to wiring 610 which can be used to power, control operation of, deliver power from, etc., the electrochromic assembly 600 . Such functionality is described below. Once the electrochromic assembly 600 is installed in the outer frame structure 602 , an interface between these two components may be sealed with silicone or rubber sealant.
[0045] In an embodiment, the outer frame structure houses a window pane 612 . Accordingly, installation of electrochromic window assembly 600 may be done such that the U-Factor is improved. For example, the electrochromic insert window assembly 600 may form a gap between window pane 612 and the electrochromic window assembly 612 . This gap may be filled with air and provide an additional layer of insulation that minimizes heat transfer.
[0046] FIGS. 7A and 7B depict a partial view of a system 700 for manufacturing an electrochromic assembly 702 . A conveyor 704 can be utilized to move the components from one station to another on the system 700 , as required. Here, a rolled sheet 708 of a thin film electrochromic device 710 unrolls and is applied to a superstrate 706 with a laminating film, pressure-sensitive adhesive, or other adhesion element 712 , which may also be unrolled or otherwise applied to the superstrate 706 . Other film layers (energy collection devices, energy storage devices, and/or controller, as described above) may be similarly applied. After each film application, the applied film may be cut and the superstrate 706 may be passed through one or more curing stations 714 . The curing stations 714 may apply pressure and heat to the assembly 702 so as to adhere each film to the superstrate 706 , while avoiding bubbles, tears, or other manufacturing defects. The completed assembly 702 may then be finished by integrating control wiring or bus bars, correcting litium loading, applying frame systems, etc. In another embodiment, the assembly 702 may be further processed as depicted in FIG. 7B , so as to form an electrochromic assembly 702 such as the type depicted in FIG. 4 . Here, the system 700 cuts or removes corners 716 from the electrochromic assembly 702 . Edges 718 of the assembly 702 are then folded so as to form the “box-like” configuration as depicted in FIG. 7B . Seams 720 at the intersection of each adjacent edge 718 may then be sealed so as to prevent water infiltration after installation. Other folds may be contemplated such as a “Z” fold or an “I” shaped fold.
[0047] FIG. 8 depicts a method 800 of manufacturing an electrochromic assembly utilizing the system of FIGS. 7A and 7B . The method 800 begins by affixing an electrochromic device (e.g., in the form of a thin-film layer) to a superstrate so as to form a subassembly, operation 802 . If desired, one or more of an energy storage device and an energy collection device can be affixed to the subassembly, operation 804 . Once the required or desired elements are affixed, a portion of the subassembly may be removed if it is desired to produce the electrochromic assembly having the configuration depicted in FIG. 4 , operation 806 . Typically, the removed portions are disposed proximate corners of the assembly. The edges disposed proximate the corners may then be folded, operation 808 . A controller, such as the type described herein can be attached to the subassembly, operation 810 , along with any control or power wiring, buses, etc. Additionally, a securement system can be attached to the subassembly, operation 812 .
[0048] FIG. 9 illustrates one example of a suitable operating environment 900 in which one or more of the present embodiments may be implemented. This is only one example of a suitable operating environment and is not intended to suggest any limitation as to the scope of use or functionality. Other well-known computing systems, environments, and/or configurations that may be suitable for use include, but are not limited to, personal computers, server computers, hand-held or laptop devices, multiprocessor systems, microprocessor-based systems, programmable consumer electronics such as smart phones, network PCs, minicomputers, mainframe computers, smartphones, tablets, distributed computing environments that include any of the above systems or devices, and the like.
[0049] In its most basic configuration, operating environment 900 typically includes at least one processing unit 902 and memory 904 . Depending on the exact configuration and type of computing device, memory 904 (storing, among other things, instructions to control an electrochromic device assembly) may be volatile (such as RAM), non-volatile (such as ROM, flash memory, etc.), or some combination of the two. This most basic configuration is illustrated in FIG. 9 by line 906 . Further, environment 900 may also include storage devices (removable, 908 , and/or non-removable, 910 ) including, but not limited to, magnetic or optical disks or tape. Similarly, environment 900 may also have input device(s) 914 such as touch screens, keyboard, mouse, pen, voice input, etc., and/or output device(s) 916 such as a display, speakers, printer, etc. Also included in the environment may be one or more communication connections, 912 , such as LAN, WAN, point to point, Bluetooth, RF, etc.
[0050] Operating environment 900 typically includes at least some form of computer readable media. Computer readable media can be any available media that can be accessed by processing unit 902 or other devices comprising the operating environment. 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, RAM, ROM, EEPROM, flash memory or other memory technology, CD-ROM, digital versatile disks (DVD) or other optical storage, magnetic cassettes, magnetic tape, magnetic disk storage or other magnetic storage devices, solid state storage, or any other medium which can be used to store the desired information. Communication media embodies computer readable instructions, data structures, program modules, or other data in a modulated data signal such as a carrier wave or other transport mechanism and includes any information delivery media. The term “modulated data signal” means a signal that has one or more of its characteristics set or changed in such a manner as to encode information in the signal. By way of example, and not limitation, communication media includes wired media such as a wired network or direct-wired connection, and wireless media such as acoustic, RF, infrared and other wireless media. Combinations of the any of the above should also be included within the scope of computer readable media.
[0051] The operating environment 900 may be a single computer operating in a networked environment using logical connections to one or more remote computers. The remote computer may be a personal computer, a server, a router, a network PC, a peer device or other common network node, and typically includes many or all of the elements described above as well as others not so mentioned. The logical connections may include any method supported by available communications media. Such networking environments are commonplace in offices, enterprise-wide computer networks, intranets and the Internet.
[0052] In some embodiments, the components described herein comprise such modules or instructions executable by computer system 900 that may be stored on computer storage medium and other tangible mediums and transmitted in communication media. Computer storage media includes volatile and non-volatile, 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. Combinations of any of the above should also be included within the scope of readable media. In some embodiments, computer system 900 is part of a network that stores data in remote storage media for use by the computer system 900 .
[0053] FIG. 10 is an embodiment of a network 1000 in which the various systems and methods disclosed herein may operate. In embodiments, portable device, such as client device 1002 , may communicate with one or more electrochromic assemblies, such as electrochromic assemblies 1004 and 1006 , via a network 1008 . In embodiments, a client device may be a laptop, a tablet, a personal computer, a smart phone, a PDA, a netbook, or any other type of computing device, such as the computing device in FIG. 9 .
[0054] The electrochromic assemblies 1004 and 1006 may have a device housing an operating environment depicted in FIG. 9 . For example, a controller on an electrochromic assembly may be include the operating environment depicted in FIG. 9 . The controller could then receive instructions from a client device, such as client device 1002 to control the opacity state of an electrochromic device. Additionally, the controller may receive instructions from a client device 1002 to decrease or increase the temperature of the assembly. This may occur when a superstrate is thermally controlled as described above.
[0055] Network 1008 may be any type of network capable of facilitating communications between the client device and one or more electrochromic assemblies 1004 and 1006 . Examples of such networks include, but are not limited to, LANs, WANs, cellular networks, and/or the Internet.
[0056] Portable device 1002 may interact with electrochromic assembly 1004 via network 1008 to send and receive information, such as status checks and instructions to change opacity states.
[0057] The embodiments described herein may be employed using software, hardware, or a combination of software and hardware to implement and perform the systems and methods disclosed herein. Although specific devices have been recited throughout the disclosure as performing specific functions, one of skill in the art will appreciate that these devices are provided for illustrative purposes, and other devices may be employed to perform the functionality disclosed herein without departing from the scope of the disclosure.
[0058] This disclosure described some embodiments of the present technology with reference to the accompanying drawings, in which only some of the possible embodiments were shown. Other aspects may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein. Rather, these embodiments were provided so that this disclosure was thorough and complete and fully conveyed the scope of the possible embodiments to those skilled in the art.
[0059] Although specific embodiments were described herein, the scope of the technology is not limited to those specific embodiments. One skilled in the art will recognize other embodiments or improvements that are within the scope and spirit of the present technology. Therefore, the specific structure, acts, or media are disclosed only as illustrative embodiments. The scope of the technology is defined by the following claims and any equivalents therein.
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An electrochromic insert adapted to be fitted into an existing window frame allowing an existing window to be retrofit to have the benefits of electrochromics. The insert may have a scaffold that fits into a window frame. Securing the insert to the frame may occur through a variety of ways including a bracket, a flexible tab, a brace, a screw, a bolt, a projection, a detent, and an adhesive. The technology allows for the electrochromic insert to include an electrochromic device, energy collection device, an energy storage device, and an electrochromic device controller. Such a configuration may be considered autonoumous such that it need not draw power from another source.
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FIELD OF THE INVENTION
This invention relates generally to devices for the dispensing of microliter volumes of liquid samples. More specifically, it relates to the dispensing of small volumes of liquid using a positive displacement technique.
BACKGROUND OF THE INVENTION
The accurate dispensing of small volume liquid samples is of great importance in many industries, particularly the biotechnology industry. Often, large numbers of liquid samples must be analyzed or manufactured. In many such processes in the biotechnology industry, the reagents used are expensive biochemicals. Therefore, it is advantageous to perform the necessary procedures with small quantities of reagent. This has created a demand for machines which can rapidly, accurately and repeatably dispense such small quantities. Typically, sample volumes in the range of 0.1-10 microliters are of interest.
Many prior art devices dispense from a pipette tip which must contact the surface or test tube which receives the sample. In such a device a drop is formed at the pipette tip and then the tip is contacted to the receiving surface or test tube to deposit the drop. This contact method suffers from contamination problems because of the necessity of contact. Such contamination problems are increased if two or more reagents are to be mixed by depositing them in the same test tube. Also, the volume of the dispensed liquid depends upon the surface characteristics of the tip and receiving surface, adversely affecting the volume accuracy. Therefore, it would be an improvement in the art to use noncontact techniques to dispense liquid samples. Noncontact implies that the liquid must be ejected as a free droplet.
Piezoelectric droplet ejectors as commonly used in ink-jet printers are well known in the art and demonstrate a technique for noncontact dispensing of liquids. However, such devices are too large and expensive to use with standard 96-well trays as used in many machines. This would require 96 piezoelectric droplet ejectors. Another problem with this solution is that the largest quantity of liquid that can be ejected is so small that many applications would require hundreds or thousands of droplets. This is time-consuming and relatively inaccurate because the sample size error increases with the number of droplets. Piezoelectric ejectors also have problems relating to reliability and wear.
It is known in the art that a syringe-type positive displacement device comprising a piston inside a pipette can be used to eject liquid samples in a noncontact (projectile) fashion. It is also known that such a device must eject the liquid with a velocity sufficient to overcome the surface tension forces that tend to form the liquid into round droplets (if accurate noncontact dispensing is desired). The formation of round droplets makes it difficult to control the precise volume of liquid dispensed. U.S. Pat. No. 5,525,302 to Astle, for example, discloses an apparatus which can be used in a manner in which the velocity of the ejected liquid is great enough to exceed the surface tension forces. One problem with the device of Astle is that the piston cannot eject the entire quantity of sample liquid inside the pipette in a positive displacement fashion. The narrowing taper at the tip of the pipette prevents the piston from positively displacing and ejecting all the liquid. This is because the piston is not free to move beyond the end of the tube. It is possible to eject the entire quantity of sample liquid by including in the pipette an air bubble and/or a quantity of inert working fluid such as water. However, this considerably complicates the procedure for aspirating and ejecting liquids. Another problem with the Astle invention and tapered pipettes generally is that the taper complicates the relationship between piston position and volume displacement. An accurate, clear relationship between piston position and volume displacement is very important for the dispensing of accurate liquid volumes.
U.S. Pat. No. 3,934,585 to Maurice discloses a device for projectile dispensing of small volumes from a tube tip. However, this invention uses a tube with a tapered tip, i.e. with a reduced diameter toward the end. Therefore, this invention has the same disadvantages associated with tapered tips as described above.
Therefore, there exists a need for a device which can accurately, conveniently and rapidly dispense small volume liquid samples in a noncontact fashion. Further, it would be advantageous for the device to be able to eject all the liquid contained within its pipette in a positive displacement fashion. It would also be advantageous for the device to have an accurate, clear relationship between piston position and volume displacement. The device should be a positive displacement device to provide the accuracy inherent in positive displacement methods.
OBJECTS AND ADVANTAGES OF THE INVENTION
Accordingly, it is a primary object of the present invention to provide a device for the dispensing of small volume liquid samples that:
1) is noncontact, i.e., does not require physical contact between the dispensing device and the receiving surface or test well;
2) rapidly dispenses liquid samples of accurate, repeatable volume;
3) provides an accurate, simple relationship between piston position and volume displacement;
4) is relatively inexpensive;
5) can be interfaced with standard, 96-well (with 9-mm centers) test trays; and
6) can dispense liquids in the volume range of approximately 0.1-10 microliters.
SUMMARY OF THE INVENTION
These objects and advantages are attained by a piston disposed inside a linear tube. The linear tube has a constant inner cross section (size and shape) along its entire length. Preferably, the linear tube is cylindrical, in which case it has a constant inner diameter. The piston is free to move axially inside the tube and preferably forms a liquid-tight seal with the inside walls of the tube. The inner cross sectional area of the tube is selected according to the volume of sample liquid to be dispensed; smaller sample volumes require a smaller tube cross sectional area.
Since the tube has a uniform inner cross sectional area and shape, a simple calculation of area X distance yields the volume displacement when the piston is displaced by a certain distance. The displacement volume is directly proportional to the piston displacement distance.
The tube has an open end through which the sample liquid is ejected. The open end also aspirates liquid when then piston is pulled back. In other words, the open end is used for both `sucking` and `spitting`. The open end of the tube is not tapered, but maintains the uniform inner cross section. This allows the piston to move out beyond the end of the tube through the open end.
A driving means such as a pneumatic actuator or solenoid is used to move the piston inside the linear tube. The driving means must be able to move the piston at a certain minimum velocity. The minimum velocity is determined by the type of liquid dispensed (its surface tension and adhesion characteristics) and the materials comprising the piston and linear tube. The piston velocity is selected such that the sample liquid is ejected from the tube end at a velocity great enough to render negligible the surface tension forces which tend to form the liquid sample into droplets.
The piston and sample liquid will need to be pulled back into the tube a distance before dispensing in order to provide the piston with a `running start` when ejecting a sample. This is because the sample liquid must exit the open tube end with a minimum velocity.
The tubes of the present invention have a small diameter which allows for accurate metering of the sample liquid. A cylindrical tube having an inner diameter of 0.48 millimeters, for example, has a volume displacement of 1.81 microliters per centimeter of piston displacement. Thus, the volume of liquid dispensed can be accurately determined by accurately positioning the piston inside the tube. Of course, there exist many well known techniques that can be used to accurately control the piston displacement.
DESCRIPTION OF THE FIGURES
FIG. 1 is a side view of a generalized version of the present invention.
FIG. 2 is a side view of an embodiment wherein the piston is a solid cylinder which does not form an airtight seal with the tube.
FIG. 3 shows how the piston can be controlled using a pneumatic linear actuator and stepper motor apparatus.
FIG. 4 shows the piston in an extended position beyond the open end of the tube.
FIGS. 5A, 5B, and 5C show how accurate sample volumes can be aspirated into the device.
FIGS. 6A, 6B, 6C, and 6D show how samples are ejected.
FIG. 7 shows a liquid sample being ejected into a test tube.
FIG. 8 shows a device which can simultaneously eject 8 liquid samples into a row of 8 test tubes.
FIG. 9 shows an alternative embodiment which can simultaneously eject 8 liquid samples into a row of 8 test tubes.
DETAILED DESCRIPTION
A specific embodiment of the present invention is shown in FIG. 1. A piston 20 is disposed within a tube 22 and is free to slide in the direction of the arrow 24 shown. The tube 22 is preferably cylindrical. The cross sectional shape and size of the interior of the tube 22 must be uniform along its length such that the piston 20 maintains contact with the inner tube walls as it moves. The uniformity of the tube shape necessarily extends to an open end 26 of the tube 22. This allows the piston 20 to exit the tube 22 through the open end 26. Sampled liquids are aspirated (inhaled) and ejected through the open end 26.
The tube 22 is preferably made of glass or quartz, but any suitable, relatively inert material may be used. Glass is preferred in part because it is inexpensively available with an accurate, uniform inner diameter. This feature of glass tubing allows the piston 20 to form a relatively good seal against the inside walls of the tube 22. Other materials that the tube 22 may be fabricated from include polymers and stainless steel.
The piston 20 preferably has a head portion 28 which is made of an inert elastomer material and a shaft portion 30 which is made of a relatively rigid metal such as stainless steel or tungsten wire. An elastomer head portion 28 can provide a fluid-tight seal, as is well known in the art of syringe construction.
Alternatively, the piston 20 can be a single, cylindrical piece of metal, plastic, or glass which is sized to fit inside the tube 22 with little clearance. This possibility is shown in FIG. 2, which illustrates a gap 25 between the piston 20 and the inner wall of tube 22. In this embodiment, the piston 20 does not form a fluid-tight seal with the inner wail of tube 22. However, the gap 25 is thin and the distance of piston-tube contact long, so the fit between the piston 20 and tube 22 is nearly fluid tight. Further, the present invention is operated in such a fashion that sample liquid does not have enough time to leak through the gap 25.
The inner diameter 32 of the tube 22 is selected according to the volume of sample liquid to be dispensed. In a particular embodiment of the invention, the tube 22 has an inner diameter 32 of 0.48 millimeters. This results in a volume displacement of 1.81 microliters per centimeter of piston 20 travel. As is explained below, the piston volume displacement is equivalent to the volume of liquid dispensed. The volume displacement is proportional to the inner cross sectional area, so a smaller inner diameter tube 20 can be used to dispense smaller volumes. It is understood that an accurate movement of the piston 20 results in an accurate amount of piston volume displacement.
FIG. 3 illustrates a preferred apparatus which can be used to control the motions of the piston 20 inside the tube 22. A compressed air source 36 is connected to both sides of a pneumatic actuator 38 through two valves 34. The actuator piston 39 can be made to move up and down by controlling the valves 34. The actuator piston 39 is connected to the piston 20 inside the tube 22. The lower limit 44 of the piston range 42 is determined by a mechanical stop 40 inside the actuator 38. The upper limit 46 of the piston range 42 is determined by a movable stop plate 43 which blocks a collar 45 on the piston shaft 30. The stop plate 43 can be moved 47 vertically by means of a lead screw 41 attached to a stepper motor. Controlling the stepper motor thus controls the upper limit 46 of the piston range 42. Other means of accurately controlling the limits 44, 46 of piston 20 motion will be obvious to one skilled in the art of mechanical engineering. Also, other means of moving the piston 20 will be obvious. The apparatus of FIG. 3, for example, may further include a means for accurately sensing and controlling the piston 20 position electronically.
FIG. 4 illustrates a preferred feature of the present invention in which the bottom limit 44 is slightly past the open end 26 of the tube 22. This feature improves the ability of the piston 20 to eject all the aspirated liquid. The distance between the open end 26 and the top limit 46 determines the amount of piston volume displacement.
It will be obvious to one skilled in the art of mechanical design that there exist techniques other than the use of mechanical stops for assuring that the piston 20 has an accurately determined range 42 of motion.
FIGS. 5A, 5B, and 5C illustrate the process by which sample liquid 48 is aspirated into the tube 22. First, while the piston 20 is at the bottom limit 44 position, the open end 26 and piston 20 are partially submerged in a reservoir 50 containing sample liquid 48. Next, as illustrated in FIG. 5B, the piston 20 is pulled back a predetermined distance. This distance is determined by the stop plate 43 as shown in FIG. 3. Also preferably, the piston 20 is pulled back slowly. Slow movement of the piston 20 can be accomplished by slowly allowing compressed air into the pneumatic actuator 38 shown in FIG. 3. Removing the tube and piston assembly (FIG. 5C) from the reservoir 50 leaves an accurately determined volume of liquid 56 (the sample) remaining in the end of the tube 22. The volumetric error due to the curved liquid surface 54 is small because, for most liquids, the curvature is small as a result of the small inner diameter 32 of the tube 22.
The length 57 and cross sectional area of the sample liquid 56 determines the volume of the sample 56. For example, if the inner diameter 32 of the tube is 0.48 millimeters, then the volume of the sample 56 is 1.81 microliters per centimeter of sample liquid length 57. A sample 56 5 millimeters long will have a volume of 0.905 microliters. It will be obvious to one skilled in the art of liquid measurement how to select the inner diameter 32 and sample length 57 to produce a sample of a desired volume. It is understood that the present invention can be used to select sample volumes approximately in the range of 0.1-10 microliters by using tubes with different inner diameters and by aspirating samples 56 of different lengths.
FIGS. 6A-6D illustrate the method by which the liquid sample 56 is ejected from the tube 22. First, the liquid sample 56 is drawn further into the tube 22 by pulling 58 the piston 20 into the tube 22. This step provides a running start for the sample 56 to reach a minimum exit velocity before it reaches the end of the tube 26. More specifically, the distance 59 between the bottom edge of the sample 56 and the tube end 26 must be great enough to allow the sample to be accelerated to the minimum exit velocity before it reaches the end 26 of the tube 22.
Next, as shown in FIGS. 6B and 6C, the piston 20 is rapidly accelerated downward, achieving the minimum exit velocity before the sample 56 reaches the open end 26. Finally, at the end of the delivery cycle shown in FIG. 6D, the piston 20 comes to a sudden stop slightly beyond the tube end 26, and the sample 56 continues as a flying cylinder of liquid 56. The sample 56 leaves the tube 22 approximately as a cylinder because its velocity is so high that surface tension forces do not have time to deform the sample 56 and are not great enough to overcome the sample inertia. This is an essential feature of the present invention. The piston 20 comes to a sudden stop of sufficient deceleration such that a droplet of the sample 56 cannot adhere to the endface 60 of the piston 20. The minimum exit velocity required for the entire sample 56 to be ejected depends upon the density and surface tension of the sample liquid 56 and on the wettability of the piston 20.
If the piston 20 is made of a material readily wettable by the sample liquid 56, then the sample 56 will adhere to it more strongly. This, in turn, results a higher required piston deceleration, which generally requires a higher piston velocity. This is undesirable in most situations. Teflon is a good material to use for the piston face 60 because it is relatively unwettable by many liquids, including water.
As an illustrative example, a sample of water can be successfully ejected from a 0.48 millimeter diameter glass tube with a teflon piston?? by providing an exit velocity of about 1.4 meters per second. It is expected that most water-based samples can be ejected using exit velocities in the approximate range of 1.2-1.6 meters per second. Minimum exit velocities for other liquids may need to be determined empirically.
The sudden stop of the piston is preferably provided by a mechanical stop 40 as shown in FIG. 3. The mechanical stop 40 is preferably made of a somewhat compliant material such as hard rubber such that the piston 20 bounces slightly at the end of the delivery cycle. A small bounce in the piston motion improves the ability of the piston 20 to eject all the sample liquid 56. In other words, a bounce helps prevent a droplet of sample liquid from adhering to the piston endface 60.
If the sample 56 is ejected too slowly (slower than the minimum exit velocity), then surface tension forces will cause the sample to form a droplet and the sample 56 will adhere to the open end 26 of the tube 22 as a droplet.
The piston 20 is preferably accelerated by means of a pneumatic linear actuator as shown in FIG. 3. Such actuators provide the smooth, even and powerful forces necessary for the present invention. Pneumatic linear actuators are very well known in the art. However, other linear actuators such as electromagnetic solenoids or spring-loaded devices may also be used.
Since the sample 56 mass is much smaller than the mass of the pneumatic actuator mechanism (actuator piston 39), the acceleration of the piston 20 during sample ejection will be relatively independent of sample mass. This implies that the running start distance 59 required will be independent of sample volume. The running start distance 59 in a particular device will only depend upon the piston acceleration and the required sample exit velocity. In the case of using a pneumatic actuator the piston acceleration can be controlled by changing the compressed air pressure.
FIG. 7 shows the present invention dispensing a liquid sample 56 into a test tube 62. Since the liquid sample is ejected from the dispenser of the present invention as a projectile, it may be aimed into a test tube 62 or test well of a 96-well tray. This feature means that the dispensing can be performed without any part of the dispenser (tube 22 or piston 20) contacting the test tube 62. Thus, the present invention provides a noncontact dispensing device.
It is an object of the present invention to provide a liquid sample dispenser which can be used with the standard 96-well trays commonly used in biochemical laboratory processes. Such an application requires that 96 tubes with 96 pistons be assembled to provide 96 liquid sample dispensers. The dispensers of the present invention are small enough to fit in a grid with 9 millimeter center-to-center distance as is standard in 96-well trays. The 96 dispensers can be individually controlled by 96 separate actuators, or may be driven by a single actuator such that they operate in unison.
FIG. 8 shows an embodiment designed for simultaneously ejecting 8 identical liquid samples 56 into 8 test tubes 62. Here, 8 pistons 20 are moved within 8 tubes 22 by a single linear actuator 38. The 8 pistons 20 are mounted to a common mechanical support 64 which is moved by the linear actuator 38. Similarly, 8 tubes are held by a common mechanical support 66. It is obvious that any number of dispensers can be operated in the fashion of FIG. 8 and that two dimensional arrays of dispensers can be constructed. Of course, mechanical stops can be used to provide an accurate range of motion for the pistons 20.
FIG. 9 shows an alternative embodiment of the present invention in which the multiple tubes 22 of FIG. 8 are replaced with a solid block of material 68 having parallel holes 70 of accurate, predetermined diameter. The pistons 20 are moved within the holes 70 by a linear actuator 38. The block 68 can be made of glass, plastic, metal or any suitable, inert material. This embodiment can provide a dispenser for a 96 well tray by drilling a grid of 96 holes with 9 mm centers in the block 68.
It will be clear to one skilled in the art that the above embodiment may be altered in many ways without departing from the scope of the invention. Accordingly, the scope of the invention should be determined by the following claims and their legal equivalents.
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A piston is disposed inside a tube having an inner cross sectional size and shape uniform along its length. The tube has an open end. The piston is free to move linearly inside the tube and preferably may move out of the tube through the open end. If the tube is cylindrical, for example, it has a constant inner diameter. The open end of the tube is neither tapered or flaring. Liquid samples are aspirated into the device by pulling the piston back. The sample is then ejected by accelerating the piston to a minimum velocity to force the liquid sample out of the open end of the tube. The velocity of the sample is sufficient to render negligible the effects of surface tension forces. The volume of the liquid sample dispensed is determined by the inner diameter of the tube and the piston displacement. Accurate positioning of the piston provides samples of accurate volumes. A specific embodiment of the present invention uses a tube with an inner diameter of 0.5 mm, resulting in a volume displacement of 1.9 microliters per centimeter of piston travel.
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FIELD OF THE INVENTION
[0001] The present invention relates optical coherence tomography (OCT). In particular, the device relates to OCT for use in the diagnosis of otitis media (OM).
BACKGROUND OF THE INVENTION
[0002] Otitis Media is a common disease of the inner ear, involving tissue inflammation and fluidic pressure which impinges on the tympanic membrane. Otitis Media may be caused by a viral infection, which generally resolves without treatment, or a bacterial infection, which may progress and cause hearing loss or other deleterious and irreversible effects. Unfortunately, it is difficult to distinguish between viral or bacterial infection using currently available diagnostic devices, and the treatment methods for the two underlying infections are quite different. For bacterial infections, antibiotics are the treatment of choice, whereas for viral infections, the infection tends to self-resolve, and antibiotics are not only ineffective, but may result in an antibiotic resistance which would make them less effective in treating a subsequent bacterial infection.
[0003] The definitive diagnostic tool for inner ear infections is myringotomy, an invasive procedure which involves incisions into the tympanic membrane, withdrawal of fluid, and examining the effusion fluid under a microscope to identify the infectious agent in the effusion. Because of complications from this procedure, it is only used in severe cases. This presents a dilemma for medical practitioners, as the prescription of antibiotics for a viral infection is believed to be responsible for the evolution of antibiotic resistance in bacteria, which may result in more serious consequences later in life, and with no efficacious result, as treatment of viral infectious agents with antibiotics is ineffective. An improved diagnostic tool for the diagnosis of otitis media is desired.
OBJECTS OF THE INVENTION
[0004] A first object of the invention is a non-invasive medical device for the identification of fluid type adjacent to a tympanic membrane.
[0005] A second object of the invention is a method for identification of a fluid adjacent to a tympanic membrane.
[0006] A third object of the invention is a method for performing optical coherence tomography for identification of a film characteristic adjacent to a tympanic membrane.
[0007] A fourth object of the invention is an apparatus for performing optical coherence tomography for identification of a fluid characteristic adjacent to a tympanic membrane.
[0008] A fifth object of the invention is an apparatus and method for characterization of a tympanic membrane and adjacent materials by coupling a pressure excitation source to a tympanic membrane, where the tympanic membrane is illuminated through a measurement path by an optical source having low coherence, the low coherent optical source also coupled to a reference path and to a mirror, where reflections from the mirror and reflections from the tympanic membrane are summed and presented to a detector, the reference path length modulated over a range which includes the tympanic membrane, the detector thereby receiving reflected optical energy from the tympanic membrane through the measurement path and also from the mirror through the reference path, such that modulation of the reference path length at a sufficiently high rate allows for estimation of the tympanic membrane position in response to the pressure excitation, thereby providing characterization of the tympanic membrane and adjacent fluid.
[0009] A sixth object of the invention is an optical coherence tomography system having a measurement path and a reference path, the reference path modulated in length, the measurement path and reference path coupled through an optical splitter to an optical source having low coherence, where reflected optical energy from the reference optical path and reflected optical energy from the measurement optical path are summed and provided to a wavelength splitter and thereafter to a plurality of detectors, one detector for each sub-range of wavelengths within the wavelength spectrum of the low coherence optical source, the plurality of detectors coupled to a controller discriminating by wavelength characteristics the detector response for at least two different reflective materials.
SUMMARY OF THE INVENTION
[0010] An optical coherence tomography (OCT) device has a low coherence optical source generating optical energy coupled through a first splitter, thereafter to a second splitter, the second splitter having a measurement optical path to a tympanic membrane and also a reference optical path to a reflector which returns the optical energy to the first splitter, where the reflected optical energy is added to the optical energy reflected from the measurement optical path. The combined reflected optical energy is then provided to the first splitter, which directs the optical energy to a detector. The reflector is spatially modulated in displacement along the axis of the reference optical path such that the detector is presented with an optical intensity and optionally a continuum of optical spectral density from a particular measurement path depth, when the measurement optical path and reference optical path are equal in path length. When the device is positioned with the measurement path directed into an ear canal and directing optical energy to a tympanic membrane, by varying the reference optical path length through translation of the location of the reflector along the axis of the reference optical path, a measurement of optical and spectral characteristics of the tympanic membrane may be performed. Additionally, an external pressure excitation may be applied to provide an impulsive or steady state periodic excitation of the tympanic membrane during the OCT measurement, and a peak response and associated time of the peak response identified. The temporal characteristics and positional displacement of the tympanic membrane can be thereafter examined to determine the tympanic membrane response to the external pressure excitation. The evaluation of the tympanic membrane response from the OCT detector data may subsequently be correlated to a particular viscosity or biofilm characteristic. By examination of the temporal characteristic, an estimate of the viscosity of a fluid adjacent to a tympanic membrane may be determined, and the viscosity subsequently correlated to the likelihood of a treatable bacterial infection.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] FIG. 1 shows a block diagram of an optical coherence tomography characterization system.
[0012] FIG. 2A shows a plot of mechanical actuator displacement vs actuator voltage.
[0013] FIG. 2B shows a plot of reference path length over time, as controlled by actuator voltage or current.
[0014] FIG. 3 shows a block diagram for an optical coherence tomography characterization system for use examining a tympanic membrane.
[0015] FIG. 4 shows a polychromatic detector.
[0016] FIG. 5A shows a plot of an example excitation waveform for modulation of a reference length
[0017] FIG. 5B shows a detector signal for a tympanic membrane adjacent to fluid such as from OME and a detector signal for a normal tympanic membrane.
[0018] FIG. 6 shows an optical waveguide system for measurement of a tympanic membrane.
[0019] FIG. 7 shows an optical waveguide system for measurement of a tympanic membrane with an excitation source.
[0020] FIG. 8A shows a plot for a sinusoidal excitation applied to deformable surface or membrane with a reflected response signal.
[0021] FIG. 8B shows a plot for a step excitation applied to a deformable surface or membrane, and a response to the step excitation.
DETAILED DESCRIPTION OF THE INVENTION
[0022] FIG. 1 shows a block diagram for an optical coherence tomography (OCT) device according to one example of the invention. Each reference number which appears in one drawing figure is understood to have the same function when presented in a different drawing figure. A low coherence source 102 such as a broadband light emitting diode (LED) with a collimated output generates optical energy along path 104 to first optical splitter 106 , and optical energy continues to second optical splitter 108 , where the optical energy divides into a measurement optical path 118 and a reference optical path 112 , which include the segment from second splitter 108 to mirror 110 to path length modulator 114 . The optical energy in the measurement optical path 118 interacts with the tympanic membrane 120 , and reflected optical energy counter-propagates to the detector via path 118 , where it is joined by optical energy from reference optical path 112 reflected from mirror 110 and splitter 108 , and the combined reflected optical energy propagates to first splitter 106 , thereafter to mirror 105 , and to detector 124 via path 122 . Detector 124 generates an electrical signal corresponding to the intensity of detected optical energy on path 122 , which is a steady state maximum when the path length for reflected optical energy from the tympanic membrane is exactly the same length as the reference optical path, and a temporal maximum if the reference optical path length is swept over a range, such as by actuating path length modulator 114 over time. Each type of reflective membrane will produce a characteristic detector signal. For example, as the reference path length traverses through a thin membrane boundary such as a healthy tympanic membrane, a single peak will result corresponding to the single reflective region of the tympanic membrane. If the reference path length is through a fluidic ear such as one containing low-viscosity infectious effusion, an initial peak of the tympanic membrane reflection will subsequently generate a region of extended reflection with an amplitude that drops from optical attenuation of the reflected signal. If the reference path length traverses through the tympanic membrane with a bacterial infection, a bacterial film may be present on the opposite surface of the tympanic membrane, which may produce a greater axial extent of reflection, followed by a pedestal indicating a high scattering coefficient and corresponding increased attenuation. Additionally, the three types of fluid viscosities behind the tympanic membrane (air vs thin fluid vs thick fluid) will respond differently to pressure excitations generated on the tympanic membrane. Accordingly, is possible to modulate the reference optical path length and optionally the pressure adjacent to the tympanic membrane, and examine the nature of the detector output signal and response to excitation pressure to determine the presence or absence of fluid adjacent to the tympanic membrane, the presence or absence of a biofilm such as bacteria adjacent to the tympanic membrane, and the viscosity of fluid adjacent to the tympanic membrane, all from movement of the tympanic membrane on the measurement optical path as presented at the detector output.
[0023] In one example of the present invention, the path length modulator 114 varies the reference path length by a distance corresponding to the measurement path length from 126 a to 126 d of FIG. 1 , corresponding to a region of movement of a tympanic membrane 115 to be characterized. As modulator 114 increases the reference path length, the signal delivered to the detector is closer to region 126 d and when modulator 114 decreases the distance of the reference path length, the region signal delivered to the detector is in region 126 a.
[0024] FIG. 2A shows an example relationship between actuator voltage or current and axial displacement of path length modulator 114 , which is driven by a mechanical driver circuit 116 , which may be a voice coil driver for a voice coil actuator coupled to mirror 114 , modulating the mirror about the optical axis of 112 . The type of driver and path length modulator 114 is dependent on the highest frequency of displacement modulation, since the energy to displace path length modulator 114 is related to the mass of the path length modulator 114 , such as the case of a moving mirror. The mirror and actuator may be micro electrical machined system (MEMS) for lower reflector mass and correspondingly faster mirror response. It may be possible to utilize a variety of other path length modulators without limitation to the use of mirrors.
[0025] FIG. 2B shows the controller 117 generating an actuator voltage in a step-wise manner, with the actuator stopping momentarily at each depth. For example, if increased actuator drive results in a longer reference path length, then from T 1 to T 2 , the actuator voltage may be 202 a , corresponding to the displacement position 126 a of FIG. 1 , and the other voltages 202 b , 202 c , and 202 d may correspond to positions adjacent to the tympanic membrane of 126 b , 126 c , and 126 d , respectively.
[0026] FIG. 3 shows an example OCT tympanic membrane characterization system 302 with the elements arranged to provide a single measurement output. For the case of free-space optics (optical energy which is not confined within a waveguide such as an optical fiber), the system splitters and combiners of FIGS. 1 and 3 are partially reflective mirrors. The principal elements show in FIG. 3 correspond to the same functional elements of FIG. 1 . By rearrangement of the reference optical path, the elements of the system may be enclosed, as shown.
[0027] In one example of the invention, detector 124 may be a single omni-wavelength optical detector responsive to the total applied optical intensity, and having a characteristic response. In another example of the invention detector 124 may include a single wavelength filter, or a chromatic splitter and a plurality of detector elements, such that each reflected optical wavelength may be separately detected. FIG. 4 shows collimated optical energy 122 entering chromatic detector 124 A, where it is split into different wavelengths by refractive prism 124 B, which separates the wavelengths λ 1 , λ 2 , λ 3 , λ 4 onto a linear or 2D detector 124 C, which is then able to provide an intensity map for the reflected optical energy by wavelength. Individual detection of wavelengths may be useful where the signature of wavelength absorption is specific to a particular type of bacteria or tympanic membrane pathology. The spectrum of detector response is typically tailored to the reflected optical energy response, which may be in the IR range for an OCT system with more than a few mm of depth measurement capability. In one example of the invention, the detector spectral response for various biological materials is maintained in a memory and compared to the superposition of responses from the plurality of optical detectors. For example, the optical reflective characteristics of cerumen (earwax), a healthy tympanic membrane, an inflamed tympanic membrane (a tympanic membrane which is infused with blood), a bacterial fluid, an effusion fluid, and an adhesive fluid may be maintained in a template memory and compared to the spectral distribution of a measured tympanic membrane response over the axial depth of data acquisition. The detector response at each axial depth over the range of reference optical path length can then be compared to the spectral characteristics of each of the template memory spectral patterns by a controller, with the controller examining the detector responses for each wavelength and the contents of the template memory and estimating the type of material providing the measurement path reflection based on this determination. The detection of a spectral pattern for cerumen may result in the subtraction of a cerumen spectral response from the detector response, and/or it may result in an indication to the user that earwax has been detected in the response, which the user may eliminate by pointing the measurement optical path in a different region of the tympanic membrane.
[0028] Because the axial resolution of the optical coherence tomography is fractions of an optical wavelength, it is possible to characterize each of the structures separately on the basis of optical spectrum, even though each of the structures being imaged is only on the order of a hundred microns in axial thickness. The axial resolution of the system may be improved by providing a very narrow optical beam with high spatial energy along the measurement axis and over the axial extent of the tympanic membrane.
[0029] FIGS. 5A and 5B show an example of the invention for use in detecting position of a tympanic membrane over time. The controller 117 generates a triangle waveform 502 for use by the path length modulator, which directs the optical energy to the tympanic membrane, which may have fluid adjacent to it, and the fluid may have a particular viscosity, which may be known to increase during the progression of a bacterial infection. Bacterial infections are known to provide a biological film on the surface of a membrane, such as the tympanic membrane, with specific optical reflection characteristics. The optical signal is directed through the outer ear canal towards the tympanic membrane to be characterized, and the detector responses of FIG. 5B are examined by controller 117 of FIG. 3 . A first set of waveforms 509 shows a time domain response which includes an initial peak 507 associated with the strong reflection of the sharp reflective optical interface provided by the tympanic membrane at a first reflective interface, and the fluid behind the tympanic membrane also generates a signal which attenuates with depth, shown as a sloped pedestal 508 . The presence of pedestal 508 indicates the presence of fluid behind the tympanic membrane. This may be contrasted with the second set of responses 511 for a normal tympanic membrane, such as the peak of waveform 522 , which is comparatively narrow and of shortened duration 520 , as reflective fluid is not present behind the tympanic membrane.
[0030] In an additional embodiment of the invention, the tympanic membrane itself may be modulated by an external excitation source, such as an air puff, or a source of air pressure which is modulated over time. Where an external pressure excitation source is provided, and the pressure excitation is selected to provide less than 1% displacement of the tympanic membrane, for example, the relative temporal position of the peak optical signal will indicate the position of the tympanic membrane. Because the refresh rate of the system is optical, rather than acoustic of prior art ultrasound devices, the speed of interrogation of the tympanic membrane is only limited by the rate of modulation of the path length modulator 114 , which may be several orders of magnitude faster than an ultrasound system. Additionally, the axial resolution of an optical system relying on optical interferometry is much greater than the axial resolution of an ultrasound system which is governed by transducer ringdown. Additionally, because the acoustic impedance boundary between air and the tympanic membrane is extremely large, the ultrasound penetration depth of ultrasound to structures beyond the tympanic membrane is very limited. By contrast, the optical index of refraction ratio from air to tympanic membrane is many orders of magnitude lower than the ultrasound index of refraction ratio across this boundary, so the optical energy loss at the interface is lower. The optical penetration is primarily bounded by the scattering losses associated with the tympanic membrane and structures beyond the tympanic membrane interface, and these losses may be mediated in part by using a very high optical energy which is pulsed with a duty cycle modulation to maintain the average power applied to the tympanic membrane in a reasonable average power range.
[0031] FIG. 6 shows a fiber-optic example of an optical coherence tomography system 600 . Controller 618 coordinates the various subsystems, including enabling low coherence source 602 , which couples optical energy to an optical fiber 604 , which delivers this optical energy thereafter to a first splitter 606 , thereafter to optical fiber 608 and to second splitter 610 . Optical energy from second splitter 610 is directed down two paths, one a measurement path 612 with length Lmeas 615 to a tympanic membrane, and the other to reference optical path 617 with length Lref and terminating into an open reflective fiber end 619 , which may alternatively be a mirrored polished end or optical reflective termination, with the optical path 617 including an optical fiber wrapped around a PZT modulator 614 , which changes dimensional shape and diameter when an excitation voltage is applied to the PZT. When the PZT modulator 614 is fed with a sine wave or square wave excitation, the PZT modulator 614 increases and decreases in diameter, thereby providing a variable length Lref. The PZT modulator 614 is also capable of high speed fiber length modulation in excess of 100 Khz in frequency. Other fiber length modulators known in the art may be used for rapidly changing the length of optical fiber on the Lref path, with the PZT modulator 614 shown for reference only. The combined optical energy from the Lmeas path and Lref path reach the second splitter 610 and return on fiber 608 , comprising the sum of optical energy reflected from PZT modulator 614 and reflected from the tympanic membrane 650 . The combined optical energy travels down path 608 to first splitter 606 , through fiber 620 , and to detector 622 , where the coherent optical energy superimposes and subtracts, forming a detector 622 output accordingly, which is fed to the controller 618 for analysis. The controller 618 also generates the PZT modulator excitation voltage 616 , such as the voltage or current waveform 502 of FIG. 5A , and may also generate a signal to enable the low coherence source 602 , and perform analysis of the detector 622 response, which may be a single intensity value over the wavelength response of the detector 622 , or the individual wavelength output provided by the sensor of FIG. 4 . The controller acts on the detector responses in combination with the Lref modulation function to determine an effusion metric which may be correlated to the likelihood of fluid being present adjacent to a tympanic membrane, and also provide an indication of the viscosity of the fluid adjacent to the tympanic membrane.
[0032] FIG. 7 shows an extension of FIG. 6 with an external tympanic membrane excitation generator 704 which delivers miniscule pressure changes such is actuated by a voice coil actuator or other pressure source, preferably with peak pressures below 50 deka-pascals (daPa) for application to a tympanic membrane. The modulation of the reference path length by the PZT modulator 614 is at a rate which exceeds the highest frequency content of the excitation generator 704 by at least a factor of 2 to satisfy the Nyquist sampling requirement.
[0033] In one example of the invention, the reference path length is modulated by a first modulator and second modulator operative sequentially, where the first modulator provides a large but comparatively slow reference path length change, and the second modulator provides a small but comparatively fast reference path length change. In this manner, the first modulator is capable of placing the region of OCT examination within a region of interest such as centered about a tympanic membrane, and the second modulator is capable of quickly varying the path length to provide a high rate of change of path length (and accordingly, a high sampling rate) for estimation of tympanic membrane movement in response to the pressure excitation.
[0034] It can be seen in the tympanic membrane shown as 115 in FIGS. 1 and 3, and 650 in FIGS. 6 and 7 , that the tympanic membrane has a conical shape with a distant vertex ( 119 of FIGS. 1 and 3, 651 of FIGS. 6 and 7 ), which is known in otolaryngology as the “cone of light”, as it is the only region of the tympanic membrane during a clinical examination which provides a normal surface to the incident optical energy. Similarly, when using an ultrasonic source of prior art systems, the cone of light region is the only part of the tympanic membrane which provides significant reflected signal energy. The optical system of the present invention is operative on the reflected optical energy from the surface, which need not be normal to the incident beam for scattered optical energy, thereby providing another advantage over an ultrasound system.
[0035] FIG. 8A shows an example sinusoidal pressure excitation from excitation generator 704 applied to a tympanic membrane, such as a sinusoidal waveform 821 applied using a voice coil diaphragm actuator displacing a volume sufficient to modulate a localized region of the tympanic membrane or surface pressure by 100 daPa (dekapascals) p-p. Sub-sonic (below 20 Hz) frequencies may require sealing the localized region around the excitation surface, whereas audio frequencies (in the range 20 Hz to 20 kHz) and super-audio frequencies (above 20 kHz) may be sufficiently propagated as audio waves from generator 704 without sealing the ear canal leading to the tympanic membrane to be characterized. The sinusoidal pressure excitation 821 results in a modulation of the surface, which is shown as plot 832 , as the modulation in surface position corresponds to a change in the associated Lref path length by the same amount. Each discrete circle of waveform 832 represents a sample point from the OCT measurement system 700 , corresponding to the Lref path length and change in tympanic membrane position, with each point 332 representing one such sample. In one example embodiment of the invention, a series of sinusoidal modulation excitation 821 frequencies are applied, each with a different period 822 , and the delay in response 830 and peak change in Lref are used in combination to estimate the ductility or elasticity of the tympanic membrane, fluid viscosity, or other tympanic membrane or fluid property. In the present examples, there is a 1:1 relationship between the displacement of the tympanic membrane and associated change in path length of the reference path which results in the peak response. For example, if the scale of FIG. 5B is a sequence of 0, −0.5 mm, −1 mm, −0.5 mm, 0 mm, 0.5 mm, etc, then this represents a corresponding displacement in the tympanic membrane by these same distances. By applying a series of audio and sub-audio tones with various cycle times 822 and measuring the change in Lref as shown in plot 832 , it is possible to estimate the displacement of the tympanic membrane and extract frequency dependent characteristics such as viscosity or elasticity of the fluid behind the tympanic membrane. For example, an exemplar elasticity metric measurement associated with the changed density or viscosity of the fluid could be an associated change in surface or membrane response time 874 for a step change, or phase delay 830 for a sinusoidal frequency. In this manner, a frequency domain response of the surface may be made using a series of excitations 821 and measuring a series of surface responses 832 . The reference path modulator 614 of FIGS. 6 and 7 , or mirror 114 of FIG. 3 , may include a first path length modulator which centers the reference path length to include the tympanic membrane, and a second path length modulator which rapidly varies the reference path length to provide adequate sampling of the axial movement of the tympanic membrane.
[0036] Whereas FIG. 8A shows a sinusoidal excitation which may be provided in a series of such excitations to generate a phase vs. frequency response plot of the surface displacement from the series of measurements, FIG. 8B shows a time domain step response equivalent of FIG. 8A , where a surface step pressure excitation 862 of 50 daPa peak is applied to the tympanic membrane, which generates the measured tympanic membrane displacement sequence 872 . It is similarly possible to characterize the surface response based on a time delay 874 and amplitude response (shown as 0.5 mm) for displacement response plot 872 .
[0037] In one example of the invention, a separate low-coherence optical source 102 or 602 such as an infrared range source is used for increased penetration depth, and a separate visible source (not shown) is used co-axially to indicate the region of the tympanic membrane being characterized while pointing the measurement optical path onto the tympanic membrane. The optical source 102 or 602 may be an infrared sources to reduce scattering, thereby providing additional depth of penetration. In another example of the invention, the low-coherence optical source 102 or 602 is a visible optical source, thereby providing both illumination of the tympanic membrane region of interest, and also measurement of displacement of the tympanic membrane, as previously described.
[0038] The present examples are provided for understanding the invention, it is understood that the invention may be practiced in a variety of different ways and using different types of waveguides for propagating optical energy, as well as different optical sources, optical detectors, and methods of modulating the reference path length Lref. The scope of the invention is described by the claims which follow.
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An OCT apparatus and method for characterization of a fluid adjacent to a tympanic membrane has a low coherence source which is coupled to a splitter which has a measurement path and a reference path. The reference path is temporally modulated for length, and the combined signals from the reference path and the measurement path are applied to a detector. The detector examines the width of the response and the time variation when an optional excitation source is applied to the tympanic membrane, the width of the response and the time variation forming a metric indicating the viscosity of a fluid adjacent to the tympanic membrane being measured.
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BACKGROUND OF THE INVENTION
The present invention relates to windows having frames with multiple tracks or channels therein for sashes and, more particularly, for features other than sashes such as screens.
Windows, including windows for doors such as storm doors, are, in many instances, desired to have features beyond a pair of window sashes therein formed as frames containing one or more transparent windowpanes. Of course, most commonly, such windows are desired to have a mesh screen added therein to the pair of window sashes so that portions of the window can be left open by adjusting the positions of one or both sashes without also allowing insects to pass therethrough. In addition, although windows are often constructed with a single large pane being used in each sash, there is a desire to have that pane appear to be divided into a plurality of smaller windowpanes, or windowlights, by placing a relatively coarse rectangular mesh, or other shaped mesh, in front of such a single windowpane so as to appear to divide that single pane into several
Furthermore, there is often a desire to provide security against intruders entering the building in which the window is positioned by going through that window. Thus, there is often a need to have security bars or a grill or the like incorporated in the window so as to prevent intruders passing therethrough by merely breaking the window. The presence of so many features in a window has, however, caused windows in the past to be complicated, bulky or expensive, or all three. Thus, there is a desire to provide a window with these features which is aesthetically pleasing, relatively secure and economical.
SUMMARY OF THE INVENTION
The present invention provides a window with an outer frame for mounting in a window opening in a structure. This outer frame has side members therein which include window sash tracks, or channels, that open, or face, one another across the window space within that frame. Window sashes formed of a window frame containing at least one transparent windowpane can be positioned between and secured in such channels so as to allow their being slid therealong to open and close the window. Protuberances extending from the windowframe secure the window sashes between and allow sliding along the channels, and removing such window sashes from those channels is accomplished by removing protuberances from the channels.
A blocking panel is positionable in the outer frame in the absence of such window sashes and can also be removed therefrom in such sash absences, but is not removable when the window sashes are present. A relatively rigid tube structure, that can be formed in a coarse mesh, is provided affixed to a panel frame provided in the blocking panel, and a screen structure with a finer mesh is also provided in that panel. Furthermore, a flexible blocking strip can be located between the panel frame and the outer frame to further secure the panel in the outer frame against forcible intrusion. The panel channels in the outer frame at the ends of the side members prevent the panel from being pulled out of the outer frame.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1A and 1B show a portion of a building having in a door opening therein a door structure with a window arrangement in a window opening therein embodying the present invention with window sashes in alternative positions,
FIG. 2 shows a cross section view of a portion of the structure shown in FIG. 1A,
FIG. 3 shows another cross section view of a portion of the structure shown in FIG. 1B,
FIG. 4 shows an exploded view of a portion of the structure shown in FIGS. 1A and 1B, and
FIGS. 5 through 10 show fragmentary cross section views of various portions of the structure shown in FIGS. 1A and 1B.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The present invention provides a decorative and secure window arrangement, 10, shown mounted in a storm door, 11, in FIGS. 1A and 1B. A handle, 12, is shown on the right side of door 11 as a part of a door latch mechanism for keeping the door against the jam when closed, and hinges, 13, are shown joining the door to the supporting structure therearound. A decorative panel, 14, is shown in the kickplate portion of door 11. FIG. 1A also indicates that a vertical cross-section view is provided in FIG. 2, and FIG. 1B indicates that a horizontal cross-section view is provided in FIG. 3.
Turning to FIGS. 2 and 3, storm door 11 is shown in cross-sectional views that are interrupted in several places to remove unneeded view portions to thereby limit the extent of the views shown. These interrupted cross-sectional views show that door 11 is formed of rails and stiles that appear integrated about a window based on combining aluminum extrusions capping aluminum patterned sheets, or cladding, laminated to underlying wooden, or composite board, framing. Thus, an upper rail, 15, is shown in FIG. 2 formed of an upper rail wooden or composite board framing member, 16, that is laminated on both the front and the back sides thereof with patterned aluminum cladding, 17. The upper side of this structure is capped with an aluminum extrusion cap, 18, press-fitted over the outer sides of cladding 17 and framing member 16 that forms the exposed outer edge of door 11 at the top thereof. An aluminum door frame, 19, for use about door 11 is affixed to the building structure in the opening therein for door I 1, and has a brush sealer, 19', against which cap 18 is forced when door 11 is closed against door frame 19 to aid in sealing that door against adverse weather conditions.
Similarly in FIG. 2, a lower rail, 20, is formed from a lower wooden or composite board framing member, 21, that is laminated on the front and back sides thereof with aluminum cladding, 22. The resulting structure is capped at its lower side with an aluminum extrusion cap, 23, press-fitted over the outer sides of cladding 22 and framing member 21 to form the exposed outer lower edge of door 11. A polymeric material wiping blade, 23', is positioned in cap 23 to wipe against the threshold or other surface, 24, beneath door 11, as installed in the building structure, as door 11 is closed to aid in sealing same against adverse weather conditions.
In FIG. 3, a left side or hinge side stile, 25, is shown formed of a wooden or composite board framing member, 26, that is laminated on both the front and back sides by aluminum cladding, 27. This arrangement is capped at its outer side by an aluminum extrusion cap, 28, press-fitted over the outer sides of cladding 27 and framing member 26 to form the exposed outer left-hand edge of door 11. Hinge 13 is formed as part of door frame 19 which again has brush sealer 19' engage cap 28 when door 11 is closed against frame 19 for weather sealing purposes. The remaining portion of hinge 13 is affixed to, or is a part of, cap 28 which is positioned in the frame portion of hinge 13 in door frame 19 to be joined therewith by a hinge pin, 29.
Finally, a right-hand or latch edge stile, 30, is formed by a righthand wooden or composite board framing member, 31, that again is laminated with aluminum cladding, 32, on both the front and back sides thereof. Here too, the resulting structure is capped with an aluminum extrusion end cap, 33, press-fitted over the outer sides of cladding 32 and framing member 31 to form the exposed outer right-hand edge of door 11. Door frame 19 again has therein brush sealer 19' which is forced against cap 33 when door 11 is closed against door frame 19.
The sides of left-hand framing member 26 of stile 25 and right-hand framing member 31 of stile 30 facing inward and those facing outward are coated with a waterproof sealant, 34 for a few inches above lower framing member 21 inner facing side and its bottom side, respectively. Lower framing member 21 of rail 20 has its inner facing side coated with waterproof sealant 34, but also has the bottom side of that member coated with sealant 34.
The inner facing sides of rails 15 and 20, and of stiles 25 and of storm door 11, provided by the corresponding framing members and aluminum cladding, form a window opening in that door over which are press-fitted sections of a multiple channel, or track, combination frame, 40, that is to contain a combination of windows, a screen and a grid. As seen in FIG. 2, upper combination frame member, 40', is press-fitted over cladding 17 on either side of upper framing member 16. A corresponding lower combination frame member, 40", can also be seen in FIG. 2 fitted against cladding 22 on one side of lower framing member 21 leaving a gap on the remaining side. Turning to FIG. 3, a left-hand combination frame member, 40'", can be seen press-fitted over cladding 27 on either side of left-hand side framing member 26, as can a right-hand combination frame member, 40 iv , shown press-fitted over cladding 32 on either side of right-hand framing member 31.
Combination frame 40 has left-hand combination frame member 40'" and right-hand combination frame member 40 iv each with three side-by-side open channel arrangements, or tracks, extending along the length thereof and facing corresponding ones of those channels in the other member across the space therebetween. One such channel arrangement or track supports a lower window, 41, that is slidable therein. Another such channel arrangement or track supports an upper window 42, that also is slidable therein, and a final such channel arrangement or track supports a combined grid and screen panel structure, 43.
Lower window 41 is formed of a windowpane, 50, mounted in a lower sash formed of upper and lower sash members, 51 and 52, as seen in FIG. 2, and right- and left-hand sash members, 53 and 54, as seen in FIG. 3. Windowpane 50 is inserted in open channels or slots in each of these window 41 sash members that face inside so that those channels in opposite sash members face toward one another. Windowpane 50 is maintained in this window sash by the use of a polymeric material sealer, 55, wrapped around each edge of windowpane 50 over which the corresponding open channel or slot in each of window 41 sash members 51, 52, 53 and 54 is press-fitted. The sash members are joined at the corners to adjacent ones thereof by corner lock keys including upper corner lock keys, or tilt keys, 56, having protrusions, 57, protruding into an adjacent channel in combination frame 40. Spring-loaded, finger-pull latches, 58, are provided in lower sash member 52 to also removably protrude into this same channel in combination frame 40.
Similarly, upper window 42 is formed of a windowpane, 60, positioned in an upper sash. The sash for upper window 42 comprises an upper sash member, 61, and a lower sash member, 62, seen in FIG. 2 with windowpane 60 therein. In FIG. 3, upper window 42 has windowpane 60 shown in a left-hand sash member, 63, and in a right-hand sash member, 64. Windowpane 60 is, here too, inserted in open channels or slots in each of these window 42 sash members that face inside so that those channels in opposite sash members face toward one another. Again, windowpane 60 is maintained in the window 42 sash members by a polymeric sealer, 65, wrapped about each end edge of window pane 60 over which the corresponding open channel or slot in each of window 42 sash members 61, 62, 63 and 64 is press-fitted as above. Here again, the sash members are joined at the corners to adjacent ones thereof by corner lock keys including upper corner lock keys, or tilt keys, 66, having protrusions, 67, protruding into an adjacent channel in combination frame 40. Spring-loaded, finger-pull latches, 68, are provided in lower sash member 62 to also removably protrude into this same channel in combination frame 40.
In FIG. 2, upper window 42 is shown in its uppermost position. Lower window 41, on the other hand, is shown in its lowermost position so that the entire opening within combination frame 40 is covered by windows 41 and 42. Upper window 42 can, however, be lowered by sliding its protrusions in the corresponding frame 40 channel to a new position that reduces the blockage thereby of the upper portion of the opening within combination frame 40. In FIG. 3, upper window 42 is shown in a lowered position. Similarly, lower window 41 can be raised by sliding its protrusions to a new position in the corresponding frame 40 channel to reduce the blockage thereby of the lower portion of the opening in combination frame 40.
Upper window 42 can be removed from combination frame 40 only if lower window 41 has been previously removed since they overlap in the space contained in frame 40. In addition, as can be seen in FIG. 3, upper window 42 can be removed from combination frame 40 only if the protrusions 57 and protruding portions of latches 58 are removed from the channel in frame 40 into which they protrude. That is, the channel facing arrangement in combination frame 40 has a pair of facing channels, 70 and 71, in side combination frame members 40'" and 40 iv . Channels 70 and 71 have corresponding sides coming close enough toward one another across the space in frame 40 so as to block movement of window 42 in FIG. 3 from either to the front or to the back to any significant extent so long as protrusions 57 and protruding portions of latches 58 are in those channels.
As can be seen in FIG. 3, lower window 41 is between a further pair of facing channels, 72 and 73, in side combination frame members 40'" and 40 iv . Channels 70 and 71, in the channel facing arrangement in side combination frame members 40'" and 40 iv , are positioned between facing channels 72 and 73, considered as a pair, and a further pair of facing channels, 74 and 75, provided for panel structure 43. Channels 72 and 73 also have corresponding sides thereof extending toward one another across the space in frame 40 sufficiently to block movement of window 41 from front or back movement in FIG. 3 to any significant extent so long as protrusions 67 and protruding portions of latches 68 are in those channels. On the other hand, lower window 41 can be moved to the back if protrusions 67 and protruding portions of latches 68 are removed from channels 72 and 73 without regard to upper window 42.
Lower window 41 is removed from between channels 72 and 73 by pulling latches 68 inward against the springs used therewith and rotating window 41 upward toward the back on protrusions 67. Thereafter, window 41 is rotated about an axis more or less perpendicular to the plane of frame 40 sufficiently to get protrusions 67 out of channels 72 and 73 to then allow full rearward movement of that window. Upper window 42 can then be removed rearward in the same manner, rotating first upward about protrusions 57 and performing another rotation about an axis more or less perpendicular to the plane of frame 40 to free the window from that frame.
The presence of window 41 in its channel position prevents, as indicated above, window 42 from being moved inward, or to the back or the right in FIG. 3, and the presence of both these windows in their respective channel positions prevents any significant inward movement (again, movement to the right in FIG. 3) of combination grid and screen panel structure 43. The left side portions of combination frame 40 as shown in FIGS. 2 and 3 that are the left-side channel walls for the channel arrangement in frame 40 corresponding to panel structure 43 also prevent that structure from being moved outward, or to the left, in either of those figures. Thus, windows 41 and 42 present in their positions between their respective channels, with the protuberances associated therewith protruding into those channels, cannot be moved significantly inward and, as a result, neither can panel structure 43. Thus, panel structure 43, if sufficiently strong, provides a security structure protecting against inward entry through the window opening in storm door 11 by someone attempting to come through the space enclosed within combination frame 40. In addition, the coarse grid structure, i.e. the cross bars as opposed to the screen (forming a fine mesh structure), are also configured and positioned to appear as dividers of window panes 50 and 60 into rectangular sections so as to make them appear to an outside observer as divided windows featuring a plurality of windowlights.
FIG. 4 shows a partially exploded view of many of the components of combination grid and screen panel structure 43. Panel structure 43 has a pair of opposite side extruded aluminum stiles, 80 and 81, which are joined to a pair of opposite end extruded aluminum rails, 82 and 83 by four metal and polymeric materials corner keys, 84, one for each corner, which lock stiles 80 and 81 into a rectangular panel frame with rails 82 and 83. A pair of semicircular-like flexible polymeric material spring latches, 85, are set into openings in outside facing channels provided in styles 80 and 81. Spring latches 85 are used in keeping panel structure 43 locked into channels 74 and 75 in combination frame 40.
The panel frame formed of styles 80 and 81 and rails 82 and 83 of panel structure 43 is constructed about the coarse grid structure. This coarse grid structure is formed by a pair of vertical, muntin-like, rectangular cross-section hollow, aluminum extruded tubes, 86 and 87, and of nine cross pieces used in three rows of three to simulate sash bars for the spacing of vertical tubes 86 and 87 apart from one another and apart from stiles 80 and 81. Six cross pieces, 88, are divided into two groups of three to separate stile 80 and vertical tube 86 from one another, and to separate stile 81 and vertical tube 87 from one another. A further set of three cross pieces, 89, are used to separate vertical tubes 86 and 87 from one another. In each instance, cross pieces 88 and 89 are formed by rectangular cross-section hollow, aluminum extruded tubes.
The coarse grid structure is constructed by connecting each of cross pieces 88 and 89 to their corresponding locations in vertical tubes 86 and 87. FIG. 5 shows one of the connection points along vertical tube 86 in cross section view with just the facing metal sides of these cross pieces 88 and 89, and of vertical tube 86, as shown in FIG. 4, removed. As can be seen, a portion of polymeric material cross key, 90, is fitted into the hollow opening in cross piece 88 adjacent the end thereof to be joined with vertical tube 86. A similar hollow opening is provided in cross piece 89. A pair of openings, 91, are provided in vertical tube 86 across from one another where cross pieces 88 and 89 are to be joined with that vertical tube. This allows cross key 90 to be inserted through vertical tube 86 and both openings 91 into the hollows of cross pieces 88 and 89 to hold then to the sides of vertical tube 86. FIG. 6 shows a top cross-section view of the same joint shown in FIG. 5, but with a portion of tube 86 removed along with removing what otherwise would be the upward facing metal sides of cross pieces 88 and 89. As can be seen, cross key 90 has a substantial number of flexible "teeth" jutting out from the sides thereof to frictionally lock these keys into the hollow openings of cross pieces 88 and 89 and between openings 91 in vertical tube 86.
Although cross keys 90 are inserted in the hollow openings at both ends of cross pieces 89, they are used only at one of the ends of cross pieces 88, the ends thereof that are to be connected to vertical tubes 86 and 87. At the other ends of each of cross pieces 88, and at both ends of vertical tubes 86 and 87, there are inserted polymeric material end keys, 95, each having an exposed end shaped more or less like a "T" extending past the end of that cross piece 88 or of that one of vertical tubes 86 and 87 in which it is used. FIG. 7 shows a cross-section view of an end of a cross piece 88 with the facing metal side thereof shown in FIG. 4 removed, that cross piece having an end key 95 partially inserted into the hollow opening therein. A top view of the same cross piece 88 with what otherwise would be the upward facing metal side of that cross piece removed is shown in FIG. 8 to provide the cross-section view shown there. Again, a large plurality of flexible "teeth" are provided on end key 95 to frictionally lock that key into the end of cross piece 88 (or of one of vertical tube 86 and 87 if used there instead). The tee end, 96, of end key 95 fits into corresponding side openings, 97, along a slot, 98, in each of stiles 80 and 81 for connecting cross pieces 88 thereto. Similarly, such tee ends 96 of end keys 95 inserted into vertical tubes 86 and 87 fit into openings 97 along slot 98 in each of rails 82 and 83 for connecting these tubes thereto.
FIG. 9 shows this joining arrangement in greater detail in again a cross-section view with a facing side removed from cross piece 88 as well as a facing portion of stile 81 being removed therefrom. As can be seen, tee end 96 of end key 95 fits through opening 97 into slot 98 of stile 81. Tee end 96 of end key 95 is held in slot 98, as well as portions of a screen, 99, serving as the fine mesh material to cover the window space in the door for insect exclusion. This key end and this screen portion are both held in slot 98 by a polymeric material "cord", 100. Cord 100 is forced deformed into slot 98 after tee end 96 of end key 95 is inserted therein and after screen material 99 is placed over the panel frame of panel structure 43 with edge portions thereof positioned over slot 98 and tee end 96, these edge portions of screen 99 being forced also into slot 98 by the forcing of cord material 100 therein.
This structural arrangement for panel structure 43 results in a strong barrier to entry for a would-be intruder seeking entry through the window opening in door 11 as it would be in other kinds of window openings. Careful configuring and fabrication of vertical tubes 86 and 87, and of cross pieces 88 and 89, along with careful assembly thereof together will result in a grid which will give an outside observer the impression of it being composed of window dividers to result in the further impression of the upper and lower windows being formed of windowlights rather than single windowpanes.
Although the present invention has been described with reference to preferred embodiments workers skilled in the art will recognize that changes may be made in form and detail without departing from the spirit and scope of the invention.
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A window with an outer frame for mounting in a window opening in a structure this outer frame having on the sides thereof sash tracks or channels facing one another across the window space. Window sashes containing a single window pane are positioned between and securable in such channels in a manner allowing them to be slid therealong for opening and closing the window. Protuberances extending from the window frame secure the window sashes in the channels so as to allow sliding therealong, and removing such window sashes from those channels is accomplished by removing the protuberances therefrom. A blocking panel is positionable in the outer frame in the absence of such window sashes, and can be removed therefrom in the absence of such sashes but not when the sashes are present. A relatively rigid tube structure that can be formed in a coarse mesh is provided for affixing to the panel frame in the blocking panel as is a finer mesh screen structure to thereby provide security against entrance through the window space.
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[0001] This application is a continuation of U.S. application Ser. No. 14/712,742 filed on May 14, 2015,which is a continuation of U.S. application Ser. No. 14/473,806 filed on Aug. 29, 2014, now issued U.S. Pat. No. 9,061,531, the contents of which are incorporated herein
FIELD OF THE INVENTION
[0002] This invention relates to a printer module and high-speed printers comprising one or more of such printer module(s). It has been developed for printing onto media webs, and particularly for use in conjunction with existing web feed mechanisms, such as those installed in offset printing presses.
CO-PENDING APPLICATIONS
[0003] The following applications have been filed by the Applicant simultaneously with the present application:
SRS002US SRS003US
[0005] The disclosures of these co-pending applications are incorporated herein by reference. The above applications have been identified by their filing docket number, which will be substituted with the corresponding application number, once assigned.
BACKGROUND OF THE INVENTION
[0006] Inkjet printing is well suited to the SOHO (small office, home office) printer market. Increasingly, inkjet printing is expanding into other markets, such as label and wideformat printing. High-speed web printing is becoming a significant commercial sector for the inkjet printing market. High-speed inkjet web printing is especially competitive with traditional offset printing presses over relatively short print runs, because digital printing does not require the initial set-up time and cost of preparing offset printing plates. In a digital inkjet web printer, it is possible to print, for example, thousands of labels on-demand.
[0007] Hitherto, the present Assignee has described a number of inkjet web printers employing Memjet® pagewidth printing technology. Memjet® pagewidth printers employ one or more fixed printhead(s) while print media, such as a media web, are fed continuously past the printhead(s). This arrangement vastly increases print speeds compared to traditional scanning printhead technologies.
[0008] US 2011/0279530 (the contents of which are herein incorporated by reference) describes a benchtop web printer suitable for printing labels. The benchtop printer includes a single multi-color pagewidth printhead, an integrated web feed mechanism and a maintenance station. The maintenance station comprises individual liftable modules which cross the media feed path in order to perform printhead maintenance. A disadvantage of this arrangement is that a media web must be broken in order to perform printhead maintenance. This maintenance regime therefore places limitations on the types and lengths of print jobs that may be performed.
[0009] US 2012/0092419 (the contents of which are herein incorporated by reference) describes an industrial web printer comprised of a plurality of monochrome pagewidth printheads aligned with each other in a media feed direction. The printheads are mounted on a common housing connected to a scissor lift mechanism. The scissor lift mechanism enables the printheads to be lifted and lowered relative to the media web. In order to perform printhead maintenance, the printheads are lifted, a maintenance assembly is slid laterally underneath the printheads and the printheads lowered onto the maintenance assembly. In this way, printhead maintenance may be performed without breaking the media web. However, a disadvantage of the printer described in US 2012/0092419 is its relatively high cost as well as difficulties in scaling the printer for printing onto wider media widths.
[0010] U.S. Pat. No. 8,485,656 (the contents of which are herein incorporated by reference) describes a wide format printer comprising a plurality of staggered overlapping printheads. Each printhead is maintained by a respective rotatable maintenance carousel positioned opposite its respective printhead. Each carousel crosses the media path in order to perform printhead maintenance, which necessitates breaking the media web.
[0011] It would be desirable to provide a relatively low-cost, high-speed inkjet web printer, which does not require breaking the media web in order to perform printhead maintenance. It would further be desirable to provide an inkjet web printer, which is readily scalable to wider media widths (e.g. widths greater than about 210 mm). It would further be desirable to provide a high-speed inkjet web printer, which is amenable to retrofitting into existing web feed arrangements, such as those used in offset printing presses. Such a retrofitted printer is an attractive proposition for commercial printing presses having a number of offset printing lines and, moreover, promotes uptake of digital web printing at a relatively low cost.
SUMMARY OF THE INVENTION
[0012] In a first aspect, there is provided a modular printer comprising:
[0013] (a) a media feed path defining a media feed direction;
[0014] (b) a first printer module suspended over the media feed path, the first printer module comprising:
[0015] a first printhead extending transversely with respect to the media feed direction;
[0016] a first maintenance sled positioned at a first side of the first printhead relative to the media feed direction, the first maintenance sled being slidable towards the first printhead parallel with the media feed direction;
[0017] (c) a second printer module suspended over the media feed path and at least partially overlapping the first printer module in the media feed direction, the second printer module comprising:
[0018] a second printhead extending transversely with respect to the media feed direction, the second printhead at least partially overlapping the first printhead in the media feed direction; and
[0019] a second maintenance sled positioned at an opposite second side of the second printhead relative to the media feed direction, the second maintenance sled being slidable toward the second printhead parallel with the media feed direction, wherein the first and second printheads are relatively proximal to each other with respect to the media feed direction, and the first and second maintenance assemblies are relatively distal from each other with respect to the media feed direction.
[0020] As used herein, the term “printhead” generally refers to a non-traversing printhead which is stationary during printing, as opposed to conventional scanning printheads which traverse across the media path printing in swathes.
[0021] The modular printer according to the first aspect advantageously enables printing onto relatively wide media webs using a readily scalable arrangement of first and second printer modules. In principle, the range of printable media widths is virtually limitless, simply by placing the first and second printer modules in an alternating overlapping arrangement across the media feed path.
[0022] In this modular arrangement, the width of the print zone is minimized by placing the printheads relatively proximal and the maintenance stations relatively distal. This arrangement maximizes print quality whilst enabling a versatile maintenance regime. Typically, a distance between the first and second printheads in the media feed direction is from 10 to 200 mm or from 20 to 100 mm. Correspondingly, the width of the print zone is in the range of 10 to 200 mm or 20 to 100 mm. The width of the print zone is defined in a direction parallel to the media feed direction.
[0023] Preferably, the first and second maintenance assemblies are configured to move in opposite directions—that is, towards each other and towards respective first and second printheads. In other words, the first maintenance sled may move in the same direction as the media feed direction, while the second maintenance sled moves in the opposite direction. Alternatively, the first maintenance sled may move in an opposite direction to the media feed direction, while the second maintenance sled moves in the same direction as the media feed direction.
[0024] Preferably, the first and second printheads are each mounted in a respective printhead cartridge, which may be user-replaceable. The printhead cartridge may comprise, for example, ink couplings and an ink feed arrangement in addition to the printhead. The printheads may be multi-color printheads or monochrome printheads.
[0025] Preferably, the printhead cartridges are identical and replaceable in each of the first and second printer modules. Providing identical, replaceable printhead cartridges in the first and second printer modules minimizes printhead cartridge production costs and is convenient for end-users.
[0026] The first and second printer modules may be the same or different from each other. Identical first and second printer modules have the advantage of reducing production costs of the printer modules. However, identical first and second printer modules require the same relative orientation of the printhead cartridge and the maintenance station. Since printheads typically have asymmetrical color planes with respect to the media feed direction, identical first and second printer modules require printhead cartridges in the first printer module to print “forwards” (e.g. CMYK) and printhead cartridges in the second printer modules to print “backwards” (e.g. KYMC). Although such a configuration is technically possible using appropriate controller firmware, in practice it is difficult to ensure consistent print quality across the media width when some printheads are printing “forwards” and some printheads are printing “backwards”. For example, the different effects of overprinting and underprinting are difficult to compensate when the color plane order is reversed.
[0027] Therefore, the printhead cartridges are preferably all oriented identically with respect to the media feed direction, such that all printheads print with the same color plane sequence. The corollary is that the first and second printer modules are preferably non-identical by virtue of the different orientations of the printheads relative to the maintenance assemblies in the first and second printer modules.
[0028] Preferably, the first and second printer modules comprise respective lift mechanisms for lifting a respective printhead cartridge relative to the media feed path. Lifting the printhead cartridges relative to the media feed path enables the printheads to be maintained without breaking the media web.
[0029] Preferably, the first and second printer modules each comprise a respective print bar carriage, the print bar carriage being slidably received within the housing and liftable relative to the housing.
[0030] Preferably, each print bar carriage carries a respective printhead cartridge.
[0031] Preferably, each print bar carriage carries a respective ink manifold, the ink manifold having at least one coupling for mating with and supplying ink to a respective printhead cartridge.
[0032] Preferably, in the first aspect, the print zone has a length greater than 216 mm and up to about 2000 mm, the length of the print zone being defined in a direction transverse to the media feed direction. In some embodiments, the print zone has a length greater than 300 mm, greater than 400 mm or greater than 500 mm. Hence, the modular printer is capable of printing onto wideformat media—that is media wider than standard A 4 or US letter-sized media.
[0033] The first and second printer modules may be fixedly mounted to, for example, a gantry suspended over the media feed path. Typically, the first and second printer modules comprise rigid mounting beams configured for mounting the printer modules over the media feed path.
[0034] In a second aspect, there is provided a printer assembly comprising:
[0035] a housing comprising a pair of opposite sidewalls, each sidewall defining a respective referencing slot;
[0036] a pair of first stops, each first stop being positioned towards a lower end of a respective referencing slot defined in a respective sidewall of the housing, each first stop defining a first datum surface;
[0037] a print bar carriage slidably received within the housing, the print bar carriage comprising:
a chassis; a printhead supported by the chassis; and a pair of lugs, each lug extending outwardly from opposite sides of the chassis, each lug being received in a respective referencing slot of the housing, and each lug being slidably movable within its respective referencing slot; and
[0041] a lift mechanism for lifting the print bar carriage relative to the housing, wherein the first datum surfaces define a printing position of the print bar carriage, the print bar carriage being in the printing position when each lug is in abutting engagement with its respective first datum surface.
[0042] The printer assembly according to the second aspect advantageously enables the printing position of the liftable print bar carriage to be defined with reference to a housing in which the print bar carriage is slidably received. In particular, the lugs, referencing slots and stops provide a compact design without any special modifications required to the printhead. Each of the printer modules described in connection with the first aspect may comprise a printer assembly according to the second aspect.
[0043] Typically, the stops have adjustable heights enabling facile user adjustment of the printing position height (e.g. for use with different media thicknesses) without requiring internal access to each printer assembly. Once the printer assembly has been installed by suspending over a media feed path (e.g. by mounting to a rigid overhead cantilever beam or gantry), the stops may then be used to control the height of the printing position relative to the media and, hence, the “pen-to-paper spacing” (PPS) or “throw distance” of ejected ink droplets.
[0044] Preferably, the printhead is mounted between opposite side panels of the chassis and each lug extends outwardly from a respective side panel.
[0045] Preferably, each first stop is mounted to an outer (external) surface of a respective sidewall of the housing. Externally mounted stops avoid any interference between the datum referencing for the printhead and a sliding maintenance sled for maintaining the printhead. Furthermore, externally mounted stops facilitate user accessibility in situ when the printer assembly is installed.
[0046] Preferably, each first stop is adjustably mounted relative to its respective sidewall to provide a plurality of different printing positions. Suitable means for providing adjustable mounting of each first stop will be readily apparent to the person skilled in the art. For example, a slider mechanism or a screw mechanism may be used for manual stop height adjustment. Alternatively, a range of predetermined stop heights may be provided using one or more detents in combination with a slider mechanism, as is known in the art.
[0047] Preferably, the housing comprises one or more upper mounting plates or beams for fixedly mounting the printer assembly on a support, so as to suspend the printer assembly over a media path.
[0048] Preferably, the lift mechanism comprises a rack and pinion mechanism.
[0049] Preferably, the carriage comprises a pair of racks and a shaft is rotatably mounted between the sidewalls of the housing, wherein a pair of pinions are fixedly mounted about the shaft, each pinion being engaged with a respective rack.
[0050] Preferably, the housing defines a guide slot engaged with part of the carriage, said guide slot constraining movement of the carriage relative to the housing.
[0051] Preferably, the guide slot is laterally spaced from one of the referencing slots and extends parallel therewith.
[0052] Preferably, a first sidewall of the housing has a respective guide slot and the carriage comprises a plurality of rotatably mounted first bearings, each first bearing travelling within the guide slot.
[0053] Preferably, the plurality of first bearings are rotatably mounted to a bracket fixed to a side panel of the chassis.
[0054] Preferably, the first bearings are aligned with each other and parallel with the racks.
[0055] Preferably, the printer assembly further comprises:
a track fixed to the housing, the track extending transversely with respect to the referencing slots; a maintenance sled mounted on the track; a transport mechanism for transporting the maintenance sled along the track;
[0059] and
a controller for coordinating the lift mechanism and the transport mechanism, the controller being configured to provide:
the printing position in which the maintenance sled is laterally displaced out of alignment with the printhead; and a maintenance position in which at least part of the maintenance sled is aligned with the printhead,
wherein the printhead is raised in the maintenance position relative to the printing position.
[0063] The printer assembly may be configured into the maintenance position (e.g. a capping position of a wiping position) by lifting the print bar using the lift mechanism, transporting the maintenance sled parallel with the media feed direction towards the printhead, and lowering the print bar such that the printhead is engaged with a suitable maintenance module (e.g. capper or wiper). The printer assembly may be configured into the printing position by lifting the print bar using the lift mechanism, transporting the maintenance sled away from the printhead, and lowering the print bar such that the printhead is in the printing position, the printing position being lower than the maintenance position.
[0064] Preferably, the maintenance sled comprises at least one of:
a capper module for capping the printhead; and a wiper module for wiping the printhead.
[0067] Preferably, the capper module comprises a pair of second stops disposed at either end of a perimeter capper, each second stop defining a second datum surface.
[0068] Preferably, landing zones are defined at either longitudinal end of the printhead for abutting engagement with the second datum surfaces in a capping position.
[0069] As described in US 2011/0279524, the contents of which are herein incorporated by reference, the perimeter capper may comprise an internal wick element positioned for capturing ink during spitting and/or priming operations. The wick element is placed accurately in close proximity with (but not in contact with) the printhead, such that a fluidic bridge (“ink bridge”) can form between the printhead and the wicking element. Accordingly, the second datum surfaces and landing zones are employed for accurate positioning of the perimeter capper, which is preferably of the type described in US 2011/0279524.
[0070] Preferably, the wiper module is resiliently mounted on the maintenance sled. Resilient mounting of the wiper module allows a degree of tolerance in the positioning of the printhead relative to the wiper in a wiping position. Typically, the wiping position is less critical than the capping position and may be controlled using suitable sensors and/or timers on the lift mechanism, rather than via datums.
[0071] Preferably, the wiper module comprises a rotatably mounted wiper roller, the wiper roller being coextensive with the printhead. A suitable maintenance sled comprising a wiper roller and perimeter capper, which may be adapted for use in connection with the present printer assembly, is described in US 2012/0092419, the contents of which are incorporated herein by reference.
[0072] In a third aspect, there is provided a printer assembly comprising:
[0073] a housing comprising a pair of opposite first and second sidewalls extending along a nominal x-axis, the first sidewall having a guide slot extending along a z-axis, the guide slot being defined between opposite first bearing surfaces;
[0074] a shaft rotatably mounted between the sidewalls, the shaft extending along a y-axis;
[0075] first and second pinions fixedly mounted at either end of the shaft for rotation therewith;
[0076] a print bar carriage slidably received within the housing, the print bar carriage comprising:
a chassis; first and second parallel racks fixed to the chassis, each rack being engaged with a respective pinion to define a rack-and-pinion lift mechanism; a set of first bearings rotatably mounted at a first side of the chassis, each first bearing being received in the guide slot; and a printhead supported by the chassis; and
[0081] a drive motor operatively connected to the shaft for rotating the shaft and thereby lifting the print bar carriage relative to the housing along the z-axis via the rack-and-pinion lift mechanism, wherein, during sliding movement of the print bar carriage, the set of first bearings travels within the guide slot and bear against the first guide surfaces to constrain rotational movement of the print bar carriage.
[0082] The printer assembly according to the third aspect advantageously provides a rigid framework for raising and lowering the print bar carriage with highly accurate positioning. In particular, cooperation of the first bearings with the guide slot of the rigid housing provides excellent constraint of undesirable printhead rotation. Each of the first and second printer modules described in connection with the first aspect may comprise a printer assembly according to the third aspect.
[0083] Raising and lowering a print bar introduces significant rotational forces due to the intrinsic moment of the print bar about the lift axis. By way of contrast, U.S. Pat. No. 8,353,566 describes a rack-and-pinion lift mechanism whereby a pair of brackets are slidably mounted on a complementary pair of guide posts. Each bracket has a rack connected to a print bar enabling the print bar to be raised and lowered via rotation of a shaft having a pair of pinions engaged with the racks. A disadvantage of the lift mechanism described in U.S. Pat. No. 8,353,566 is that the elongate guide posts inevitably lack true parallelism, which is problematic for printhead positioning as well as operation of the lift mechanism. U.S. Pat. No. 8,353,566 attempts to address this problem by allowing a degree of play in the bracket mountings and relying solely on datums in the lowered position for correcting misalignments in theta y during lifting/lowering. However, the prior art arrangement inevitably results in undue wearing of the lift mechanism and, moreover, does not ensure accurate positioning of the printhead in the printing position. The printer assembly according to the third aspect ensures smooth lifting and lowering of the printhead with minimal wear and accurate printhead placement in the printing position.
[0084] Preferably, the carriage comprises a second bearing rotatably mounted to an inner surface of the second sidewall, wherein the second bearing bears against a second bearing surface of the print bar carriage, said second bearing surface extending along the z-axis. The first and second bearings, therefore, cooperate to constrain rotational movement of the print bar carriage in theta z as well as theta y.
[0085] Preferably, the second bearing surface is defined by a non-toothed surface of the second rack. Typically, the non-toothed surface is opposite a toothed surface of the second rack, the toothed surface being intermeshed with the second pinion.
[0086] Preferably, the shaft and pinions cooperate with the parallel racks to constrain rotational movement of the print bar about the x-axis. Thus, the print bar carriage is preferably constrained in theta x, theta y and theta z during lifting and lowering.
[0087] Preferably, the chassis comprises first and second opposite side panels, the set of first bearings being rotatably mounted to a bracket fixed to the first side panel of the chassis.
[0088] Preferably, the housing comprises a track extending transversely with respect to the referencing slots, wherein the printer assembly further comprises:
[0089] a maintenance sled mounted on the track;
[0090] a transport mechanism for transporting the maintenance sled along the track; and
[0091] a controller for coordinating the lift mechanism and the transport mechanism, the controller being configured to provide:
the printing position in which the maintenance sled is laterally displaced out of alignment with the printhead; and a maintenance position in which at least part of the maintenance sled is aligned with the printhead, wherein the printhead is raised in the maintenance position relative to the printing position.
[0094] Preferably, the transport mechanism comprises an endless drive belt tensioned about a plurality of pulleys, the maintenance sled being attached to the drive belt for movement therewith.
[0095] Preferably, the bracket is configured to avoid contact with the drive belt in the printing position. Preferably, the bracket is L-shaped or U-shaped.
[0096] Preferably, each sidewall of the housing comprises a pair of first stops, each first stop defining a first datum surface, each first stop being positioned towards a lower end of a respective referencing slot defined in each sidewall, each referencing slot being laterally spaced from and parallel with the guide slot; and
[0097] the print bar carriage comprises a pair of lugs, each lug extending outwardly from opposite sides of the chassis, each lug being received in a respective referencing slot of the housing, and each lug being slidably movable within its respective referencing slot, wherein the first datum surfaces define a printing position of the print bar carriage, the print bar carriage being in the printing position when each lug is in abutting engagement with its respective first datum surface.
[0098] Preferably, the print bar carriage comprises a chassis having opposite side panels, the printhead being mounted between the side panels, and wherein each lug extends outwardly from a respective side panel.
[0099] Preferably, each first stop is mounted to an outer surface of a respective sidewall of the housing.
[0100] Preferably, each first stop is adjustably mounted relative to its respective sidewall to provide a plurality of different printing positions.
[0101] Preferably, the maintenance sled comprises at least one of: a capper module for capping the printhead; and a wiper module for wiping the printhead.
[0102] Preferably, the capper module comprises a pair of second stops disposed at either end of a perimeter capper, each second stop defining a second datum surface.
[0103] Preferably, landing zones are defined at either longitudinal end of the printhead for abutting engagement with the second datum surfaces in a capping position.
[0104] Preferably, the wiper module is resiliently mounted on the maintenance sled.
[0105] Preferably, the wiper module comprises a rotatably mounted wiper roller, the wiper roller being coextensive with the printhead.
[0106] It will be appreciated that preferred and other embodiments described herein may be applicable to any one or more of the first, second and third aspects.
BRIEF DESCRIPTION OF THE DRAWINGS
[0107] Embodiments of the present invention will now be described by way of example only with reference to the accompanying drawings, in which:
[0108] FIG. 1 is a perspective of a printer module according to the present invention;
[0109] FIG. 2 is a perspective of the printer module with mounting beams removed;
[0110] FIG. 3 is a perspective of the printer module configured in a printing position with mounting beams removed;
[0111] FIG. 4 is a perspective of the printer module configured in a maintenance position with mounting beams removed;
[0112] FIG. 5 is an exploded perspective of the printer module;
[0113] FIG. 6 is a perspective of a print bar carriage;
[0114] FIG. 7 is an exploded perspective of the print bar carriage;
[0115] FIG. 8 is schematic system control block diagram;
[0116] FIG. 9 is a perspective of the printer module in a printing position with mounting beams, a housing sidewall and print bar chassis side panels removed;
[0117] FIG. 10 is a side view showing engagement of a guide slot with first bearings in a raised position;
[0118] FIG. 11 is a side view showing engagement of a guide slot with first bearings in a printing position;
[0119] FIG. 12 is a top plan view of the printer module with mounting beams removed;
[0120] FIG. 13 is a perspective of the printer module in a maintenance position with mounting beams, a housing sidewall and print bar chassis side panels removed;
[0121] FIG. 14 is a rear view of a printhead cartridge and maintenance sled;
[0122] FIG. 15 is a perspective of the maintenance sled;
[0123] FIG. 16 is a perspective of the maintenance sled and transport mechanism;
[0124] FIG. 17 is a perspective of the maintenance sled and transport mechanism with drive belt removed; and
[0125] FIG. 18 is a top plan view of a modular printer according to the present invention.
DETAILED DESCRIPTION OF THE INVENTION
Printer Module Overview
[0126] Referring to FIG. 1 , there is shown a printer assembly in the form of a printer module 1 comprising a housing 10 having a first sidewall 12 and an opposite second sidewall 14 . The first and second sidewalls 12 and 14 are connected via upper mounting beams 15 and 17 , and lower connecting beams 19 and 21 to provide a rigid framework for housing a print engine comprised of a print bar carriage 100 and maintenance sled 200 (see FIG. 5 ). Each of the mounting beams 15 and 17 has mounting fixtures 18 for mounting the printer module 1 to a gantry or cantilever beam (not shown). Thus, the printer module 1 is configured for suspending over a print media path. Print media, such as a media web, may be fed past the printer module 1 using, for example, suitable feed rollers as is known in the art. The housing 10 has no base to facilitate feeding of the media web past a lower portion of the printer module 1 .
[0127] The print bar carriage 100 is slidably received within the housing 10 enabling lifting and lowering of the print bar carriage relative to the housing 10 using a lift mechanism. As shown in FIGS. 1 and 2 , the print bar carriage 100 is raised in a transition position; as shown in FIG. 3 , the print bar carriage 100 is lowered in a printing position; and as shown in FIG. 4 , the print bar carriage 100 is raised in a maintenance position.
[0128] Referring briefly to FIGS. 6 and 7 , the print bar carriage 100 comprises an ink manifold 101 and printhead cartridge 102 , such as a replaceable Memjet® printhead cartridge, mounted on a chassis 104 for printing onto print media in a single pass. (For a detailed description of the printhead cartridge 102 , reference is made to U.S. Pat. Nos. 8,540,353; 8,025,383 and 7,845,778, the contents of which are incorporated herein by reference). The ink manifold 101 is configured for supplying ink to and receiving ink from the printhead cartridge 102 via a pair of couplings, such as the couplings described in U.S. Pat. No. 8,540,353, the contents of which are herein incorporated by reference. The ink manifold 101 forms part of an ink delivery system (not shown) in fluid communication with the printhead 105 . The printhead cartridge 102 comprises a printhead 105 mounted to a lower surface thereof ( FIG. 14 ), which requires periodic maintenance. Maintenance may be required to wipe nozzles free of ink and debris, to unblock nozzles which have become blocked with ink or to minimize evaporation of ink by capping the printhead 105 .
[0129] Referring to FIGS. 2 to 4 , the maintenance sled 200 is slidable along a nominal x-axis of the printer module 1 using a transport mechanism (described below), the x-axis being defined as an axis parallel to a media feed direction. Maintenance modules in the form of a capper module 202 and a wiper module 204 are mounted on the maintenance sled 200 for performing respective capping and wiping operations on the printhead.
[0130] In order to perform a capping or wiping operation, the print bar carriage 100 is raised to its transition position ( FIGS. 1 and 2 ), the maintenance sled is moved along the x-axis so as to be positioned below the printhead 105 , and the print bar carriage lowered onto either the capper module 202 or the wiper module 204 ( FIG. 4 ). Of course, the precise positioning of the maintenance sled 200 relative to the printhead 105 will depend on whether a capping or wiping operation is being performed. Generally, the printhead 105 is maintained in a capped state during idle periods.
[0131] In order to perform printing, the print bar carriage 100 is raised to its transition position and the maintenance sled 200 is laterally displaced to one side of the printhead 105 by slidably moving the maintenance sled along the x-axis ( FIGS. 1 and 2 ). Once the maintenance sled 200 has been laterally displaced from the printhead 105 , the print bar carriage 100 is lowered to a printing position ( FIG. 3 ), which is the lowest position of the print bar carriage.
[0132] Referring to FIG. 8 , a controller 500 is employed to coordinate various operations of a media feed mechanism 501 ; an ink delivery system 502 which delivers ink to the printhead; a print bar system 503 comprising the print bar carriage 100 , printhead 105 and lift mechanism; and a maintenance system 504 comprising the maintenance sled 200 , transport mechanism and maintenance modules. The ink delivery system 502 may be of the type described in U.S. Pat. No. 8,485,619, the contents of which are incorporated herein by reference. For example, the ink delivery system 502 may be a circulatory system having an ink container, which delivers ink to inlet ports 105 of the printhead cartridge 102 and receives ink from outlet ports 107 of the printhead cartridge. Various printing, purging, pressure priming and depriming operations may be coordinated via a pump and valve arrangement of the ink delivery system, as described in U.S. Pat. No. 8,485,619. However, it will of course be appreciated that other ink delivery systems may be used, as known in the art. The controller 500 coordinates all maintenance and printing operations via suitable signal communication with the ink delivery system 502 and maintenance system 504 , as well as the print bar system 503 and media feed mechanism 501 .
Lift Mechanism
[0133] The print bar carriage 100 is slidably liftable relative to the housing 10 (along a nominal z-axis) using a rack-and-pinion lift mechanism. Referring initially to FIG. 7 , the rack-and-pinion lift mechanism comprises first and second toothed racks 110 and 112 fixedly mounted to respective first and second side panels 114 and 116 of the chassis 104 . The chassis 104 further comprises an end panel 118 and a base panel 120 interconnecting the side panels 114 and 116 to provide a rigid framework which ensures parallelism of the side panels and, therefore, parallelism of the racks 110 and 112 mounted to the side panels. As best shown in FIGS. 3, 5 and 9 , a shaft 25 is rotatably mounted between the sidewalls 12 and 14 of the housing 10 . First and second toothed pinions 26 and 28 are fixedly mounted about the shaft 25 at opposite ends thereof for rotation with the shaft. The first and second pinions 26 and 28 are intermeshed with respective first and second racks 110 and 112 to provide the rack-and-pinion lift mechanism.
[0134] Rotation of the shaft 25 is driven by a lift motor 30 , which is engaged with the shaft via a worm gear arrangement. The worm gear arrangement comprises a worm 32 connected to the lift motor 30 and an intermeshing worm wheel 34 mounted about the shaft 25 adjacent the second pinion 28 ( FIG. 9 ). Hence, the lift motor 30 is used to rotate the 25 shaft in either direction to perform either lifting or lowering of the print bar carriage 100 via the rack-and-pinion lift mechanism.
Constraint of Print Bar Carriage Movement
[0135] As described above, the print bar carriage 100 is lifted and lowered by actuation of the lift motor 30 operatively connected to the rack-and-pinion lift mechanism. In order to provide a smooth and reliable lift mechanism, it is preferable to constrain any rotational movement of the print bar carriage about the y-axis of the printer module 1 . As viewed in FIG. 10 , the print bar carriage 100 experiences a clockwise rotational biasing force about the pinion 26 due to the weight of the print bar carriage 100 indicated by arrow W.
[0136] In order to constrain any rotational movement, a pair of first bearings 150 A and 150 B are rotatably mounted to the first side panel 114 of the chassis 104 via a mounting bracket 152 . The first bearings 150 A and 150 B are received in a guide slot 47 defined by the first sidewall 12 of the housing 10 and a guide bracket 49 fixed to an outer surface of the first sidewall 12 . The guide slot 47 extends along the z-axis of the printer module 1 and is laterally displaced from a referencing slot 40 (described below) extending parallel therewith.
[0137] The guide bracket 49 defines a pair of opposite first bearing surfaces 50 A and 50 B extending along opposite longitudinal sides of the guide slot 47 . The first bearing surfaces 50 A and 50 B provide a reaction force to the intrinsic rotational bias of the print bar carriage 100 . The first bearings 150 A and 150 B, aligned parallel with the guide slot 47 , travel within the guide slot along the z-axis and bear against respective bearing surfaces 50 A and 50 B during lifting and lowering of the print bar carriage 100 . In practice, a marginal degree of clearance (e.g. 0.01 to 0.1 mm) between the first bearings and the first bearing surfaces allows the upper first bearing 150 A to bear against the right-hand first bearing surface 50 A and the lower first bearing 150 B to bear against the left-hand first bearing surface 50 B (as viewed in FIG. 10 ) with the rotational bias of the print bar carriage 100 .
[0138] FIG. 11 is a side view of the first bearings 150 and guide slot 47 when the print bar carriage 100 is in its lowermost printing position. With the print bar carriage 100 supported by the first stops 36 in this lowermost position, the rotational bias of the print bar carriage is reversed.
[0139] Referring to FIGS. 12 and 13 , a second bearing 60 is rotatably mounted to an inner surface of the second sidewall 14 of the housing 10 via a mounting block 62 . The second bearing 60 is positioned to bear against a non-toothed surface of the second rack 112 . The non-toothed surface is opposite the toothed surface of the second rack 112 and defines a second bearing surface 155 for the second bearing 60 to bear against during lifting and lowering of the print bar carriage 100 . FIG. 13 has the second sidewall 14 and second side panel 116 removed to show the engagement of the second bearing 60 with the second bearing surface 155 more clearly.
[0140] The first bearings 150 and the second bearing 60 cooperate with their respective first bearing surfaces 50 and second bearing surface 155 to constrain rotational movement of the print bar carriage 100 about the y- and z-axes (theta y and theta z) during lifting and lowering. This constraint of rotational movement minimizes any undue wearing of the rack-and-pinion mechanism upon repeated lifting and lowering of the print bar carriage 100 .
Datum Arrangements
[0141] Referring to FIGS. 1 to 4 , the printing position of the print bar carriage 100 is defined by a pair of first stops 36 mounted to the outer surfaces of the first and second sidewalls 12 and 14 . Each of the first stops 36 is positioned towards a lower end of respective referencing slots 40 defined in respective sidewalls 12 and 14 of the housing 10 . The chassis 104 has a pair of lugs 130 extending outwardly from respective side panels 114 and 116 , and the lugs are received in respective referencing slots 40 of the housing 10 . The lugs 130 are slidably movable along the z-axis within their respective referencing slots 40 . The first stops 36 define respective first datum surfaces 37 for abutting engagement with respective lugs 130 in the printing position ( FIG. 3 ). When each of the lugs 130 has been lowered into abutting engagement with its respective abutment surface 37 , the print bar carriage 100 is in its printing position.
[0142] During lifting and lowering, the print bar carriage 100 may bow in the z-axis, causing one of the lugs to engage with its respective abutment surface before the other lug. In order to accommodate potential bowing of the print bar carriage 100 , the controller 500 receives feedback from the lift motor 30 —when the lift motor experiences a sharp increase in resistance, corresponding to one of the lugs engaging with its respective abutment surface, the controller instructs the motor to continue for a predetermined period to ensure that the other lugs also engages with its respective abutment surface. In this way, seating of the print bar carriage 100 in its printing position is ensured with each lowering operation.
[0143] The first stops 36 are each slidably mounted to respective sidewalls 12 and 14 to provide adjustable printing positions. Accordingly, after installation of the printer module 1 , users are able to adjust the printing position of the printhead in order to optimize print quality, for example, when printing onto different media thicknesses. Each of the stops 36 is secured into position, after sliding adjustment of the stop, via a respective pair of locking screws 45 .
[0144] The printing position of the print bar carriage 100 is critical for controlling the throw distance of ejected ink droplets (otherwise known in the art as the “pen-to-paper spacing” (PPS)) and, as described above, the first datum surfaces 37 provide accurate control of this distance in combination with the lugs 130 attached to the chassis 104 .
[0145] Since the capper module 202 typically comprises an internal wick element (not shown), which should be positioned in close proximity to but not touching the printhead 105 during capping (see US2011/0279524, the contents of which are incorporated herein by reference), it is important to control the printhead-capper distance when the print bar carriage 100 is positioned in the capping position.
[0146] Referring to FIG. 14 , the capper module 202 comprises a perimeter capper 210 , extending a length of the printhead 105 , having resiliently deformable sidewalls defining an internal cavity. The capper module 202 further comprises a pair of seconds stops 212 positioned at either end of the perimeter capper 210 . The second stops 212 define respective second datum surfaces 214 for abutting engagement with respective landing zones 215 defined by the printhead cartridge 102 at either end of the printhead 105 . When the print bar carriage 100 is lowered into the capping position ( FIG. 4 ), the landing zones 215 abut with the second datum surfaces 214 to define the capping position.
[0147] Hence, the printing position of the print bar carriage 100 is controlled by abutting engagement of the lugs 130 with the first datum surfaces 37 ; and the capping position of the print bar carriage 100 is controlled by abutting engagement of the landing zones 215 with the second datum surfaces 214 .
Maintenance Sled and Transport Mechanism
[0148] As described above in connection with FIGS. 1 to 4 , the maintenance sled 200 is slidable towards and away from the printhead 105 in a direction parallel with the media feed direction. Referring to FIG. 15 , the maintenance sled comprise a sled frame 201 on which is mounted the capper module 202 and the wiper module 204 (collectively known herein as “maintenance modules”).
[0149] As described above the capper module 202 is fixedly mounted to the sled frame 201 , while the wiper module 204 is resiliently mounted to the sled frame via coil springs 217 , which bias the wiper module towards the printhead 105 during wiping operations. The wiper module 204 comprises a wiper roller 218 having a microfiber surface, which is configured to wipe ink and debris from the printhead 105 when rotated or translated in contact therewith. A metal transfer roller (not shown in FIG. 15 ) is in permanent contact with the microfiber wiper roller 218 to receive ink carrying entrained debris from the wiper roller. For a more detailed description of the wiper module, reference is made to US 2012/0092419, the contents of which are incorporated herein by reference
[0150] The distance between the wiper roller 218 and the printhead 105 during wiping is less critical than the capping distance. Accordingly, the biasing of the wiper module 204 via the springs 217 is sufficient to provide a suitable wiping force without accurate control of the printhead position during wiping operations.
[0151] The maintenance sled 200 is slidably mounted between the sidewalls 12 and 14 of the housing 10 to enable sliding movement along the x-axis of the printer module 1 . Referring briefly to FIG. 5 , a sled guide 65 is fixedly mounted to an inner surface of the second sidewall 14 and extends along the x-axis. The sled guide 65 receives a set of sled bearings 222 rotatably mounted to a second side of the sled frame 291 .
[0152] Turning to FIGS. 16 and 17 , a rail 67 is fixedly mounted to an inner surface of the first sidewall 12 and extends along the x-axis. A sled carriage 69 is slidably mounted on the rail 67 for movement therealong. The sled carriage 69 is connected to a sled mount 224 fixed to the sled frame 201 . Hence, the maintenance sled 200 is slidable along a track defined by the sled guide 65 and the rail 67 .
[0153] Movement of the sled carriage 69 along the rail 67 is driven by a transport mechanism comprised of a transport motor 70 operatively connected to a drive pulley 72 , and an endless drive belt 73 tensioned between the drive pulley 72 and idler pulleys 74 A, 74 B and 74 C. A first idler pulley 74 A is mounted to the first sidewall 12 at one end of the rail 67 , while second and third idler pulleys 74 B and 74 C are mounted to the first sidewall 12 at the other end of the rail 67 . The idler pulleys 74 A, 74 B and 74 C serve to steer the drive belt 73 between the two ends of the rail 67 and around the drive pulley 72 .
[0154] As shown in FIG. 16 , the drive belt 73 has a toothed inner surface engaged with the sled mount 224 . Thus, movement of the drive belt 73 , driven by the transport motor 70 , causes the maintenance sled 200 to move along the x-axis of the printer module 1 , either towards or away from the print bar carriage 100 .
Modular Printer Comprising Array of Printer Modules
[0155] Referring to FIG. 18 , and having described the printer module 1 in detail, there is shown in plan view a modular printer 600 comprising three printer modules A, B and C arranged in a staggered overlapping array. The printer modules A, B and C are mounted to a gantry (not shown) extending over a media web 602 so that each printer module is suspended over the web. The media feed direction is indicated by the arrow M. With this staggered overlapping arrangement, it is possible to print onto relatively wide media widths; in principle, the modular printer 600 may comprise any number of printer modules from, for example, 2 to 10 modules.
[0156] Each printer module overlaps with at least one neighboring printer module in the media feed direction M With suitable timing and control of nozzle firing in each printer module, an image may be printed seamlessly onto the web 602 using each of the overlapping modules. An analogous arrangement of staggered overlapping printheads, albeit with a different maintenance arrangement, was described in U.S. Pat. No. 8,485,656, the contents of which are incorporated herein by reference.
[0157] In the modular arrangement shown in FIG. 18 , the printer modules A, B and C are oriented such that the printhead cartridges 102 are relatively proximal to each other and the maintenance sleds 200 relatively distal from each other with respect to the media feed direction. In other words, the middle printer module B has it orientation reversed compared to the two outer printer modules A and C. This arrangement positions the printheads 105 in relatively close proximity and, therefore, minimizes the width of the print zone. (As used herein, the width of the print zone is defined parallel with the media feed direction, while the length of the print zone is defined perpendicular to the media feed direction). Thus, in order to perform maintenance on all printer modules simultaneously, the maintenance sled 200 of printer module B moves in an opposite direction to the maintenance sleds 200 of printer modules A and C. In other words, all maintenance sleds 200 move towards the print zone in order to perform maintenance operations on their respective printheads 105 . This arrangement of printer modules enables high print quality by minimizing the width of the print zone and, furthermore, enables printhead maintenance without breaking the media web 602 .
[0158] Still referring to FIG. 18 , it should be noted that printer module B is similar, but not identical to printer modules A and C. Printer modules A and C are identical to the printer module 1 described above and has the ink manifold 101 relatively proximal to the maintenance sled 200 in the printing position, as shown. However, printer module B is subtly different than printer modules A and C inasmuch as the ink manifold 101 of printer module B is relatively distal from the maintenance sled 200 in the printing position, as shown. This subtle difference enables all printhead cartridges 102 , and thereby all printheads 105 , to be oriented identically with respect to the media feed direction M. Accordingly, all printheads 105 , having a predetermined order of color channels, print in the same directional sense and the same firing order of color channels. Therefore, any print artifacts arising from overprinting or underprinting during multi-color printing are minimized.
[0159] It will, of course, be appreciated that the present invention has been described by way of example only and that modifications of detail may be made within the scope of the invention, which is defined in the accompanying claims.
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A method of maintaining a printer including a plurality of printheads positioned in a staggered overlapping arrangement across a width of a media feed path. Each printhead has a respective wiper and the method includes the step of moving the wipers towards respective printheads in a direction parallel to a media feed direction. The wipers for neighboring printheads are moved in opposite directions towards their respective printheads.
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This application is a continuation of application Ser. No. 591,416, filed Mar. 20, 1984, now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates in general to a shock absorber and more particularly to an engine mount through which an automotive engine unit is mounted to the vehicle body.
2. Description of the Prior Art
Usually, automotive engines are mounted to the vehicle bodies through rubber insulators which are arranged and constructed to absorb or block the vibration transmission from the engine unit to the vehicle body or vice versa. However, as will be described hereinafter, some of the conventional rubber insulators, viz., engine mounts fail to exhibit satisfied performance particularly against the vibration which is transmitted from the engine unit to the vehicle body.
SUMMARY OF THE INVENTION
It is therefore an object of the present invention to provide an improved engine mount which exhibits satisfied vibration absorbing performance particularly against the vibration which is transmitted from the engine unit to the vehicle body.
According to the present invention, there is provided an engine mount for mounting an engine unit on a vehicle body, which comprises first and second retaining members which are separated from each other, the first and second retaining members being connected respectively to the engine unit and the vehicle body or vice versa, a first shock absorbing block of elastomer disposed between the first and second retaining members, a magnetic member connected to the first retaining member to move therewith, and a magnet connected to the second retaining member to move therewith leaving a certain clearance between the magnet and the magnetic member, the magnet being arranged and oriented to effectively attract the magnetic member thereby to compress the first shock absorbing block.
BRIEF DESCRIPTION OF THE DRAWINGS
Other objects and advantages of the present invention will become apparent from the following description when taken in conjunction with the accompanying drawings, in which:
FIG. 1 is a sectional view of a conventional engine mount;
FIG. 2 is a graph showing the deflection characteristics of the conventional engine mount of FIG. 1 under varying loads;
FIG. 3 is a sectional view of a first embodiment of the engine mount according to the present invention;
FIG. 4 is a graph showing the deflection characteristics of the engine mount of the first embodiment (FIG. 3) under varying loads;
FIG. 5 is a sectional view of a second embodiment of the engine mount of the present invention;
FIG. 6 is a graph showing the deflection characteristics of the engine mount of the second embodiment (FIG. 5) under varying loads;
FIG. 7 is a graph showing the attractive force characteristics of magnet means employed in the second embodiment with respect to the distance between the magnet means and a magnetic member; and
FIGS. 8, 9 and 10 are views similar to FIG. 5, but showing third, fourth and fifth embodiments of the present invention.
DESCRIPTION OF A PRIOR ART ENGINE MOUNT
Prior to describing in detail the invention, a conventional engine mount will be outlined with reference to FIGS. 1 and 2 in order to clarify the invention.
Referring to FIG. 1, there is shown a conventional engine mount. The engine mount comprises generally a block 10 of elastomer, such as rubber, which is disposed between two retaining plates 12 and 14 to which it is bonded or vulcanized. Mounting bolts 16 and 18 are respectively secured to the retaining plates 12 and 14 and extend therefrom in the opposite directions. Upon assembly, the upper retaining plate 12 is bolted to a mounting bracket (not shown) of the engine unit and the lower retaining plate 14 is bolted to a supporting bracket (not shown) of the vehicle body, so that the mounting of the engine unit on the vehicle body is achieved through the elastomer block 10.
However, it has been revealed that the engine mount of the above-mentioned type is particularly poor in absorbing or blocking the vibration which is transmitted from the engine unit to the vehicle body. This undesirable phenomenon is seen from the graph of FIG. 2 which indicates the deflection characteristics of this type engine mount under varying loads. As is understood from this graph, the engine mount shows a relatively high spring constant (about 20 kgf/mm) at the deflection produced when a static load of the engine unit is applied thereto. As is known, in general, the blocking ability of a shock absorber against the vibration produced by the engine reduces as the spring constant thereof increases. Thus, hitherto, many attempts have been carried out to provide the engine mount under compressed condition with a smaller spring constant. However, nevertheless, some of them fail to exhibit the performance to the satisfied levels.
DETAILED DESCRIPTION OF THE INVENTION
Therefore, to provide the engine mount under compressed condition with a smaller spring constant is an essential object of the present invention. In the following, the present invention will be described in detail with reference to FIGS. 3 to 10.
Referring to FIG. 3, there is shown a first embodiment of the engine mount of the present invention. The engine mount of this embodiment comprises a block 10 of elastomer, such as rubber, which is coaxially disposed between two parallel circular plates 12 and 14 to which it is bonded or vulcanized. The diameter of the plate 14 is greater than that of the other plate 12, as shown. The plate 14 is constructed of a highly magnetic material such as soft iron. Two mounting bolts 16 and 18 are respectively secured to the plates 12 and 14. Upon assembly, the bolt 16 is connected to a mounting bracket (not shown) of the engine unit, while, the other bolt 18 is connected to a supporting bracket (not shown) of the vehicle body proper, so that the mounting of the engine unit to the vehicle body is effected through the elastomer block 10. A cup-shaped member 2 having an annular flange portion 2a is coaxially connected to the plate 12 with the flange portion 2a protruded toward the plate 14, as shown. An annular magnet 4 is coaxially fixed to the flange portion 2a and oriented to positively attract the plate 14.
In the following, function of the first embodiment will be described with reference to the graph of FIG. 4 which shows the deflection characteristics of it under varying loads.
As is seen from this graph, by the function of the magnet 4, the deflection rate of the engine mount increases acceleratively as the load applied thereto increases. This is because the deflection characteristics of the first embodiment is provided by combining the characteristics "B" of the elastomer block 10 per se and that "M" of the magnet 4. Thus, a smaller spring constant can be established at the high deflection region "E", viz., at the deflection produced when the static load of the engine unit is practically applied to the engine mount. That is, the spring constant K E at the region "E" is expressed by K E =K B +K M , wherein K B is the spring constant of the elastomer block 10, while K M is that of the magnet 4 which is negative. Thus, in normally experienced vibrational ranges, the engine mount of this first embodiment exhibits outstanding shock absorbing performance. However, due to its inherent construction, the engine mount has the following drawback.
That is, as is seen from the graph of FIG. 4, when the engine mount is suddenly applied with a great shock or great kinetic load to such a degree that the magnet 4 is brought into contact with the plate 14, the load increases infinitely. In this condition, the shock absorbing function of the engine mount disappears completely.
The following description is directed to second, third, fourth and fifth embodiments of the present invention which are free of the above-mentioned drawback of the first embodiment.
Referring to FIG. 5, there is shown a second embodiment of the engine mount of the present invention. The engine mount of this embodiment comprises a tubular block 20 of elastomer, such as rubber, which is coaxially disposed between two parallel annular plates 22 and 24 to which it is bonded or vulcanized. The outer diameters of the plates 22 and 24 are substantially equal to each other. Two mounting bolts 26 and 28 (or 30 and 32) are secured to the plate 22 (or 24) and extend parallelly therefrom outwardly. Preferably, the bolts 26 and 28 (or 30 and 32) are arranged at the diametrically opposed positions of the plate 22 (or 24). Similar to the case of the first embodiment of FIG. 3, the mounting bolts 26 and 28 are used for bolting the engine mount to the mounting bracket (not shown) of the engine unit, and the other mounting bolts 30 and 32 are used for bolting the engine mount to the supporting bracket (not shown) of the vehicle body. A generally frusto-conical block 34 of elastomer is coaxially disposed at its enlarged diameter side on the inboard surface of the plate 24. Vulcanizing technique may be employed for securing the block 34 to the plate 24. The top portion of the block 34 is formed with a circular recess 36 into which is tightly received a circular holder 38 constructed of a highly magnetic material such as soft iron. Within the holder 38 is received a cylindrical rare-earth magnet 40 which is bonded to the bottom of the holder 38 by a known bonding techique. The magnet 40 is oriented in such a manner that the line of magnetic force thereof has a direction indicated by the arrow "A". That is to say, the magnet 40 is so arranged and oriented as to attract a magnetic substance located above it. If desired, a number of rare-earth magnets may be arranged in the holder to produce increased magnetic force. A circular dished pate 42 of highly magnetic material is coaxially secured to the upper annular plate 22 by nuts 44 and bolts 46. If desired, the connection of the circular dished plate 42 to the upper annular plate 22 may be made by caulking. The dished portion 42a of the plate 42 is protruded toward the magnet 40, but it keeps a predetermined distance from the magnet 40 even when the static load of the engine unit is applied to the engine mount. The dished portion 42a is provided with annular projections 48 and 50 of elastomer which are vulcanized thereto. The mechanical strength viz., the thickness of each part used in the engine mount should be determined by considering the maximum load which may be applied thereto in practical use. The dished portion 42a of the plate 42 is formed with air breathing openings 52, each having an air filter 54 connected thereto.
In the following, function of the engine mount of the second embodiment will be described with reference to the graph of FIG. 6 which shows the deflection characteristics of an engine mount in which the spring constants of the tubular elastomer block 20 and the frusto-conical block 34 are 8 kgf/mm and 20 kgf/mm, respectively, and the magnet 40 is a cylindrical cobalt magnet having a size of 20 mm in diameter and 20 mm in length.
As is seen from the graph, like the case of the first embodiment, the deflection rate of the engine mount of the second embodiment increases acceleratively as the load applied thereto increases. This is because the deflection characteristics of this second embodiment is provided by combining the characteristics "B" of the elastomer block 20 per se and the characteristics "B'+M" of a spring system consisting of the magnet M and the other elastomer block 34. The characteristics of the magnet 40 per se is shown by the broken line M. Thus, like the case of the first embodiment, a smaller spring constant is established at the high deflection region "E", viz., at the deflection produced when the static load of the engine unit is practically applied to the engine unit. In this case, the spring constant K E at the region "E" is expressed by the following equation: ##EQU1## wherein, K 20 is the spring constant of the elastomer block 20, K 40 is that of the magnet 40 which is negative, and K 34 is that of the other elastomer block 34.
Thus, in normally experienced vibrational ranges, the engine mount of this second embodiment exhibits outstanding shock absorbing performance, like the case of the first embodiment. Furthermore, in the second embodiment, the undesirable sudden disappearance of the shock absorbing function which would occur in the first embodiment is eliminated by the following reasons.
That is, as is seen from the graph of FIG. 6, when the engine mount is suddenly applied with a great shock or great kinetic load to such a degree that dished portion 42a of the plate 42 is brought into contact with the magnet 40, the frusto-conical block 34 is compressed to absorb the shock with a spring constant K F which is expressed by K F =K 20 +K 34 . This desirable phenomenon is clearly shown at section "F" of the graph.
The provision of the shock absorbing projections 48 and 50 on the dished portion 42a of the plate 42 promotes smooth transition from the shock absorbing achieved with the spring constant K E to that achieved with the spring constant K F .
FIG. 7 is a graph showing attractive force generated by the magnet 40 under varying distances between the dished portion 42a and the magnet 40 of the second embodiment. Indicated by the broken line is the characteristics of the magnet 40 per se, while indicated by the solid line is the characteristics of the spring system consisting of the frusto-conical block 34, the magnet 40 and the dished plate 42. As is seen from the graph, in the spring system, the negative spring constant thereof can be remarkably changed by only changing the spring constant K 34 of the frusto-conical block 34. Thus, it is easy to select a magnet 40 appropriate for the desired specification of the engine mount.
Referring to FIG. 8, there is shown a third embodiment of the present invention. The same parts as those of the second embodiments are designated by the same numerals. As is seen from the drawing, the engine mount of this third embodiment is substantially the same in construction as the second embodiment except for an additional block 56 of elastomer which is disposed between the magnet 40 and the dished portion of the plate 42. The additional block 56 is constructed of a soft elastomer, such as rubber sponge or foamed polyurethane having a relatively small spring constant. With this construction, the transition from the shock absorbing achieved with the spring constant K E to that achieved with the spring constant K F is much more smoothly carried out. Preferably, the upper surface of the magnet 40 is entirely covered with the block 56 as shown. In this case, the magnetically sensitive portion of the magnet 40 can be protected from being contaminated with dust.
Referring to FIG. 9, there is shown a fourth embodiment of the present invention. In this embodiment, a circular magnetic member 58 is disposed in another frusto-conical block 60 of elastomer which extends from the magnet 40 to a flat circular plate 62. The flat circular plate 62 is secured to the upper annular plate 22 by nuts 44 and bolts 46. With this, the mass consisting of the magnet 40, the holder 38 and the magnetic member 58 and the spring element consisting of the frusto-conical blocks 34 and 60 form a so-called resonance system which is usable as a dynamic damper for absorbing the vibration of specified frequency. Designated by numerals 64 are air breathing openings formed in the plate 62, each having an air filter 54 connected thereto.
Referring to FIG. 10, there is shown a fifth embodiment of the present invention. The engine mount of this embodiment comprises a lower part which has substantially the same construction as the engine mount of the third embodiment (FIG. 8) and an upper part which is mounted on the lower part in series. The upper part comprises a plurality of parallel blocks 66 of elastomer which are disposed between an upper annular plate 68 and a lower circular dished plate 70. Each block 66 is secured to the plates 68 and 70 by vulcanization. The lower dished plate 70 is secured to the circular plate 62 of the lower part by the nuts 44 and bolts 46. A circular dished plate 72 is coaxially connected to the annular plate 68 by nuts 74 and bolts 76. A mounting bolt 78 is secured to the plate 72 and extends therefrom outwardly. By the provision of the upper part, the shock absorbing function of this fourth embodiment is more effectively achieved. If desired, an air spring element may be employed as a substitute for the upper part.
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Disclosed herein is an improved engine mount which comprises first and second retaining members which are separated from each other, a first shock absorbing elastomer block disposed between the first and second retaining members, a highly magnetic member connected to the first retaining member to move therewith, and a magnet connected to the other of the first and a magnet connected to the second retaining member to move therewith leaving a certain clearance between the magnet and the highly magnetic member. The magnet is arranged and oriented to effectively attract the highly magnetic member thereby to compress the first shock absorbing elastomer block.
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FIELD OF THE INVENTION
[0001] This invention relates to a method of providing an immediate anti-wrinkle effect and/or an immediate tensor effect on the skin. The invention also relates to a process for obtaining a polysaccharide-rich active ingredient of high molecular weight that is derived from oat bran, having an immediate anti-wrinkle effect and/or immediate tensor effect on the skin, to the active ingredient that can be obtained by this process, its uses, and the related cosmetic compositions.
BACKGROUND OF THE INVENTION
[0002] To appear younger, many people want to tone up their skin and attenuate the directly visible, unsightly physical changes that are linked to cutaneous aging.
[0003] The aging of the skin results from various alterations caused by factors that are both genetic and environmental. It manifests itself in particular by the loss of mechanical strength and viscoelastic and lifting properties of the dermis. The skin then has the tendency to stretch under the influence of its own weight, thus causing surface deformations, and the formation of wrinkles and unsightly folds. The epidermis also loses its thickness, and the cutaneous microrelief is modified.
[0004] To fight against this phenomenon, cosmetic active ingredients are therefore sought that make it possible both to lift and smooth the cutaneous microrelief, and to improve the viscoelastic properties of the skin at the same time.
[0005] To date, to meet their lifting needs, the formulators have had at their disposal two types of substances:
Synthetic and sticky polymers that are often difficult to formulate because they are only soluble in alcohol, and Proteins.
SUMMARY OF THE INVENTION
[0008] A purpose of this invention is another molecular means to eliminate the drawbacks of the prior art by proposing a method of providing an immediate anti-wrinkle effect and/or immediate tensor effect on the skin by administering to a subject, oat bran polysaccharide alpha-glucans. The alpha-glucans preferably have a molecular weight of between 25 kDa to 300 kDa.
[0009] The invention also relates to a process for obtaining an active ingredient with an immediate tensor effect that is effective, soluble and stable in water, of plant origin, and that limits the protein content as much as possible.
[0010] To this end, the invention includes a process for obtaining an active ingredient with an immediate anti-wrinkle effect and/or immediate tensor effect on the skin, characterized in that it consists in extracting and purifying specific polysaccharides of high molecular weight from oat bran and in solubilizing and stabilizing these polysaccharides in water.
[0011] The active ingredient according to the invention can be obtained from simple oat fibers and/or from oat bran, residue of the oat grounds obtained from the pericarp of seeds that, in addition to fibers, contains proteins, mineral salts, and vitamins, and/or from oat seeds.
[0012] Advantageously, the active ingredient that is obtained, polysaccharide-rich and of a high molecular weight, produces a sensation of stretched and toned skin and has an immediate tensor effect that is characterized by a smoothing of the cutaneous microrelief and an improvement in the mechanical properties of the skin, thus an immediate anti-wrinkle effect.
DETAILED DESCRIPTION OF THE INVENTION
[0013] This invention is now described in detail by using non-limiting examples of compositions, as well as test results grouped in tables.
[0014] The invention relates to a method of providing an immediate anti-wrinkle effect and/or immediate tensor effect on the skin by administering to a subject in need thereof an effective amount of oat bran polysaccharides of alpha-glucans. Oat bran polysaccharides of alpha-glucans can have a molecular weight of between 25 kDa to 300 kDa.
[0015] Preferably the invention relates to a method of providing an immediate anti-wrinkle effect and/or immediate tensor effect on the skin by administering to a subject in need thereof an effective amount of an active ingredient obtained from oat bran containing polysaccharides of alpha-glucans preferably having a molecular weight of between 25 kDa to 300 kDa. Preferably the polysaccharides having a molecular weight of between 25 kDa to 300 kDa represent 90% of the oat bran polysaccharides in the active ingredient.
[0016] The invention also relates to a method of providing an immediate anti-wrinkle effect and/or immediate tensor effect on the skin by administering to a subject a cosmetic composition comprising between 1% and 5% by weight of the active ingredient obtained from oat bran containing polysaccharides of alpha-glucans, preferably having a molecular weight of between 25 kDa to 300 kDa.
I/Process For Obtaining the Polysaccharides and the Active Ingredient
[0017] The process according to this invention comprises at least two essential stages:
A stage for solubilization of oat bran and/or fibers and/or seeds in a basic solution, and A stage of successive or simultaneous enzymatic hydrolysis(es) of polysaccharides that are contained in the oat bran and/or fibers and/or seeds, so as to facilitate their solubilization without disrupting their molecular structure.
[0020] According to an embodiment of the invention, to facilitate the solubilization of polysaccharides, at least one adjuvant for solubilization in the basic solution, preferably a salt, a polyphosphate and/or an oxidizer, is added.
[0021] The concentration of alkaline agent of the basic solution for solubilization can be adjusted so that the physical properties of the polysaccharides are not altered by simple sugars during hydrolysis.
[0022] Preferably, the process according to this invention also comprises a deproteinization stage.
[0023] According to a preferred embodiment, the process according to the invention comprises the series of the following stages:
Solubilization of an oat bran and/or fibers and/or seeds at a rate of 30 g/l to 300 g/l, more particularly from 50 g/l to 150 g/l, in a basic solution, Successive or simultaneous enzymatic hydrolysis(es) of polysaccharides, Inactivation by heat or chemical treatment to block the enzymatic reactions, Separation of the soluble and insoluble phases by filtration, decanting, and/or centrifuging, Successive concentrations, Deproteinization by precipitation or selective adsorption, Purification of the active fraction that contains polysaccharide alpha-glucans by ultrafiltration, and Sterilizing filtration.
[0032] Advantageously, the process according to the invention allows the preservation of native polysaccharides that are derived from oat bran and/or fibers and/or seeds, while facilitating the industrial feasibility of the active ingredient.
II/Characterization of the Active Ingredient
[0033] II.1/Dry Material
[0034] The level of dry material is measured by running a sample with a given initial weight through the oven at 105° C. until a constant weight is obtained.
[0035] The level of dry material is between 20 and 200 g/l, more particularly between 60 and 110 g/l.
[0036] II.2/Measurement of pH
[0037] The pH that is measured by the potentiometric method at ambient temperature leads to values of between 4 and 8, more particularly between 5 and 6.
[0038] II.3/Determination of the Content of Total Sugars
[0039] The method of DUBOIS (DUBOIS, M. et al. (1956), Analytical Chemistry, 28, No. 3, pp. 350-356) is used.
[0040] In the presence of concentrated sulfuric acid and phenol, the reducing sugars provide a yellow-orangey compound.
[0041] Starting from a standard range, it is possible to determine the level of total sugars of a sample.
[0042] The level of total sugars of the active ingredient according to this invention is 19 to 190 g/l, preferably 57 to 105 g/l.
[0043] The ratio of the total sugars to the level of dry material for the active ingredient according to this invention is greater than 50%, preferably greater than 80%.
[0044] II.4/Mean Polymerization Degree of Polysaccharides
[0045] The mean polymerization degree of polysaccharides is determined by the ratio of the level of total sugars to the level of reducing sugars.
[0046] The metering of reducing sugars is carried out as follows:
The active ingredient to be metered is brought into the presence of a solution of 4-hydroxybenzoic hydrazide in 0.5 M hydrogen chloride and a 0.5 M soda solution, A standard range is produced with glucose, and The absorbance is measured at 410 nm to determine the content of reducing sugars of the active ingredient relative to the glucose range.
[0050] The mean polymerization degree of the polysaccharides of the active ingredient according to this invention is greater than 40, preferably greater than 60.
[0051] II.5/Polysaccharide Size
[0052] The distribution by size of the polysaccharides that are obtained by the implementation of the process according to the invention is carried out by studying the chromatograms.
[0053] The polysaccharides that are obtained by the implementation of the process according to the invention are polysaccharides of high molecular weight. They have a polysaccharide size of between 25 kDa and 700 kDa. Preferably, more than 90% of the polysaccharides have a molecular weight of between 25 kDa to 300 kDa, and preferably these polysaccharides are alpha-glucans.
[0054] II.6/Identification of the Molecular Structure of Polysaccharides of the Active Ingredient
[0055] II.6.1/Main Chain of Glucose in Alpha-1.4 Linkage
[0056] After specific enzyme action on the alpha-1.4 linkage of the active ingredient according to the invention, two types of compounds were found in the chromatogram: 77% free glucose (molecular weight=180 Da, polymerization degree=1) and 23% oligomeric glucose (molecular weight=666 Da, polymerization degree=4). This mean that 77% of glucose molecules are present in alpha-1.4 linkage.
[0057] II.6.2/Main Chain of Glucose Molecules Bound in Alpha-1.6
[0058] The action of a mixture of two enzymes (the first specific for the alpha-1.4 linkages between 2 glucose molecules and the second specific for alpha-1.6 linkages) showed that the product is composed of 100% free glucose. This proves the presence of both types of linkages in the active ingredient according to the invention.
[0059] II.6.3/Modeling Molecular Structure
[0060] According to the preceding data, a structural model of the active ingredient polysaccharides can be made. It was estimated there is one alpha-1.6 linkage every 12 molecules of glucose. Active ingredient polysaccharides are composed of a glucose chain linked by alpha-1.4 linkages, forming a helicoidally structure, ramified by an alpha-1.6 linkage every 12 glucoses, on average.
[0061] II.7/Determination of Free Glucose
[0062] The free glucose of different samples was determined:
Active ingredient according to the invention. Active ingredient according to the invention hydrolyzed by acid for 2 hours. This hydrolysis can drastically cut the set of all glucose-glucose links, whatever the nature of the linkage. Active ingredient according to the invention hydrolyzed by a cellulase enzyme (CELLULYVE® Lyven, France) having a beta-glucanase activity. This hydrolysis allows hydrolyzing only beta linkages between two glucose molecules, thus hydrolyzing beta-glucans exclusively.
[0066] The analysis is performed by liquid chromatography ion (Dionex ICS 3000) under the following conditions:
[0067] Column: CARBOPAC PA14*250 mm, the pre-column with the same characteristics as the column,
[0068] Flow rate: 1 ml/min,
[0069] Solvent:
A: distilled water B: 100 mM NaOH (sodium ultrapure Fischer, S/4940/17) C: 100 mM NaOH+500 mM CH 3 COONa (VWR PROLABO, RECTAPUR, 27650.292)
[0000]
Time (min)
% A
% B
% C
0
80
20
0
15
80
20
0
20
80
0
20
42
50
0
50
48
50
0
50
48
0
0
100
65
0
100
0
65
80
20
0
70
80
20
0
[0073] Detector: pulsed amperometric,
[0074] Oven temperature: 30° C.,
[0075] Injection: 25 μl.
[0076] The results are as follows:
[0000]
Analysed Products
Free glucose content (g/l)
Active ingredient according to the invention
0
Active ingredient hydrolyzed by acid for 2
72.0
hours
Active ingredient hydrolyzed by beta
1.8
glucanase
[0077] The results suggest that all the glucose present in the active ingredient according to the invention is in a bound form, since the content of free glucose in the active ingredient is zero and the active ingredient contains 72 g/l of glucose in a bound form, as the content free glucose of the active ingredient completely hydrolyzed is 72 g/l.
[0078] The enzyme beta-glucanase can cut glucose links only in beta, and the beta glucanase enzyme frees 1.8 g/l of the 72 g/l of glucose of the active ingredient.
[0079] Therefore the active ingredient according to the invention contains 2.5% beta linked glucose, thus 2.5% as beta-glucans.
[0080] Because the glucose binds in either beta or alpha, it is concluded that the active ingredient glucose content contains 97.5% of alpha-glucans.
III/Evaluation of the Effect of the Active Ingredient
[0081] III-1/Evaluation of the Tensor Effect by Cutometer
[0082] This study has as its objective to evaluate the tensor effect of an active ingredient that is obtained according to the invention from oat bran.
[0083] The study is performed on volunteers using a Cutometer. A Cutometer is a device that is equipped with a probe that is applied to the skin in which a constant depression is maintained. The depth of penetration of the skin in the probe is measured under the intake effect.
[0084] When subjected to these depressions, the skin becomes tired more or less quickly and the response times as well as the measured amplitudes make it possible to determine the parameters, in particular:
An elastic component, Ue, which corresponds to an instantaneous deformation, and Uf, which corresponds to the extensibility.
[0087] If Ue decreases, the skin is less flexible and therefore more stretched. If Uf decreases, the skin is less extensible, and therefore also more stretched.
[0088] The operating protocol is as follows:
A zone is identified on the volunteers' forearms, and a first series of measurements is taken with the Cutometer, The active ingredient that is derived from oat bran that is obtained according to the invention at 4% in emulsion or a placebo is applied to the identified zone, and Two hours after the application, a new series of measurements is taken on the identified zone.
[0092] As reference results, the BSA (bovine serum albumin) metered at 4% is used.
[0093] The results that are obtained for the active ingredient that is derived from oat bran according to the invention are expressed relative to the placebo in the table below:
[0000]
Cosmetic
Effectiveness/Placebo
(ΔUf)
(ΔUe)
4% BSA
−5.0%
−7.1%
Active Ingredient According to
−8.4%
−9.9%
the Invention
[0094] It is noted that the active ingredient according to the invention reduces the elastic component and the extensibility of the skin: it has an immediate tensor effect on the skin.
[0095] III-2/Evaluation of the Tensor Effect in Sensory Analysis
[0096] The objective of this study is to quantify in vivo the tensor effectiveness of an active ingredient according to the invention, obtained from oat bran, formulated at 10% of counter-placebo gel.
[0097] The sensory evaluation test consists in having a panel of experts make a blind evaluation of the tightening and non-sticky sensation. The study is performed on 15 healthy volunteers at the level of the eye and the crow's-feet.
[0098] The operating protocol is as follows:
At T minus 5 minutes, the volunteers remove make-up from the selected eye and crow' s-feet, At T 0, 80 μl of a gel that is to be tested is applied: placebo gel, gel that contains 10% of the active ingredient according to the invention that is derived from oat bran, gel that contains 5% BSA, gel that contains 10% BSA, and gel that contains 20% BSA, and At T 3 minutes, T 5 minutes, and T 10 minutes, the tightening sensation is evaluated on a scale of 0 to 10, using a cursor.
[0102] The analysis of the scales is carried out by totaling the scores over three cycles.
[0103] The various gels are tested randomly over several days (one gel per day).
[0104] The results that are obtained are presented in the table below:
[0000]
Total of the Scores over 3 Cycles
Placebo
4.1
Active Ingredient According to the
13.6
Invention at 10%
5% BSA
8.2
10% BSA
12.9
20% BSA
14.6
[0105] It is noted that after a single application, the experts identify the active ingredient according to the invention as tightening and non-sticky, and score it at an effectiveness of 13.6, which is higher than that of BSA metered at 10%.
[0106] III-3/Evaluation of the Immediate Anti-Wrinkle Effect
[0107] The object of this study is to quantify the immediate anti-wrinkle effectiveness of an active ingredient according to the invention, obtained from oat seeds, formulated at 4% in counter-placebo emulsion.
[0108] The study is performed on healthy female volunteers.
[0109] Anti-wrinkle effectiveness is measured by means of silicone imprints made in the crow's-feet of volunteers.
[0110] The analysis of these imprints using a profilometer equipped with an image analyzer makes it possible to obtain three parameters: the number of wrinkles, the total wrinkled surface area, and the total length of the wrinkles.
[0111] The study is performed according to the following protocol.
[0112] At T 0, two symmetrical cutaneous zones are identified at the crow's-feet—one intended to be treated by placebo, the other by the active ingredient—and imprints are made of these two zones.
[0113] After the imprints are made, the placebo and the active ingredient according to the invention, derived from oat seeds and formulated at 4%, are applied to the defined zones.
[0114] At T 2 hours, the imprints are made on the two zones that are being studied.
[0115] The results that are obtained for the active ingredient according to the invention, derived from the oat seeds, are expressed in the table below by percentage relative to those obtained for the placebo:
[0000]
Variation/Placebo (%)
Number of Wrinkles
−11.5
Total Wrinkled Surface Area
−17.4
Total Length
−13.9
[0116] It is noted that after two hours, in comparison to the placebo, the active ingredient according to the invention that is formulated at 4% reduces the number of wrinkles, the total wrinkled surface area, and the total length of the wrinkles at the same time. It therefore has an immediate anti-wrinkle effect.
[0117] III-4/Evaluation of the Tensor Effect in Sensory Analysis
[0118] The objective of this study is to quantify in vivo the tensor effectiveness of the active ingredient according to the invention, obtained from oat seeds, formulated at 4% of counter-placebo gel.
[0119] The sensory evaluation test consists in having a panel of experts make a blind evaluation of the tightening and non-sticky sensation, formed with this tightening sensation. The study is performed on 15 healthy volunteers at the level of the eye and the crow's-feet.
[0120] The operating protocol is as follows:
At T minus 5 minutes, the volunteers remove make-up from the selected eye and crow's-feet, At T0, 80 μl of a gel that is to be tested is applied: a placebo gel or a gel that contains 4% of the active ingredient according to the invention that is derived from oat seeds, and At T 3 minutes, T 5 minutes, and T 10 minutes, the tensor sensation is evaluated on a score scale that ranges from 0 to 10, using a cursor.
[0124] The results that are obtained, corresponding to the mean of the scores with three cycles, are presented in the table below:
[0000]
Mean Score
Placebo
2.1
Active Ingredient According to the
4.4
Invention at 4%
[0125] It is noted that after a single application, the experts identify the active ingredient according to the invention as tightening and non-sticky, and score it at an effectiveness of 4.4.
IV/Cosmetic Composition Including the Active Ingredient
[0126] This invention also covers the cosmetic compositions including the active ingredient according to this invention in various galenical forms, in particular gel, solution, emulsion, cream.
[0127] It is then advisable to analyze the stability of the galenical forms, including the active ingredient according to the invention, in proportions of between 1 and 5%. The stability is characterized by an absence of precipitation of the active ingredient, an absence of creaming, and an absence of phase shift.
[0128] It is possible to cite formulations that have shown a physical stability that includes 5% of active ingredient according to the invention.
Clear Gel:
[0000]
CARBOPOL: 0.5% with triethanolamine—sufficient quantity for pH=6.5
Preservative: 0.7%
Active ingredient: 5.0%
Water: 93.8%
Opaque Gel:
[0000]
SEPIGEL 305: 2.0%
Preservative: 0.7%
Active ingredient: 5.0%
Water: 92.3%
Emulsified Gel:
[0000]
MONTANOV 202: 3.0%
Isopropyl palmitate: 12.0%
Preservative: 0.7%
VISCOLAM AT 64: 2.0%
Active ingredient: 5.0%
Water: 77.3%
Non-Ionic Emulsion:
[0000]
MONTANOV 202: 3.0%
SIMULSOL 165: 2.0%
Isopropyl palmitate: 20.0%
Preservative: 0.7%
Active ingredient: 5.0%
Water: 69.3%
Anionic Emulsion:
[0000]
Stearic acid: 7.0%
Triethanolamine: 3.5%
Isopropyl palmitate: 20.0%
Preservative: 0.7%
Active ingredient: 5.0%
Water: 63.8%
Cationic Emulsion:
[0000]
Quatemium-82: 5.0%
Cetyl alcohol: 2.0%
Cetearyl alcohol: 1%
PEG100 stearate: 1%
Isopropyl palmitate: 15.0%
Preservative: 0.7%
Active ingredient: 5.0%
Water: 70.3%
[0163] In addition, tests have shown the compatibility of the active ingredient with the raw material used in cosmetics.
EXAMPLES OF COSMETIC FORMULAS
Example 1
Liquid Make-up Foundation
[0164]
[0000]
A.
Water
q.s. 100%
DUB DIOL (Stearinerie Dubois)
6%
Glycerol (Univar)
4%
Montanox 60 (Seppic)
0.4%
SATIAXANE CX 930 (Degussa)
0.2%
B.
SIMULSOL 165 (Seppic)
3%
Rita stearic (Rita)
2%
Rita CA (Rita)
1%
DC 345 (Dow Corning)
3%
DUB Vinyl (Stearinerie Dubois)
6%
Gemseal 40 (Total)
7%
C.
White W9775(LCW/Sensient)
7%
Yellow W1771 (LCW/Sensient)
4.2%
Brown W8770 (LCW/Sensient)
1.5%
Black W9774 (LCW/Sensient)
0.5%
D.
Phenoxyethanol (Sigma)
0.8%
Ethylhexylglycerine (Seppic)
0.2%
E.
Active Ingredient (oat bran polysaccharide alpha-glucans)
4%
Heat A and B to 80° C. Add B to A with mixing.
At 60° C. add C. Homogenize until the color is uniform.
Cool to 30° C. and add D then E.
Continue homogenizing until the make-up foundation is uniform.
Example 2
Day Cream
[0169]
[0000]
A.
Water
q.s. 100%
Glycerol (Univar)
10%
SATIAXANE CX 930 (Degussa)
0.2%
B.
SENSANOV WR (Seppic)
3%
Phytosqualane (Sophim)
5%
Seppifeel one (Seppic)
2%
LANOL 2681(Seppic)
5%
Sophim MC 30 (Sophim)
4%
DUB PTC (Stearinerie Dubois)
3%
SEPINOV EMT10 (Seppic)
1%
C.
Phenoxyethanol (Sigma)
0.8%
Ethylhexylglycerine (Seppic)
0.2%
D.
Active ingredient (oat bran polysaccharide alpha-glucans)
4%
E.
SIMULGEL EPG (Seppic)
0.5%
Heat A and B to 80° C. Add B to A with mixing.
Cool to 30° C. and add C, D and E.
Continue homogenizing until the cream is uniform.
Example 3
Transparent Fluid Serum
[0173]
[0000]
A.
Water
q.s. 100%
Glycerol (Univar)
10%
DUB DIOL (Stearinerie Dubois)
10%
CAPIGEL 98 (Seppic)
4%
B.
Phenoxyethanol (Sigma)
0.8%
Ethylhexylglycerine (Seppic)
0.2%
C.
Active ingredient (oat bran polysaccharide
4%
alpha-glucans)
NaOH
q.s. pH = 6.8
Mix A, B and C
Adjust the pH to 6.8 with sodium hydroxide.
Continue homogenizing until the serum is uniform.
Example 4
Body Milk
[0177]
[0000]
A.
Water
q.s. 100%
Glycerol (Univar)
3%
B.
MONTANOV 202 (Seppic)
2%
LANOL 14M (Seppic)
1%
LANOL 1688 (Seppic)
10%
DC 200 (Dow Corning)
1%
C.
Ethanol
8%
D.
Phenoxyethanol (Sigma)
0.8%
Ethylhexylglycerine (Seppic)
0.2%
E.
Active Ingredient (oat bran polysaccharide alpha-glucans)
4%
F.
Sepigel 501 (Seppic)
2%
Heat A and B to 80° C. Add B to A with mixing.
Cool to 30° C. and add C, D and E, then F.
Continue homogenizing until the milk is uniform.
Example 5
Facial Tensor Emulsified Gel
[0181]
[0000]
A.
Water
q.s. 100%
Glycerol (Univar)
1%
SATIAXANE CX 930 (Degussa)
4%
B.
DC 345 (Dow Corning)
2%
Cetearyl Alcohol (Rita)
1%
MONTANOV 68 (Seppic)
5%
DUB LAHE (Stearinerie Dubois)
5%
C.
Phenoxyethanol (Sigma)
0.8%
Ethylhexylglycerine (Seppic)
0.2%
D.
Active ingredient (oat bran polysaccharide alpha-glucans)
4%
Heat A and B to 80° C. Add B to A with mixing.
Cool to 30° C. and add C then D.
Continue homogenizing until the gel is uniform.
|
The invention relates to a method for obtaining an active ingredient having an immediate anti-wrinkle and skin-tensioning effect, by extracting and purifying high molecular weight polysaccharides from oat bran, fibers and/or grains, and solubilizing and stabilizing the polysaccharides in water. The invention also relates to the product thus obtained, to uses thereof, and to cosmetic compositions containing this active ingredient. The oat bran polysaccharides include alpha-glucans having a molecular weight of between 25 kDa and 300 kDa.
| 0
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BACKGROUND OF THE INVENTION
1. Field of Use
The process of this invention relates to a process for removing lower alcohols from a tetrahydrofuran stream. More particularly, the process of this invention relate to a process for removing lower alcohols from a tetrahydrofuran stream by extractive distillation with water.
2. Prior Art
In the production of tetrahydrofuran (THF) from acetylene and formaldehyde, crude 1,4-butanediol (BAD) is heated in a cyclization reactor in the presence of sulfuric acid to cyclize the BAD to form THF with water and small quantities of methanol. The THF and water produced are vaporized from the cyclization reactor through a distillation column with the small quantities of methanol. However, in the process of dehydrating the THF the amount of methanol tends to build up in the system due to the formation of a low boiling binary azeotrope between methanol and THF which is not readily separable by direct distillation. Methanol can be removed or reduced by means of a purge. Purging, to remove the methanol cannot be achieved without a loss of THF. It is estimated that for every pound of methanol removed from the system some 5 to 10 pounds of THF are lost.
BAD can also be produced by hydrogenation of a mixture of formyl acetals containing, for example, 2-β-formylethyl-5-methyl- 1,3-dioxane. The product of said hydrogenation includes BAD, an aqueous byproduct mixture of lower alcohols and THF. This alcohol mixture may contain methanol, ethanol, normal propanol and normal and iso butanol. Recovery of a substantially pure THF-water azeotrope from this mixture is desirable. The separatin of n-propyl and the normal and isobutyl alcohols can be accomplished by direct distillation, but in the case of methanol and ethanol, due to azeotrope formation, separation cannot be made by direct distillation.
In the manufacture of polybutylene terephthalate resins by reaction of BAD with the methyl ester of the terephthalic acid, methanol and THF are formed. An efficient procedure is needed to separate THF and methanol.
U.S. Pat. No. 2,198,651 discloses a process for the separation of constant boiling ternary mixtures of an alcohol, acetone and an unsaturated compound(s) whereby two binary mixtures are formed. A ternary mixture disclosed is methanol, acetone and tetramethylene oxide (THF). In all mixtures disclosed, acetone is present. The scope of the disclosure and teaching is therefore limited to ternary mixtures containing acetone. Acetone is a known entrainer for THF in a wet system. In such a system, acetone would be taken overhead with the THF and thus be an undesirable contaminant.
SUMMARY OF THE INVENTION
Now it has been found that certain alcohols can be separated from tetrahydrofuran in a conventional distillation column by extractive distillation of the alcohol with water in the absence of acetone. The extractive distillation is achieved by contacting a tetrahydrofuran stream with water in a distillation column generally by adding water above the point where the tetrahydrofuran stream is fed to the column.
The alcohol which the present invention separates from the tetrahydrofuran is one or more of the group consisting of methanol, ethanol, isopropanol and tertiary butanol. The preferred alcohols subjected to the process of this invention are methanol and ethanol.
The tetrahydrofuran stream of this invention from which the alcohol is separated comprises tetrahydrofuran, one or more alcohols selected from the group consisting of methanol, ethanol, isopropanol and tertiary butanol and optionally water. Generally water is present in the tetrahydrofuran stream, but the process of this invention is operable without the presence of water in the THF stream.
Thus, the present invention involves a process for separating one or more alcohols selected from the group consisting of methanol, ethanol, isopropanol and tertiary butanol, from a mixture of tetrahydrofuran (THF), one or more of methanol, ethanol, isopropanol and tertiary butanol and optionally water, said process comprising feeding said mixture into a distillation column and extractively distilling THF from the mixture in said distillation column by adding water into the distillation column above the feed of said mixture to permit the countercurrent contact of the water and the mixture containing the alcohol to be separated. The alcohol(s) is removed from the bottom of the column as a water solution which can be further distilled to recover the alcohol. The THF is removed from the top of the column as a water azeotrope.
DESCRIPTION OF THE INVENTION
Mixtures of THF and one or more of said alcohols to be removed can result in a variety of ways. In reactions involving the cyclization of 1,4-butanediol to THF, one or more of the above alcohols form, thereby contaminating the tetrahydrofuran product of the reaction. The particular alcohol(s) that may be present with THF vary depending on the process for the preparation of the tetrahydrofuran or vary with the particular THF mixture. Such alcohols are difficult to separate from tetrahydrofuran by conventional distillation.
In the production of tetrahydrofuran (THF) from acetylene and formaldehyde, 1,4-butanediol, which is first formed, is converted to THF in the presence of an acid, e.g., sulfuric acid by a cyclization reaction. Certain amounts of methanol are produced in the cyclization reaction.
In another process, in which butanediol is produced by hydrogenation of a mixture of formyl acetals containing, for example, 2-β -formylethyl-5-methyl-1,3-dioxane, an aqueous byproduct mixture of lower alcohols and THF is produced. This alcohol mixture may contain methanol, ethanol, normal propanol and normal and iso butanol.
There are processes for the manufacture of polybutylene terephthalate resins in which 1,4-butanediol is reacted with the methyl ester of the terephthalic acid. Methanol is formed in the product which is frequently contaminated by THF formed from the butanediol during the exchange reaction and an efficient procedure is needed to separate THF and methanol.
It is desired to recover substantially pure THF-water azeotrope from the tetrahydrofuran stream of this invention. The separation of methanol and ethanol by direct distillation is impossible due to azeotrope formation and difficult with isopropanol and tertiary butanol due to relatively small volatility difference in the isopropanol-THF system and tertiary butanol-THF system.
Generally a weight ratio of water to organic feed (tetrahydrofuran and alcohol) of at least 0.1:1 is used. When a weight ratio of 0.1:1 or more of water to organic feed is added to the THF stream, the THF becomes more volatile than the alcohol over the whole composition range of the THF stream permitting THF to be removed as a water azeotrope from the top of the column wherein the extractive distillation is taking place while the alcohol, whose volatility is suppressed by the water, migrates down the column. The preferred ratio of water to organic feed is from 0.4:1 to 4:1. Ratios less than 0.1:1 do not result in the removal of substantially all of the alcohol. Thus, the lower limit of 0.1:1 is critical. Below 0.1:1 the relative volatility, within the range of weight fractions possible, will be less advantageous or in the case of methanol or ethanol an azeotrope with the THF will form making it impossible to remove all the ethanol or methanol. There is no upper limit of water to organic feed ratio. As the amount of water used is increased relative to the organic feed, the relative volatility of the THF increases but difficulties can arise regarding the presence of excessive amounts of water in the bottoms.
In the process of the invention there is a small amount of THF that is washed into the bottoms from the extractive distillation.
The greater the water feed relative to the organic feed, the greater the amount of THF present in the bottoms. Unless recovered from the bottoms, this THF is lost. Recovery of THF from bottom mixtures containing greater amounts of water is difficult and expensive. Therefore, excessive water feed should be avoided. It is therefore desirable to maintain said ratio at from 0.4:1 to 4:1. At weight ratios below 0.4:1 of water to organic feed, e.g., 0.3:1, 0.2:1 and 0.1:1, separation of the alcohol from the tetrahydrofuran is achieved but is more costly due to the need for a substantially greater number of plates in the distillation column as compared to where the weight ratio is 0.4:1 or above.
FIG. 1 shows a THF-methanol vapor liquid equilibrium curve at various levels of water addition at atmospheric pressure.
FIG. 2 shows a THF-ethanol vapor liquid equilibrium curve with and without a specific ratio of water at atmospheric pressure.
FIG. 3 shows a THF-isopropanol vapor equilibrium curve with and without a specific ratio of water at atmospheric pressure.
FIG. 4 shows a THF-tertiary butanol vapor equilibrium curve with and without a specific ratio of water at atmospheric pressure.
Referring now to FIG. 1 it can be seen that direct distillation is not a feasible method of removing methanol. Assuming a perfect distillation, the highest concentration of methanol which can be removed overhead when a dry mixture is used is the azeotrope with about 33% by weight methanol; thus substantially all of the methanol cannot be removed. It can be seen that at water to organic feed ratios of as low as 0.1:1 all of the methanol can be removed. At any given weight fraction of THF in the liquid, the weight fraction in the vapor is more concentrated when said water ratio is 0.1 or greater. Thus, in the present process, there is sufficient water to render the THF more volatile while the methanol whose volatility is suppressed migrates down the column. At ratios of from 0.1:1 to 0.4:1 of water to organic feed, all of the methanol can be removed but the reflux ratio and the required plates would not be as advantageous as when said ratios are more than 0.4:1. At ratios of greater than 0.4:1, the relative volatilities are more advantageous than in the range of 0.1:1 to 4:1. Note that the curves at various water-organic feed ratios is dotted in part. The dotted part is an extension of the curve from the data obtained based on curves known. Note also that the curve at a ratio of 0.05:1 extends below the 45° line.
Referring now to FIG. 2, it can be seen that the highest concentration of ethanol which can be obtained overhead is the azeotrope of ethanol and THF containing about 12% ethanol. However, at a ratio of 1:1 of water to organic feed (THF and ethanol) all of the ethanol can be removed.
Referring now to FIG. 3, it can be seen that no azeotrope is formed between THF and isopropanol but the separation of the isopropanol is difficult due to the fact that the relative volatility curve lies close to the 45° line.
Referring now to FIG. 4, it can be seen that no azeotrope is formed between THF and tertiary butanol but the separation of the tertiary butanol is difficult due to the fact that the relative volatility curve lies close to the 45° line.
The process of this invention is a method of separating alcohols, that are present in the THF stream of this invention, from THF. The THF in such a stream is recovered as a water azeotrope which contains, at atmospheric pressure, some 6% water. Methods for obtaining dry THF from the azeotrope, such as distillation or by treatment with caustic soda are well known.
The relative volatility of a mixture of two compounds is a number that indicates the relative ease of separation of the two compounds. The relative volatility, α, can be calculated by the use of the equation:
Relative Volatility, α=(X.sub.B Y.sub.A /Y.sub.B X.sub.A)
wherein X A is the concentration of the more volatile compound in the liquid, Y A is the concentration of the more volatile compound in the vapor, X B is the concentration of the less volatile compound in the liquid and Y B is the concentration of the less volatile compound in the vapor. To illustrate such a calculation, using the equilibrium curve for methanol, FIG. 1, wherein a 2:1 ratio of water to organic feed and at a 80% THF, 20% methanol mixture it can be seen that where X A is 0.80, Y A is about 0.96 and where X B is 0.2, Y B is about 0.04. Thus α is calculated below:
α=(0.20×0.96)/(0.04×0.80)=6.0
Similarly calculated values follow:
______________________________________Water/Organic α______________________________________2.0 6.01.0 4.10.5 2.90.4 2.20.3 1.70.2 1.40.1 1.250.05 0.90 0.75______________________________________
Thus, when said ratio is at least 0.1:1, THF becomes more volatile over the whole composition range, permitting it to be removed as a water azeotrope from the top of the column. Optimum water rates also depend on reflux ratio since the higher the reflux, the greater the flow of THF-alcohol(s) down the column. At a fixed reflux ratio and constant feed of THF-alcohol(s) the water feed rate will be chosen to give the desired composition throughout the column.
At an α of less than about 2.2, separation becomes difficult and expensive. The above data illustrates the remarkable improvement obtained in ease of separation of methanol and THF by water extractive distillation.
A conventional distillation column may be used to conduct the extractive distillation of this invention. The column may be operated at superatmospheric pressure to ease condensation of the THF-water azeotrope and reduce column size, but atmospheric pressure can also be used, particularly if a low pressure steam is available for heating. Little advantage is seen otherwise in superatmospheric pressure operation. As anyone skilled in the art would know, the particular temperature used will depend on the pressure selected. Generally, the present process is operable at pressures of from 5 psia to 100 psia or even more. Preferably, the pressure is from atmospheric to 50 psia. Pressures below 5 psia are difficult to attain. Pressures above 100 psia are operable, but no particular advantage is gained by such greater pressures.
The THF from which the alcohols are removed is useful as a solvent for resins and polymers.
The following examples further illustrate the invention. In the examples all percentages are by weight unless otherwise indicated.
EXAMPLE 1
A distillation column was set up to demonstrate the separations attained by use of the water by the extractive distillation process of this invention with THF and the alcohols of this invention. The column consisted of three sections of 1" I.D. glass tubing filled with 0.16" stainless steel protruded packing above a pot. The two lower sections were 15" long and the upper section 8". A mixture of THF and alcohol(s) was fed in between the two lower sections, and the water, when used, was fed at the bottom of the upper section. The pot was a 1-liter flask fitted with a constant level overflow device and heated with a Glas-col mantle. Reflux was provided by a Corad variable reflux head set at 2.5/1 for the purposes of these tests.
To the distillation column were fed the materials indicated below at the rates shown and the heat to the column was adjusted to provide the split indicated between products removed from the top of the column and from the still pot overflow.
Water feed: 270 g/hr.
Ratio of H 2 0:Organic feed 1.8:1.
______________________________________Feed Overhead Bottoms______________________________________Rate g/hr 156 152.0 274.0% MeOH 2 0.1 1.1% THF 92 93.9 0.1% H.sub.2 O 6 6.0 98.8______________________________________
The methanol in the THF was reduced to 0.1% in the material passing overhead in the distillation column. The weight of the THF lost per pound of methanol purged from the bottom of the column was 0.1.
It can readily be seen that substantially all of the methanol was removed or that a purge will lose about 0.1 of a part of THF per part of methanol removed.
COMPARATIVE EXAMPLES A, B AND C
To illustrate results that occur without a water addition, a series of three tests were carried out as a control with the heat to the column being adjusted to provide a varying split between the products removed from the top of the column and from the still pot overflow as described in Example 1 except for the conditions indicated below:
COMPARATIVE EXAMPLE A--(No Water Feed)
______________________________________Feed Overhead Bottoms______________________________________Rate g/hr 400 12.0 388.0% MeOH 2 10.5 1.74% THF 92 87.4 91.96% H.sub.2 O 6 2.1 6.30______________________________________
COMPARATIVE EXAMPLE B--(No Water Feed)
______________________________________Feed Overhead Bottoms______________________________________Rate g/hr 400 25.0 375.0% MeOH 2 9.9 1.45% THF 92 88.34 92.15% H.sub.2 O 6 1.76 6.40______________________________________
COMPARATIVE EXAMPLE C--(No Water Feed)
______________________________________Feed Overhead Bottoms______________________________________Rate g/hr 400 75.0 325.0% MeOH 2 5.16 0.91% THF 92 92.44 92.29% H.sub.2 O 6 2.40 6.80______________________________________
The THF lost in the overhead was about 8.5 lb/lb methanol purged in Comparative Example A and in no comparative example was the methanol in the bottoms reduced below 0.9% from 2.0 initial.
EXAMPLE 2
Example 1 was repeated except the organic feed was a mixture containing 57% THF and 43% tertiary butanol without any water and distillation carried out for 3 hours, at which time a steady state had been achieved. The water feed was introduced at a rate of 920 g/hr. (Ratio of water to organic feed of 3.5:1.) Feed and product rates and compositions are shown below:
______________________________________Feed Overhead Bottoms______________________________________Rate g/hr 265 160.0 1025.0% 3° BuOH 43.4 1.0 11.1% THF 56.6 93.0 0.1% H.sub.2 O -- 6.0 88.8______________________________________
COMPARATIVE EXAMPLE D--(No Water Feed)
A control experiment for comparison purposes was performed as per Example 2 except that no water was fed and the organic feed and rates were as indicated below:
______________________________________Feed Overhead Bottoms______________________________________Rate g/hr 400 220.0 180.0% 3° BuOH 43 5.0 90.0% THF 57 95.0 10.0______________________________________
Thus, the amount of THF lost in a purge to remove the alcohol would be greater than when operating under the present invention.
EXAMPLE 3
Example 1 was repeated except that the organic feed did not contain water and the amount of water fed was 200 g/hr. The organic feed makeup and the conditions were as indicated below:
Water:organic feed ratio=0.5:1.
______________________________________Feed Overhead Bottoms______________________________________Rate g/hr 400 149.0 451.0% Isobutanol 13.75 <0.1 12.2% n-Propanol 40.08 <0.1 36.2% Ethanol 9.25 <0.1 8.2% Methanol 0.35 <0.1 0.3% THF 36.57 94.0 0.9% H.sub.2 O -- 6.0 42.2______________________________________
Substantially pure THF was recovered except for about 6% water.
COMPARATIVE EXAMPLE E--(No Water Feed)
A control experiment for comparison purposes was performed as per Example 3 except that no water was fed and the organic feed and rates were as indicated below:
______________________________________Feed Overhead Bottoms______________________________________Rate g/hr 400 164.0 236.0% Isobutanol 13.75 <0.1 23.6% n-Propanol 40.08 <0.1 69.2% Ethanol 9.25 11.9 8.0% Methanol 0.35 0.85 <0.1% THF 36.57 87.25 0.2______________________________________
While the invention has been described in considerable detail in the above specification, it is to be understood that such detail is solely for the purpose of illustration and that variations can be made by those skilled in the art without departing from the spirit and scope of the invention.
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A process for separating one or more aliphatic alcohols selected from the group consisting of methanol, ethanol, isopropanol and tertiary butanol from a tetrahydrofuran stream comprising tetrahydrofuran, one or more of said alcohols and optionally water by extractive distillation with water.
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[0001] This application is a Continuation-in-Part of U.S. Application No. 11/066,099, having been filed May 23, 2005, which application is a Continuation-in-Part of U.S. Application Ser. No. 10/347,489 (now U.S. Pat. No. 6,860,074), having been filed on Jan. 21, 2003, which in turn is a Continuation-in-Part of U.S. Application Ser. No. 09/986,414, having been filed on Nov. 8, 2001, and U.S. Application Ser No. 10/748,852, having been filed on Dec. 31, 2003, each of which is herein incorporated by reference in its entirety.
BACKGROUND
[0002] 1. Field of the Invention
[0003] The invention is a joint cover assembly that includes a molding, similar to a transition molding between two separate parts, such as a T-Molding, for covering a gap that may be formed between adjacent panels in a generally planar surface, such as between two adjacent flooring or wall or ceiling materials; or between a floor and a hard surface or carpet, or even a riser and a runner in a step (or a series of steps).
[0004] 2. Background of the Invention
[0005] Hard surface floors, such as wood or laminate flooring have become increasingly popular. As such, many different types of this flooring have been developed. Generally, this type of flooring is assembled by providing a plurality of similar panels. The differing types of panels that have developed, of course, may have differing depths and thicknesses. The same is true when a laminate floor (often referred to as a “floating floor”) abuts another hard surface, such as a resilient surface (such as vinyl), tile or another laminate surface, a ceramic surface, or other surface, e.g., natural wood flooring. Thus, when laminate panels having different thicknesses or different floor covering materials are placed adjacent to a laminate floor, transition moldings are often used to create a transition between the same.
[0006] Additionally, one may desire to install floor panels adjacent to an area with different types of material. For example, one may desire to have one type of flooring in a kitchen (e.g., solid wood, resilient flooring, laminate flooring or ceramic tile), and a different appearance in an adjacent living room (e.g., linoleum or carpeting), and an entirely different look in an adjacent bath. Therefore, it has become necessary to develop a type of molding or floorstrip that could be used as a transition from one type of flooring to another.
[0007] A problem is encountered, however, when flooring materials that are dissimilar in shape or texture are used. For example, when a hard floor is placed adjacent a carpet, problems are encountered with conventional edge moldings placed therebetween. Such problems include difficulty in covering the gap that may be formed between the floorings having different height, thickness or texture.
[0008] Moreover, for purposes of reducing cost, it is important to be able to have a molding that is versatile, having the ability to cover gaps between relatively coplanar surfaces, as well as surfaces of differing thicknesses.
[0009] It would also be of benefit to reduce the number of molding profiles that need to be kept in inventory by a seller or installer of laminate flooring. Thus, the invention also provides a method by which the number of moldings can be reduced while still providing all the functions necessary of different styles transition moldings.
SUMMARY OF THE INVENTION
[0010] The invention is a joint cover assembly for covering a gap between edges of adjacent floor elements, such as floor panels of laminate or wood, although it may also be used as a transition between a laminate panel and another type of flooring, e.g., carpet, linoleum, ceramic, wood, etc. The assembly typically includes a body having a foot positioned along a longitudinal axis, and a first arm extending generally perpendicularly from the foot. The assembly may include a second arm also extending generally perpendicular from the foot. Securing elements are provided to secure attachments to the at least one of the first and second arms. These securing elements may take the form of adhesive. The securing elements may also be in the form of a tab, which may be provided on at least one of the first or second arms, displaced from, or adjacent, the foot, extending generally perpendicularly from the arm.
[0011] The outward-facing surface of the assembly may be formed as a single, unitary, monolithic surface that covers both the first and second arms. This outward-facing surface may be treated, for example, with a laminate or a paper, such as a decor, impregnated with a resin, in order to increase its aesthetic value, or blend, to match or contrast with the panels. Preferably, the outward facing surface has incorporated therein a material to increase its abrasion resistance, such as hard particles of silica, alumina, diamond, silicon nitride, aluminum oxide, silicon carbide and similar hard particles, preferably having a Moh's hardness of at least approximately 6. This outward-facing surface may also be covered with other types of coverings, such as foils (such as paper or thermoplastic foils), paints or a variety of other decorative elements.
[0012] The assembly is preferably provided with a securing means to prevent thee assembly from moving once assembled. In one embodiment, the securing means is a clamp, designed to grab the foot. Preferably, the clamp includes a groove into which the foot is inserted. In a preferred embodiment, the clamp or rail may joined directly to a subsurface below the floor element, such as a subfloor, by any conventional means, such as a nail, screw or adhesive.
[0013] A shim may also be placed between the foot and the subfloor. In one embodiment, the shim may be positioned on the underside of the clamp; however, if a clamp is not used, the shim may be positioned between the foot and the subfloor. The shim may be adhered to either the foot or subfloor using an adhesive or a conventional fastener, e.g., nail or screw.
[0014] The assembly may also include a leveling block or reducer positioned between at least one of the first and second arms and the adjacent floor. The leveling block generally has an upper surface that engages the arm, and a bottom surface that abuts against the adjacent floor. In a preferred embodiment, the leveling block has a channel or groove formed in an upper surface, configured to receive the tab on the arm. The particular size of leveling block is often chosen to conform essentially to the difference in thicknesses between the first and second panels. The exposed surfaces of the leveling block are typically formed from a variety of materials, such as a carpet, laminate flooring, ceramic or wood tile, linoleum, turf, paper, natural wood or veneer, vinyl, wood, ceramic or composite finish, or any type of covering, while the interior of the leveling block is generally formed from wood, fiberboard, such as high density fiberboard (HDF) or medium density fiberboard (MDF), plastics, or other structural material, such as metals or composites, at least over a portion of the surface thereof may be covered with a foil, a plastic, a paper, a decor or a laminate to match or contrast with the first and second arms. The leveling block additionally facilitates the use of floor coverings having varying thicknesses when covering a subfloor. The leveling block helps the molding not only cover the gap, but provide a smoother transition from one surface to another.
[0015] Alternatively, the tab may be positioned to slidingly engage the edge of a panel when no leveling block is used. A lip may additionally be provided and positioned on the tab in order to slidingly engage a protuberance, adjacent an upper edge of the clamp, in order to retain the assembly in its installed position.
[0016] The tab is preferably shaped as to provide forces to maintain the assembly in the installed position. Thus, typically the tab may be frustum-shaped, (e.g., dove-tailed) with its narrow edge proximate the arm and the wider edge furthest from the arm. Additionally, the tab may be lobe shaped, having a bulbous end distal from the arm. In another embodiment, only one side of the tab need be tapered (e.g., half dove-tailed). Of course, any suitable shape is sufficient, as long as the engagement of the tab and groove can provide enough resistive forces to hinder removal of the installed assembly. By forming a suitable groove in the leveling block, the tab can help to secure the assembly in place. Typically, a corresponding groove, having a similar shape as the tab is included in the leveling block or reducer, e.g., having its wider base distal the arm and its narrower opening proximate the arm. It is to be understood by those skilled in the art that although the description throughout this specification is that the position of the tab is on the at least one of the first and second arms, and the groove is on the attachment, e.g., leveling block, the relative position of the tab and groove can be reversed.
[0017] The assembly may additionally be used to cover gaps between tongue-and-groove type panels, such as glueless laminate floor panels. In addition to the uses mentioned above, the tab may also be designed to mate with a corresponding channel in the panel, the edge of one of the flooring elements, or may actually fit within a grooved edge. In order to better accommodate this type of gap, a second tab may be positioned to depend from the second panel engaging surface.
[0018] An adhesive, such as a glue, a microballoon adhesive, contact adhesive, or chemically activated adhesive including a water-activated adhesive, may be also positioned on the tab, in the groove, on the foot, and on at least one of the arms. Of course, such an adhesive is not necessary, but may enhance or supplement the fit of the assembly over the gap between the floor elements. Additionally, the adhesive may assist in creating a more air-tight or moisture-tight joint.
[0019] The assembly may be used in other non-coplanar areas, such as the edge between a wall and a floor, or even on stairs. For example, the assembly may include the first and second arms, and foot as described above, but instead of transitioning between two floor elements placed in the same plane, may form the joint between the horizontal and vertical surfaces of a single stair element.
[0020] The inventive assembly may be used for positioning between adjacent tongue-and-groove panels; in this regard, the assembly functions as a transition molding, which provides a cover for edges of dissimilar surfaces. For example, when installing floors in a home, the assembly could be used to provide an edge between a hallway and a bedroom, between a kitchen and living or bathroom, or any areas where distinct flooring is desired. Additionally, the assembly may be incorporated into differing types of flooring, such as wood, tile, linoleum, carpet, or turf.
[0021] The invention also is drawn to an inventive method for covering a gap between adjacent panels of a generally planar surface. The method includes multiple steps, including, inter alia, placing the foot in the gap, pressing the respective arms in contact with the respective floor elements, and configuring at least one of the tab and the foot to cooperate to retain the assembly in the gap after the assembly has been installed.
[0022] Other objects, features and advantages of the present invention will become apparent from the following detailed description. It should be understood, however, that the detailed description and the specific examples, while indicating preferred embodiments of the invention, are given by way of illustration only, since various changes and modifications within the spirit and scope of the invention will become apparent to those skilled in the art from this detailed description.
BRIEF DESCRIPTION OF THE DRAWINGS
[0023] FIG. 1 is an exploded view of an embodiment of the joint cover assembly in accordance with the invention;
[0024] FIGS. 1A and 1B are alternate embodiments for the molding of the invention;
[0025] FIG. 2 is a perspective view of a second embodiment of the joint cover assembly in accordance with the invention;
[0026] FIGS. 3 and 3 A are comparative perspective views of embodiments of the leveling block;
[0027] FIG. 4 is perspective view of an additional embodiment of the joint cover assembly in accordance with the invention;
[0028] FIGS. 5 and 5 A are comparative perspective views of embodiments of the leveling block;
[0029] FIGS. 6-16 show comparative cross-sectional views of various embodiments of the molding portion of the joint cover assembly;
[0030] FIG. 17 depicts an embodiment of the assembly of the invention for use with stairs:
[0031] FIG. 18 shows a second embodiment of the assembly for use with stairs;
[0032] FIG. 19 is a side view of a generic element, which may be broken into the components of the invention; and
[0033] FIGS. 20-81 are various modifications of molding of the invention.
[0034] FIGS. 82-111 depict additional modifications of the molding the invention.
[0035] FIGS. 112-119 show even further modifications of the molding of the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0036] FIG. 1 shows an exploded view of the various parts of the inventive joint cover assembly 10 . The assembly 10 includes a T-shaped molding 11 , having a foot 16 formed so that it can fit in a gap 20 between adjacent floor elements 24 , 25 . FIG. 1 demonstrates a typical use, in which the gap 20 is formed adjacent an edge 27 of a floor element 24 . Although FIG. 1 depicts all of the floor elements 24 to be conventional tongue-and-groove type floor panels (having a groove 27 positioned adjacent to the gap 20 ), this is merely one of any number of embodiments. For example, floor elements 24 , 25 need not be the same type of floor element. Specifically, the floor elements 24 can be any type of flooring designed to be used as a floor or placed over a subfloor 22 , e.g., tile, linoleum, laminate flooring, concrete slab, parquet, vinyl, turf, composite or hardwood. As is known, laminate floors are not attached to the subfloor 22 , but are considered “floating floors.” Although the figures illustrate particular locations for features such as the tab 18 and channel 42 , it is within the scope of the invention to reverse the relative locations of such features.
[0037] The molding 11 is provided with a first arm 12 and a second arm 14 extending in a single plane generally perpendicular to the foot 16 . Preferably, the foot 16 , first arm 12 , and the second arm 14 form a general T-shape, with the arms 12 and 14 forming the upper structure and the foot 16 forming the lower structure. Although the foot 16 is shown as being positioned at a central axis of the molding 11 , such is only a preferred embodiment. In other words, it is within the scope of the invention to vary the position of the foot 16 “off center”with respect to the first and second arms 12 , 14 . For example, the foot 16 may be placed at the midpoint, or anywhere in between, as is depicted, for example, in FIGS. 82-99 .
[0038] As shown in FIGS. 82-111 , a molding 1110 need not form a true right angle with its foot 1116 . For example, the transition from a respective outstretched arm 1112 or 1114 to a foot 1116 may be achieved by one or more rounded sections, or a plurality of straight sections. While the figures only illustrate an angle of other than 90° between arm 1114 and foot 1116 , it is within the scope of this invention to provide the transition between arm 1112 and foot 1116 , or both transitions with such an angle. Typically, these transitions are formed by undercutting the desired angle, as will be described in greater detail below.
[0039] The molding 11 , as well as any of the other components used in the invention, may be formed of any suitable, sturdy material, such as wood, polymer, fiberboard, plywood, or even a wood/polymer composite, such as stranboard. Due to the growing popularity of wood and laminate flooring and wood wall paneling, however, a natural or simulated wood-grain appearance may be provided as the outward facing surface 34 of the molding 11 . The outward facing surface 34 may be a conventional laminate, such as a high pressure laminate (HPL), direct laminate (DL) or a post-formed laminate (as described in U.S. application Ser. No. 08/817,391, herein incorporated by reference in its entirety); a foil; a print, such as a photograph or a digitally generated image; or a liquid coating including, for example, aluminum oxide. Thus, in the event natural wood or wood veneer is not selected as the material, the appearance of wood may be simulated by coating the outer surface 34 with a laminate having a decor sheet that simulates wood. Alternatively, the decor can simulate marble, ceramic, terrazzo, stone, brick, inlays, or even fantasy patterns. Preferably, the outward facing surface 34 extends completely across the upper face of the molding, and optionally under surface 36 and 38 of arms 12 and 14 , respectively.
[0040] The core structure of components of the invention, including the center of the molding 11 , that is in contact with the outward facing surface 34 is formed from a core material. Typical core materials include wood based products, such as high density fiberboard (HDF), medium density fiberboard (MDF), particleboard, strandboard, plywood, and solid wood; ploymer-based products, such as polyvinyl chloride (PVC), thermoplastics or thermosetting plastics or mixtures of plastic and other products, including reinforcements; and metals, such as aluminum, stainless steel, brass, aluminum or copper. The various components of the invention are preferably constructed in accordance with the methods disclosed by U.S. application Ser. No. 08/817,391, as well as U.S. application Ser. No. 10/319,820, filed Dec. 16, 2002, each of which is herein incorporated by reference in its entirety.
[0041] The resulting products typically have durability rating. As defined by the European Producers of Laminate Flooring, such products can have a durability rating of anywhere from AC1 to AC5. Preferably, the products of this invention have a rating of either AC3 or AC5.
[0042] A securing element, such as a metal clamp, track or rail 26 , may be coupled to the subfloor 22 within the gap 20 formed between the two floor elements 24 . The clamp may be coupled to the subfloor 22 by fasteners, such as screws or any conventional coupling method, such as nails or glue. The clamp 26 and the foot 16 are preferably cooperatively formed so that the foot 16 can slide within the clamp 26 without being removed. For example, the clamp 26 may be provided with in-turned ends 30 designed to grab the outer surface of the foot 16 to resist separation in a vertical direction. Typically, the foot 16 has a dove-tail shape, having the shorter parallel edge joined to the arms 12 and 14 ; and the clamp 26 is a channeled element having a corresponding shape as to mate with the foot 16 and hold it in place. Additionally, the securing element may take the form of an inverted T-element 50 ( FIG. 1A ), configured to mate with a corresponding groove 52 in an end of foot 16 , such that friction between the T-element 50 and the groove 52 secures the molding 11 in place, or, in the alternative, the end of the foot 16 may be provided with a narrowed section, designed to mate with a groove in the securing element. Finally, each of the T-element 50 , mating section of the foot 16 and/or various grooves, may be provided with notched or barbed edges 55 to simultaneously assist in mating and resist disassembly ( FIG. 1B ). However, in an alternative embodiment, the securing element can be eliminated because the molding 11 can be affixed to one of the floor elements 24 , 25 , by, for example, an adhesive. Preferably, however, the molding 11 is not secured to both floor elements 24 , 25 , as to permit a degree of relative movement, or floating, between the floor elements 24 , 25 .
[0043] The clamp 26 may additionally be formed of a sturdy, yet pliable material that will outwardly deform as the foot 16 is inserted, but will retain the foot 16 therein. Such materials include, but are not limited to, plastic, wood/polymer composites, wood, and polymers. The clamp 26 may additionally engage recesses in, for example, sides of the foot 16 .
[0044] A tab 18 is shown as extending downwardly from the first arm 12 . As shown in FIG. 1 , the tab 18 extends downward, or away from an outward facing surface 34 of the molding, and runs generally parallel to the foot 16 . As shown in FIG. 1 , the tab 18 may also be in the shape of a dove-tail with a shorter edge adjacent to the first arm 12 ; however, other suitable shapes are possible. The shape of the outwardly facing surface 34 of the molding 11 is shown as being convex in some of the Figures (e.g., FIGS. 1A, 1B and 7 ), and substantially planar in others (e.g., FIGS. 1, 2 , 4 , and 6 ). When the outwardly facing surface 34 is substantially planar, the edges of the molding 11 may either be upright or at an angle, typically angling away from the foot 16 . However, the relative positions of the tongue/groove may also be reversed.
[0045] The assembly may further include a leveling block 40 otherwise known in the art as reducers. When flooring elements 24 and 25 are of differing heights, the leveling block 40 is positioned between either the first arm 12 or the second arm 14 and the subfloor 22 . Preferably, the size of the leveling block 40 is selected to correspond essentially to the difference in heights of the two flooring elements 24 and 25 . However, if an adjustable pad 1120 (as described below) is used, the particular height of the reducer is not particularly important. For example, if one flooring element 24 is a ceramic tile, having a thickness of 2″and the second flooring element 25 is vinyl, having a thickness of ¼″, the leveling block 40 would typically have a thickness of 13/4″ to bridge the difference and be placed between arm 12 and the other flooring element 25 . Without the leveling block 40 , a significant space would exist between the second flooring element 25 and the molding 11 , allowing for moisture and dirt to accumulate. While the difference in heights of the flooring elements 24 , 25 is generally caused by a difference in thickness between the two flooring elements 24 , 25 , the present invention may also be used to “flatten out” an uneven subfloor 22 . In addition, a shim may be placed under the track to adjust for differences in floor thickness. In a preferred embodiment, the leveling block is provided with a channel 42 designed to receive the tab 18 .
[0046] The width of the foot 16 , 1116 may be different, depending upon the particular application. For example, when a reversible molding element 1250 is used, it is preferred that the width of the foot 16 , 1116 be narrower to accommodate the proximal portions of the molding element. Typically, the clamp 26 , 1126 is also adjusted to accommodate the appropriate foot 16 , 1116 .
[0047] Even though the assembly 10 may function without any type of glue or adhesive, an alternate embodiment includes the placement of adhesive 31 on the molding 11 . The adhesive may be placed on molding 11 at the factory (for example, pre-glued). Alternatively, the glue may be applied while the floor elements 24 , 25 are being assembled. As shown in FIG. 6 , the adhesive 31 may be provided as a strip-type adhesive, but any type of adhesive, such as glue, chemical or chemically-activated adhesive, water-activated adhesive, contact cements, microballoon or macroballoon encapsulated adhesive may be used. Additionally, while the embodiment in FIG. 6 shows a single adhesive strip 31 attached to the arm 12 , the adhesive 31 may be attached to the tab 18 , foot 16 , and/or any location where two pieces of the assembly are joined. In some embodiments, the adhesive may be used as an alternative to tab 18 and groove 42 . Preferably, adhesive 31 is only applied to one of the arms 12 , 14 in order to allow or accommodate some slight relative movement that may occur during changes of temperature, for example. This relative movement is known in the flooring art as “float”. Allowing float may also eliminate unneeded material stresses as well, thereby reducing warping or deterioration of the material surface. Typical adhesives used in the invention include a fresh adhesive, such as PERGO GLUE (available from Perstorp AB of Perstorp, Sweden), water activated dry glue, dry glue (needing no activation) or an adhesive strip with a peel off protector of paper.
[0048] FIG. 2 shows a typical embodiment of the assembly 10 in an installed condition, wherein the floor elements 24 and 25 are of differing thicknesses (H and H′ respectively). Of course, the element 24 may be of any type of covering, such as carpet, turf, tile, linoleum or the like. As shown in FIG. 3 , the leveling block 40 typically includes a substantially flat bottom 46 , and a top 45 having a groove 42 , and an inner surface 44 . The top 45 of the leveling block 40 is designed to firmly abut the under surface 36 of the first arm 12 , while the bottom 46 abuts floor element 25 . Typically, the groove 42 is shaped as to firmly hold the tab 18 . By having a corresponding shape, for example, the groove 42 can have a dove-tail shape, where both lateral sides diverge from the upper surfaces or a “half-dove tail,” where only one of the two sides is so configured. The inner surface 44 of the leveling block 40 need not abut the foot, as generally, a small amount of clearance is provided between the clamp 26 or foot 16 and the inner surface 44 of the leveling block. However, the inner surface 44 may be configured to contact either of the clamp 26 or foot 16 . The tab 18 may also be of a shape different than groove 42 , e.g., a wedged-shaped tab fitting within a straight-wailed groove. In other embodiments, friction will be sufficient to maintain the position of the tab and groove elements.,
[0049] The leveling block 40 may be made of a composite, pliable material that is also resilient. For example, the tab 18 may be formed to be slightly larger than the opening of the channel 42 , thereby forcing the channel 42 to outwardly deform in order to accommodate the tab 18 , and therefore snap-fit together.
[0050] As shown in FIG. 3 , the outer surface 47 of the leveling block 40 is generally treated to match or blend with the outer surface 34 of the molding or the floor element 24 , 25 in order to improve aesthetics.
[0051] FIG. 3A shows an alternate embodiment of a leveling block 40 ′. An outer surface 47 ′ of this embodiment is configured generally perpendicular to an upper surface 44 ′ and a lower surface 46 ′ of the leveling block 40 ′. This alternate configuration of the outer surface 47 ′ not only provides a different appearance, it also has been shown to be preferred when softer surfaces, such as carpet or turf, are positioned beneath the lower surface 46 ′ of the leveling block 40 ′.
[0052] FIG. 4 shows yet another alternate embodiment of the leveling block 140 . The leveling block 140 includes a bottom 146 , and a top 145 and an inner surface 144 . The top 145 of the leveling block 140 is designed to firmly abut the under surface 36 of the first arm 12 , while the bottom 146 abuts floor element 25 . This leveling block 140 is positioned between a first arm 112 of the molding 111 and the flooring element 125 . In this embodiment of the assembly 110 , the tab 118 engages the inner surface 144 of the leveling block 140 .
[0053] FIG. 5 shows an embodiment of a leveling block 140 that may be used in the assembly shown in FIG. 4 . Specifically, the leveling block 140 in FIG. 5 has a solid, uninterrupted upper surface 145 , without the need for a channel because the tab ( 118 , as in FIG. 4 ) will engage the inner surface 144 of the leveling block instead of the top surface 145 . In such an embodiment, the tab 118 may also be adjacent the foot. In some embodiments, the use of adhesive will reinforce the positioning of the leveling block 140 relative to tab 118 .
[0054] FIG. 5A shows an additional shape of a leveling block 140 ′ that can be incorporated into the assembly shown in FIG. 4 . Leveling block 140 ′ has a front surface 146 ′ that will be generally perpendicular to a floor 122 (as shown in FIG. 4 ) when the leveling block 140 ′ is installed. This perpendicular configuration of the front surface 147 ′ not only provides a different appearance, it has also been found to be preferred with softer surfaces, such as carpet or turf. FIG. 6 shows an underside view of the molding 11 . In particular, the first under surface 36 of the first arm 12 , and the second under surface 38 of the second arm 14 are shown. In one embodiment, under surface 36 is provided with the adhesive 31 positioned to adhere to a surface of a floor element 24 , 25 or leveling block 40 , 40 ′, 140 , 140 ′.
[0055] FIGS. 7-15 show various cross-sectional views of the molding 11 . These figures show comparative configurations for the arms 12 , 14 , the tab 18 , and the shape of molding 11 .
[0056] In FIG. 7 , the tab 18 is selected to be an outward-facing hook having a barb facing away from the foot 16 , while the upper surface of the molding has a convex curvature. This particular selection for the tab 18 may be used to engage an edge or groove of an adjacent floor element 24 , 25 , or, in the alternative, an adjacent leveling block 40 . Additionally, a shim 48 may be positioned between the foot 16 and the subfloor 22 . The shim 48 is generally formed of a pliable and flexible, yet durable, material, such as a polymer, preferably a polymer exhibiting electrometric properties. The shim 48 may be used in place of, or in combination with, clamp 26 . Preferably, the shim 48 is sized in accordance with the size of the clamp 26 , 1126 .
[0057] FIGS. 8-15 show cross-sections of other shapes for the molding 11 . The configurations of the moldings are very similar, except for the shape of the tab 18 . The differing tabs have been assigned decimal numbers beginning with 18 , for clarity purposes. A tab 18 . 1 ( FIG. 8 ) is a bulbous shape, having its rounded end furthest from the arm 12 . tab 18 . 2 ( FIG. 9 ) is provided with a hook-shape with a point facing the foot 16 . In the embodiment shown in FIG. 10 , a tab 18 . 3 is in the shape of a dove-tail, similar to the shape of the tab 18 shown in FIG. 2 . The tab 18 may additionally be configured to have a substantially rectangular cross section with two opposite rounded off corners, as shown in FIGS. 82-111 , or any of the other shapes described herein, with one or more of the corners/ends being rounded.
[0058] The purpose of the various-shaped tabs ( 18 - 18 . 8 ) is multi-fold. Primarily, the tab 18 serves to engage the channel 42 of the leveling block 40 , which is used when covering of differing thickness is used. Alternatively, the respective tab ( 18 - 18 . 8 ) may engage an edge of a panel, carpet, turf, or other type of floor covering. As shown herein, the respective tab ( 18 - 18 . 8 ) may even be configured to engage a leveling block.
[0059] It is additionally considered within the scope of the invention to eliminate the tab. In such an embodiment, preferably, the molding 11 includes an adhesive on the under surface 36 , 38 of one of the arms 12 , 14 .
[0060] With respect to FIG. 16 , the invention may also be used when the floor elements are not co-planar. For example, one embodiment includes a stair nose attachment 210 that can be attached to the same molding 11 , as described above. As used herein, a stair nose attachment is a component capable of mating with the molding 11 so as to conceal, protect or otherwise cover a joint forming a single stair. Typically, the molding 11 is provided atop the first floor element 24 on the horizontal, or run 220 of the stair, such that the stair nose attachment 210 bridges the joint between the first floor element 24 and the second floor element 25 , forming the vertical section of the stair, or rise 230 . As a result, the invention can be used to cover and protect joints between flooring elements on stairs. While in a preferred embodiment, the floor elements covering the rise 220 and run 230 are the same type of flooring material, the flooring elements need not be of the same construction or type of materials.
[0061] The stair nose attachment 210 may include a tab receiving groove 212 , permitting connection of the stair nose attachment 210 to the molding 11 . Because the tab receiving groove 212 in the stair nose attachment 210 is preferably shaped according to the shape of the tab 18 of the molding 11 , the stair nose attachment 210 may be attached to the molding 11 by, for example, snapping or sliding.
[0062] However, in other embodiments, the tab on the under surface 36 is eliminated. While the tabs and corresponding grooves may be eliminated, it is nevertheless considered within the scope of the invention to utilize an adhesive, as described herein. Alternatively, the stair nose attachment 210 may include a tab 218 to mate with a corresponding groove 219 on the foot 16 of the molding 11 ( FIG. 17 ), or vice-versa.
[0063] By allowing an end user to purchase the generic element 300 instead of separate components, the retailers and/or distributors may accordingly reduce their inventory requirements. For example, typically over one-hundred different design patterns for the outwardly facing surface 34 of the molding 11 (as well as for the leveling block 40 and stair nose attachment 210 ) are produced. By allowing for the inventory to include only the generic elements of the invention, the total number of components retained can be reduced from three per design to one per design. Similarly, the installer only need purchase the generic elements 300 , rather than three individual components. Thus, both retailers and installers may profit from having less storage and/or retail bays to service the same types of accessories as prior to the invention.
[0064] FIGS. 20-53 depict alternate embodiments for the leveling block (or other pieces) and the molding 11 .
[0065] FIG. 20 shows a general representation of the molding with a track 101 and shim 102 , below the molding 11 . Preferably, the track 101 is metal, and the shim 102 is plastic. However, it is within the scope of the invention to form either of these pieces out of either material. Additionally, other materials may be used, such as materials which flex, but return to their original configuration when pressure is applied and then released. In one embodiment, a track 101 , formed of metal, is fastened to a subfloor with screws. For thicker laminate flooring, the shim 102 may be snapped to the underside of the track before it is fastened to the subfloor. Use of the shim 102 offers a height adjustment for multiple thicknesses of laminate, or other flooring. Thus, where the height of a surface below the molding 11 requires the molding to be raised, the shim 102 can be used to provide the necessary spacing. However, it must be noted that, although FIG. 20 shows the shim 102 being used, such is an optional element, as the shim 102 may be used with each of the shapes and designs of moldings 11 disclosed herein, or similarly, eliminated from each embodiment, as required by the particular circumstances.
[0066] As shown in FIGS. 90-99 and 102 - 111 , the shim 102 may be in the form of a pad 1102 , which may be provided with one or more upturned ends 1102 a and 1102 b . Preferably, the upturned ends 1102 a and 1102 b of the pad 1102 are sized and shaped to receive foot 1116 if desired. Thus, in a number of embodiments, shown for example in FIGS. 102-111 , the foot 1116 is positioned in the pad 1102 , such that the upturned ends 1102 a and 1102 b grip or grasp the clamp 1126 . If the upturned ends 1102 a and 1102 b , or even the entire pad, 1102 are formed from a resilient material, such as a plastic or elastomer or certain types of metal, the gripping force provided can be greater. However, the pad 1102 and the parts thereof can be constructed of any material. The pad 1102 may additionally be affixed to a clamp 1126 with a fastener, such as a screw or nail, and/or an adhesive, such as a glue or adhesive tape. In the embodiment shown in FIGS. 98, 99 , 110 and 111 , the pad 1102 is inverted, such that upturned ends 1102 a and 1102 b are directed toward the subfloor and away from the clamp 1126 in order to provide the clamp 1126 with additional height. This allows a single pad 1102 to accommodate a variety of height requirements. Moreover, if needed, it is possible to cut off a terminal section of the upturned ends 1102 a and 1102 b to accommodate an unlimited number of additional heights. The size and depth of the pad 1102 is not limited by the present invention and is typically any height, from 1 mm up to 4 mm, with additional height being provided when the pad 1102 is inverted. Typically, the pad 1120 , just like the shim 102 , is sized in accordance with the clamp 26 , 1126 .
[0067] The size of the clamp 1126 is not particularly limited by the present invention. Typical clamp 1126 heights can be any dimension, preferably from 6-10 mm, most preferably 6.55 or 6.8 mm.
[0068] The embodiment of FIG. 21 has a leg of the molding 11 extended. Herein, there is a choice of height adjusting shims, which, in addition to the snap-on shim 102 , may additionally include a second shim 103 , formed of any material, such as wood, plastic, fiberboard, stone, metal, etc., that can be attached via any method to either the molding or the subsurface, such as with an adhesive, or screw. Typically, the extended leg of the T-molding is fastened to a subfloor with a silicone sealant, acting as an adhesive. Such a construction permits easy and quick installation, especially avoiding the need to drill holes and insert plugs for screws when installing over a concrete subfloor. The shim 102 can be attached to the underside of the extended leg of the T-molding to provide the appropriate height adjustment.
[0069] FIGS. 20 and 21 additionally represent the double and reversed tongue-and-groove configuration that functions to fasten a foot, hard surface reducer or carpet/end molding to the T-molding. In this configuration the tongue that extends from the underside of the T-molding is placed so that it falls within the expansion space of the installed flooring transition. This configuration does not require the removal of this tongue in order to install the T-molding part as a T-molding only. Should the laminate floor expand, the pressure will be sufficient to shear off this tongue on the underside of the molding, and the floor can move freely as if there were no extended tongue present in the expansion space.
[0070] Preferably, the shim 102 is a metal or plastic structure, having a pair of grabbing flanges 102 a for the purpose of clamping onto, for example, the track 101 . The grabbing flanges 102 a typically form an acute angle with respect to the remainder of the shim 102 , such that when the molding 11 is inserted into the shim 102 , the grabbing flanges 102 a are forced outward, and the grabbing flanges 102 a function to hold the molding 11 in place.
[0071] In a preferred embodiment, the molding 11 and a second member, such as a reducer, leveling block, stair nose, or any other molding attachment, are joined by one or more tongue-and-groove joints. For example, the second member can be provided with a tongue and the molding 11 is provided with a matching groove. As shown in FIGS. 25 and 26 , the tongue, which may be located on the second member, may be shaped as a dove-tail or a “half dove-tail,”wherein only one of the two sides defines an angle other than ninety degrees. Such a tongue may extend over any potion of the mating surface, such as small amount ( FIG. 25 ), approximately half ( FIG. 26 ), or even substantially the entire mating surface.
[0072] Typically, the tongue-and-groove are not simply rectangular in shape, but are provided with elements which tend to hold the pieces together. For example, as shown in FIGS. 20, 21 , 25 , 28 , and 29 , the tongue may have, on at least one side, a tapered surface, resembling a dovetail, such that the pieces cannot simply dissociate without manipulation.
[0073] In the embodiments of FIGS. 20 and 21 , the reducer has on its mating surface, one tongue and one groove, while the molding 11 has the matching groove and tongue. In FIG. 21 a , the extended leg of the T-molding allows the T to be adhered to the sub-floor with construction adhesive or tapes or other adhesives. A shim can be placed on the bottom of the extended leg of the T-molding to raise the height, either a snap-on type of shim or a simple rectangular piece of material which can be adhered onto the bottom of the foot and then the assembly is adhered to the floor.
[0074] FIGS. 22 through 27 can represent either installation method, with a track or with an extended leg on the T-molding for, T-molding, hard surface reducer, carpet/end molding and stair nosing.
[0075] In the embodiments of FIGS. 22 and 23 , the pieces are provided with a horizontal flange 1 1 land the molding 1 1 has a similarly shaped groove. In FIG. 22 , the groove is not provided with any locking elements, while in FIG. 23 , the groove is provided with a locking flange 121 , which joins with a locking groove 1 12 on the second member to hold the pieces together. Although not specifically shown, it is within the scope of the invention to swap the location of the tongue/groove, such that the tongue is on the molding 11 , and the groove is positioned on the second member. Similarly, there may be any number of matching tongues/grooves, and each piece may have any combination of tongues and grooves. Similarly, as shown in FIG. 27 , the tongue and groove need not be positioned adjacent to the underside of one of the arms of the molding 11 , and a gap 114 may be provided in the second member to allow for greater movement between the second member and the first member without permitting dissociation. This gap may be a break-away feature.
[0076] In FIG. 22 , a recess lateral slot is present on the underside of the T-molding, as well as a groove in the leg of the T-molding. The recessed slot and raised platform of the top of each foot hinders lateral movement of the foot and the tongue and groove stabilize the foot against the top of the T-molding.
[0077] In FIG. 23 , there is a tongue and groove with a snap-fit ridge or tab at the end of the groove or in the tongue of the leg of the T-molding. There is also shown a corresponding groove in the underside of the tongue of each foot that snaps into the tab.
[0078] In the embodiment of FIG. 24 , the locking element 110 is a downwardly facing flange, sized and shaped to mate with the locking groove 112 on the second member. When the pieces are connected, the locking element 110 and locking groove 112 function to resist separation of the pieces in a horizontal direction. Although not shown, the locking element 110 and locking groove 112 , as shown in FIG. 24 , may be combined with any of the structures as shown in any of the other embodiments disclosed herein in order to assist in maintaining a secure connection between the elements.
[0079] In one embodiment, the extension 114 is affixed to the subfloor, by a means for securing. The securing means may be, for example, a mechanical fastener or a chemical fastener through, for example, boss 134 . As used herein, a mechanical fastener is any device which joins the elements with, e.g., pressure, and includes, but is not limited to, a nail, screw, staple, claw, clamp, barb, cant hook, clapper, crook, fang, grapnel, grappler, hook, manus, nipper, paw, pincer, retractile, spur, talon, tentacle, unguis, ungula, brad, point, push pin, and tack. Additionally, a chemical fastener is a component, such as a sealant or adhesive, and includes tapes, glues and epoxies. This extension 114 may also attach to the track.
[0080] The embodiments shown in FIGS. 28-35 each have an extension 120 of the second member which extends below the foot of the molding. In such embodiments, typically, the second member is a stair molding and is secured to the subfloor. The T-molding is then attached to the second member, as the T-molding does not contact the subfloor. However, it is considered within the scope of the invention to additionally provide an extension bracket (not shown) for securing the T-molding to the subfloor. As shown in FIGS. 28, 29 and 35 , the second member may include a recess 124 into which the foot of the T-molding is inserted, or in the alternative, a depression 126 ( FIGS. 30, 33 and 34 ).
[0081] Additionally, the second member may have a wedge 128 ( FIGS. 31 and 32 ) to secure the T-molding in place. The foot of the T-molding may either be angled into position to bypass the uppermost section of the wedge 128 , or the wedge may be formed such that it deflects under pressure and snaps back after the foot of the T-molding is properly positioned. Again, the embodiments of FIGS. 28-35 may be combined with one or more of the tongue and groove configurations as shown or described in connection with FIGS. 20-27 .
[0082] The second member, shown as a stair nosing, in FIGS. 28-35 may be installed using construction adhesives, specialized tapes (such as simple double-sided tapes), silicone or other sealants (such as epoxies or glues) or mechanical fasteners (such as screws or nails).
[0083] The embodiments of FIGS. 36-42 can be installed using a track 101 , similar to the embodiments shown in FIGS. 20-27 . In particular, either one or both of the T-molding and second member (shown as a stair nose) may be secured with the track 101 . The members can also be fastened to the track 101 after a construction adhesive or sealant/adhesive has been applied into the track and/or additional mechanical fasteners may be used to assist in fixing the second member to the subfloor (or tread, as necessary).
[0084] FIG. 43 demonstrates an extended face for a stair nose. Therein, the extended face is sufficient in breadth to cover the edge of common stair treads, thus eliminating the need to place a separate piece of flooring on the edge of stair treads or to cover the edge of a subfloor when stepping down from a floating floor installation to a lower level floor. However, stair noses may also be installed using the method described in connection with FIG. 21 , above, without the need of a track 101 , when the T-molding has an extended leg.
[0085] The embodiments of FIGS. 44-53 allow installation of the multipurpose flooring transition using only adhesives, tapes or sealants, as no track 101 is required. The additional surface area beneath the transition is increased adding additional adhesion area for strength in bonding the transition to the subfloor. This installation method also avoids the need for a track, screws and/or plugs (although they are certainly not prohibited), and additionally allows for faster installation over subfloors formed from, for example, wood based products or concrete.
[0086] FIGS. 44 and 45 show two assembled members held together with glue before fastening to the subfloor. Such members may also be installed by other methods described herein.
[0087] FIGS. 46-49 depict two members joined together with a snap-fit, such that no glue is necessary. Such members may also be installed by another method described herein. Although FIGS. 46-49 show a particular location for various snap-fitting elements, i.e., tongue and groove, it is certainly within the scope of this invention to increase the size, shape, location and number of the tongues and grooves as necessary. For example, FIG. 30 depicts one groove on either side of the foot of the T-molding and corresponding tongues on the second member. However, additional tongues/grooves may be located on the bottom of the foot or even on the underside of the arm. Additionally, the second member may include both tongues and grooves, combining the features illustrated in FIGS. 46 and 47 with FIGS. 48 and 49 .
[0088] FIG. 50 represents a shim, which can be made from waste cuttings of the core material during the manufacture of the transition. This shim may be used to elevate the foot of the assembly to accommodate a thicker flooring material.
[0089] FIG. 51 shows an additional embodiment wherein the second member is a stair molding. The pieces, i.e., the T-molding and the stair molding, can be held together with glue before fastening to the subfloor, or by any other installation method described herein.
[0090] In FIG. 52 , an additional T-molding is shown that can snap-fit, i.e., without the need for glue, and FIG. 53 shows a corresponding track or structure to be incorporated into a second member. Specifically, the second member piece of FIG. 53 includes a plurality of alternating tongues and grooves, such that the foot of the T-molding, also having alternating tongues and grooves, form a snap action that functions to hold the T-molding firmly. Additionally, this design permits the elimination of the shim 102 , as the foot of the T-molding need not be completely seated in the second member. In other words, because the T-molding can be secured to the second member with a gap or space remaining between the bottom of the foot 130 and the inner-most part of the second member 130 , height variations can be accounted for without the need for an additional part.
[0091] FIGS. 54-66 show an alternate embodiment of the invention. Specifically, as shown in FIG. 64 , a single reversible molding element 1001 has an outer face 1005 , which extends over a front face 1007 and a rear face 1009 . This outer surface 1005 is the same on both the front face 1007 and the rear face 1009 , and preferably includes a laminate, but may also be of a foil. While the outer surface 1005 may be limited to only the front face 1007 and the rear face 1009 , the outer surface 1005 may extend across any additional surfaces as well. Due to the novel construction of the reversible molding element 1001 , the versatility of the invention can be greatly increased.
[0092] An example of the versatility of the reversible molding element 1001 is specifically shown in FIGS. 55 and 56 , wherein the significant distinction between FIGS. 55 and 56 is the orientation of the reversible molding element 1001 . In FIG. 55 , the reversible molding element 1001 has its front face 1007 facing outward, while in FIG. 56 , the opposite, or rear face 1009 facing outward. As a result, when the front face 1007 is oriented outward, reversible molding element 1001 functions as a hard surface reducer. In contrast, when reversible molding element 1001 is reversed, and the rear face 1009 is oriented outward, the reversible molding element 1001 functions as an end molding. Thus, when the T-molding is put together in a single package with the reversible molding element 1001 , the combination can be used as either a hard surface reducer or an end molding, in contrast to other systems which require three independent pieces to accomplish the same result.
[0093] When using two parts instead of three, maximum use of materials is accomplished, making the invention more economical to produce and, as a result, more environmentally friendly sound. This new configuration of two pieces allows a third piece to be introduced, also reversible, that broadens the use of the pieces to include a increased range of flooring thicknesses found in such products as hardwood and other finished flooring that could not be previously accommodated. An additional option that increases the range of use of the invention is to permit it to transition to a broader range of flooring thicknesses by adding a second reversible part that is higher (thicker) than the first reversible part.
[0094] In FIG. 54 , there is a tongue/groove connection in the attachable parts, for example, on the underside of the T-molding. However, it is within the scope of the invention to reverse the position of each of the tongue and groove from that illustrated. This figure shows the reversible molding element 1001 in a configuration with the track and shim, as optionally used in the other embodiments discussed herein.
[0095] In FIG. 57 the underside of the T-molding does not have a tongue or groove. It does, however, have a notch or shoulder, which holds the other molding piece, such as the reversible molding element 1001 , from moving laterally toward the track. The reversible molding element 1001 , preferably, is smooth, without a groove or tab on the surface which comes into contact with the underside of the T-molding. The underside of the reversible molding element 1001 preferably has a groove to accommodate an extension from the track that stabilizes the lateral movement of the reversible molding element, preventing movement away from the track. In order to hold the element 1001 in place, the track can be provided with a gripping flange 1010 , which may be formed as a break-away section on the remainder of the track, such that when the gripping flange 1010 is not to be used, it can be easily removed to have the track in a different configuration.
[0096] FIG. 58 shows both a groove and stabilizing notch on the underside of the T-molding, with a tab on the reversible molding element 1001 .
[0097] FIG. 59 shows an extendable track extension 1012 , which may be one piece or with break-away elements, and may also act as a shim to raise the track. When used as one piece, the raised tab, on the extension that affixes to the underside of the reversible molding element 1001 , can slide beneath the finished flooring when the track is used to hold a T-molding or the height of the tab can be the equivalent to the height of underlayments used in the floating floor application, and will not interfere with the floating floor, because the extension is no higher than the foam underlayment commonly used in such installations, the apparatus does not interfere with the floating floor. When used with the break-away feature, the extension can be removed and the remaining part can be used as a shim to raise the track to accommodate a thicker floor. The track may be joinable with a tongue/groove connection system to prevent relative movement. FIGS. 60 and 62 show a similar attachable extension using thinner material and a different attachment configuration.
[0098] In FIG. 61 , the underside of the T-molding does not have either a tongue or groove. It does, however, have a notch or shoulder that holds the reversible molding element from moving laterally toward the track. The reversible molding element may also be smooth, i.e., no tongue or groove, on the surface that comes into contact with the underside of the T-molding. These parts can be assembled with any type of glue or adhesive, such as fresh glue, pre-applied glue, encapsulated glue, reactive adhesives, contact adhesives or adhesive tapes.
[0099] In FIG. 63 , the T-molding has a milled groove 1012 . The top of, for example, the reversible molding element also has a groove 1014 . To complete assembly, a loose double-sided tongue 1016 can be pressed into the groove 1012 as the reversible molding element 1001 is attached to the tongue 1016 . The tongue 1016 can be pressure fit or glued into one or both of the grooves 1012 , 1014 .
[0100] The two different sizes of elements 1001 of FIGS. 65 and 66 allow for accommodation of a wide range of thicknesses.
[0101] In FIG. 67 a , there is a groove and stabilizing notch on the underside of the T-molding, and a tab on the reversible molding element 1001 (not shown). Here, the T-molding can accommodate either reversible parts (such as those shown in FIGS. 65 and 66 ), and a shim can be used with an extension (which can be broken away or folded under the shim) to increase its thickness to raise the track and accommodate thicker flooring. FIG. 67 b shows the break-away shim extension with tabs that can snap to the underside of the shim.
[0102] FIGS. 68-80 utilize the reversible concept with aluminum or other metals or composites. Generally all of the same features of the previously described materials can be used with these elements. These structures may additionally be covered, at least in part, by a decor layer (which may be, optionally directly, digitally printed and coated or a decor sheet which can be subsequently coated), such as a foil or other laminate structure.
[0103] FIG. 69 shows two grooves in the T-molding and two matching tongues on the second or reversible molding element. Again, the location of the tongue/groove of any embodiment described herein can be swapped without departing from the invention.
[0104] FIG. 70 shows a T-molding with one single foot and a track to accommodate this foot, similar to FIGS. 1A and 1B .
[0105] FIG. 71 shows a T-molding and a reversible molding element with grooves that can accommodate a clip 1020 that joins the two parts together. The clip has a similar function as the double-tongue of FIG. 63 .
[0106] FIG. 72 shows a reversible molding element with a tab on the top and groove on the underside to accommodate a track extension and aid the prevention of lateral movement, similar to that which is shown in FIG. 57 .
[0107] In FIG. 73 , the T-molding is provided with serrated grooves 1022 which match similar grooves 1024 on the reversible molding element. These grooves may be serrated “inwards” to hinder pulling-out of the reversible molding element, or inwards, to hinder the reversible molding element from being pushed inward, i.e., toward the foot of the T-molding. Alternate embodiments which differ from the traditional tongue/groove connection are shown in FIGS. 75 and 76 . The T-molding can have a notch or shoulder and the reversible molding element can have a corresponding tongue to prevent lateral movement away from the track. The pieces may also be smooth and held together with an adhesive, as described elsewhere herein, or may be held together using only the track extension.
[0108] In FIG. 74 , the track is shown with an extension as a break-away section, similar to that which is shown in FIGS. 60 and 62 .
[0109] FIGS. 77-80 show a metal or composite stair nose attachment in accordance with the invention.
[0110] In FIG. 77 , the stair nose is attached to a T-molding, which need not be formed from an aluminum. This structure may be from HDF, MDF, plastic, or other metal or composite materials. Such composites can include combinations of wood based and plastic resin composites. Hidden fasteners, which are not visible from the surface of either element can be used to secure the elements to the subfloor. There can also be a track to hold the elements in place.
[0111] In FIG. 78 , the stair nose is a separate piece apart from the T and the track. It can be fastened to the subfloor or stair tread with screws through apertures 1030 integrated into the structure of the stair nose. The separate track can be secured to the subfloor also with separate screws. Additionally, the same screws may be used to affix the track and the stair nose. The T-molding can be attached to the stair nose by the tongue and groove and can be held to the subfloor or stair tread by the track.
[0112] FIGS. 79 and 80 show the stair nose and track as one piece. While the track and stair nose can be separately formed, and joined, for example, by a tongue/groove system, they can also be formed and sold as a single unit.
[0113] FIG. 81 shows a modification of the T-molding of the invention. Specifically, it is possible to remove one of the arms or members from the T-molding to create an end molding or carpet reducer. This T-molding 1801 can be in accordance with any of the embodiments described herein. For example, the T-molding 18801 may be formed from HDF, MDF, metal or composite, and optionally provided with a decor layer, which may be printed or otherwise provided directly on the surface. Additionally, the removable section may be pre-fabricated as a frangible section, as is shown and described in accordance with FIG. 19 . A kit, such as a single package, may also be provided which includes at least two, but preferably all, of the individual parts described herein.
[0114] As shown in FIG. 19 , it is also possible to form the molding 11 , leveling block 40 and stair nose attachment 210 from the same element. Specifically, a generic element, indicated at 300 can be milled, sawed or otherwise constructed with a variety of “break away,” or readily separable, sections 300 A, 300 B, and 300 C. When one or more sections 300 A, 300 B, 300 C are removed, by for example, scoring and snapping, cutting, sawing or simply bending, the individual pieces can result. Preferably, the generic element 300 is initially formed as a unitary structure which is then scored as to provide stress-points to allow the removal of the sections. While not required by the present invention, typically, the removal of the break away sections 300 A, 300 B, 300 C requires a significant amount of physical force or labor, as the remaining structure must maintain its structural integrity. Alternatively, removal of the sections 300 A, 300 B, 300 C may require the use of a specialized tool.
[0115] By designing the generic element 300 in accordance with the invention. An installer can manipulate the generic element 300 to produce any needed component. For example, removing sections 300 B and 300 C would produce a typical stair nose attachment 210 , while removing sections 300 A and 300 C would produce a typical molding 11 . Due to this construction, it is possible to manufacture the generic elements to be purchased with appropriate selection being left to the installer. Similarly, when removing sections 300 A and 300 C to form the molding 11 , section 300 A can be used as a leveling block as described herein.
[0116] By allowing an end user to purchase the various pieces as an assembled generic element 300 instead of separate components, the retailers and/or distributors may accordingly reduce their inventory requirements. For example, typically over one-hundred different design patterns for the outwardly facing surface 34 of the molding 11 (as well as for the leveling block 40 and stair nose attachment 210 ) are produced. By allowing for the inventory to include only the generic elements of the invention, the total number of components retained can be reduced from three per design to one per design. Similarly, the installer only need purchase the generic elements 300 , rather than three individual components. This results in savings both to the retailer and installer by reducing the space needed for retailing bays and storage, respectively.
[0117] The molding 1110 may also be provided with a shoulder 1115 , located preferably on the underside of one of the arms 1114 , 1112 . This shoulder can be similar to the stabilizing notch shown in FIGS. 56-61 . The position of the shoulder is typically selected to provide a stop surface to the attachment 1140 to help prevent lateral movement of the attachment 1140 with respect to the molding 1110 . This shoulder 1115 is preferably formed by a beveled cut into the surface, such that when the attachment 40 is seated in shoulder 1115 , movement of the attachment 40 is hindered. The presence of this shoulder 1115 can eliminate any gap or space at the distal or exposed edge of the molding element 1140 , 1250 as it meets the surface of the subfloor or floor element.
[0118] The attachment 1140 can also be provided with one or more spacing gaps 1200 on an undersurface thereof ( FIGS. 86-99 , 100 , 102 , 104 , 106 , 108 and 110 ). When used with an appropriately sized spacer 1210 , the molding 1110 and attachment 1140 can be used with a wide variety of flooring thicknesses, from as small as 6 mm or smaller to as large as 15 mm or larger. The spacers 1210 are typically formed from a rigid or flexible plastic material, preferably, a solid thermosetting plastic However, it is within the scope of the invention to construct the spacers 1210 of a thermoplastic, such as polyvinyl chloride (PVC) or a resilient foam material. Additionally, the spacer 1210 preferably includes at least one extension 1212 , sized and shaped to fit within a spacing gap 1200 .
[0119] In one embodiment, at least the extension 1212 is formed from a resilient compressible material, such as a structural foam, and is slightly larger in width than the width of the spacing gap 1200 . When the extension 1212 is inserted into the spacing gap 1200 , it is necessary to compress the extension 1212 . Because the extension 1212 in this embodiment must be compressed to be inserted into the spacing gap 1200 , the internal forces of the material of the extension 1212 should maintain the spacer 1210 in the correct position.
[0120] As a substitute for the compressible embodiment or in addition thereto, the spacer 1210 may be joined to the spacing gap 1200 with an adhesive. Typical adhesives include any of the other adhesives discussed elsewhere. However, it is within the scope of the invention to eliminate any means for securing the spacer 1210 in the spacing gap 1200 .
[0121] In a preferred embodiment, a different reversible molding element 1250 can be used, having an end molding surface 1252 and a hard surface reducer surface 1254 and two spacing gaps 1212 a , 1212 b in the lower surface thereof. The presence of one spacing gap associated with each of the molding surfaces allows one spacer 1210 to be used closest to the exposed surface of the reversible molding element 1250 , as shown in FIGS. 94, 96 and 98 . Although these figures show the reversible molding elements 1250 having two spacing gaps 1200 positioned in an underside thereof, it is within the scope of the invention to utilize a single spacing gap 1200 positioned, for example, centrally or not centrally, i.e., off center, in the underside of the reversible molding element 1250 .
[0122] Typically, the height of the reversible molding element 1250 or 1140 permits the molding 1110 to rest parallel to the higher surface element 1111 when used with an appropriately sized spacer 1210 . In order to provide such appropriately sized spacers 1210 for a variety of different applications, the spacer 1210 may include a second extension 1212 . As shown, for example in FIG. 98 , the extensions 1212 are preferably located on opposite sides of the spacer 1210 , such that inverting the spacer 1210 allows insertion of the correct extension 1212 into the spacing gap 1200 . It is also considered within the scope of the invention to provide the spacer 1210 with up four or more extensions 1212 of different lengths to permit use in a large number of different installations.
[0123] It should be understood that the spacer 1210 is not necessary. The shape of the molding element 1140 and/or reversible molding 1250 allows an installation wherein the molding element 1140 , 1250 rests directly on the subfloor. In certain installations, depending in part on the height of the adjacent flooring elements, this can cause the molding 1110 to form an angle with the flooring elements. However, such an angle is not problematic, as clamps 1126 used in accordance with the invention are preferably versatile enough to sufficiently grip the foot 1116 of the molding 1110 despite the presence of such an angle.
[0124] By utilizing the embodiments shown in FIGS. 100-111 , it is possible to eliminate a gap 1300 between the subfloor and the molding by providing the molding 1140 , 1250 with an angled cut 1305 . The moldings 1140 , 1250 depicted in these figures are similar to that which are shown in FIGS. 112-119 with the same undercut. However, the foot 1116 that fits into the clamp 1126 is longer than the foot 1116 of FIGS. 112-119 .
[0125] The embodiment of FIGS. 112-119 differs from prior designs in a variety of ways. The molding 1110 can be made thicker to provide additional strength, as well as to allow for easier placement of an undercut 1150 . This undercut 1150 is preferably located on the portion of the molding 1110 that rests on a surface of the finished flooring. In some embodiments, the undercut 1150 provides close contact, i.e., no gap, between the surface of the floor and the outer edge of the molding 1110 as the flooring increases in thickness and raises the molding 1110 from a horizontal position to a more angular position, as described above.
[0126] Additionally, the clamp 1126 and pad 1120 configuration may be replaced by a reconfigured track 1126 ′ as shown, for example, in FIG. 114 . In this embodiment, the clamp 1126 and pad 1120 are combined into a single structure, which structure is secured to the subfloor and grips the foot 1116 of the molding 1110 . Preferably, the track 1126 ′ has a general H-shape, with two upstanding sections 1128 and a middle horizontal section 1130 . As the pad 1120 may also be used in an inverted orientation to achieve multiple configurations, the track 1126 ′ may also be inverted for the same purpose. Accordingly, in a preferred embodiment, the middle horizontal section 1130 is not placed exactly at the middle of the heights of the upstanding sections. Thus, when the molding 11 , 1110 is inserted into the track 1126 ′, the lowest point of the foot 16 , 1116 can be supported by the middle horizontal section 1130 . The entire structure of the track 1126 ′ can be formed from a resilient, but structural material, just as the clamp 26 , 1126 may be.
[0127] The track 1126 ′ may be secured to the subfloor though a variety of methods. In one embodiment, as shown, for example, in FIG. 116 , one or both of the upstanding sections 1128 may have a base 1132 which can be secured to the subfloor with a screw or nail or adhesive. A fastener may also be positioned through the middle horizontal section 1130 to secure the lowermost portions of the upstanding sections to the subfloor.
[0128] The invention additionally includes packaging to be used by, for example, wholesalers or retailers. In one embodiment, multiple individual pieces, e.g,, a reversible molding 1250 , a molding 11 , 1110 , a pad 1120 and a clamp 1126 may be bundled in a single package or kit. In another embodiment, the package or kit includes two, or three, or even up to twenty or more, of each piece packaged therein. For example, a single package may include three approximately one-meter (or three foot) sections of each item contained therein, for a total length of about three meters (about nine feet). It is additionally within the scope of the invention to include different sets of items in a single package, for example, one set being about one meter (about three feet) long and an additional set being about two meters (about six feet) long.
[0129] It should be apparent that embodiments other than those specifically described above may come within the spirit and scope of the present invention. Hence, the present invention is not limited by the above description.
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The invention is a joint cover assembly for covering a gap adjacent an edge of a panel that covers a sub-surface, and a method of covering such a gap. The assembly includes a molding having a foot, a first arm, and a second arm. The foot is positioned along a longitudinal axis of the molding, and the first arm extends generally perpendicularly to the foot. The second arm may also extend generally perpendicularly to the foot. A tab depends from at least one of the first and second arms. At least one of the tab and the foot engage a track in order to position the assembly over the gap. The method includes the steps of placing the foot in the gap, pressing the respective panel engaging surfaces into contact with respective panels, and configuring at least one of the tab and the foot to cooperate to retain the molding in the gap when the assembly is in an installed condition.
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FIELD OF INVENTION
[0001] The present invention relates to a fire retardant panel door, and more particularly to a reinforced fire retardant panel door that provides additional structural support, stiffness and fire resistance for preventing the spread of fire through the fire retardant panel door and door frame.
BACKGROUND OF THE INVENTION
[0002] A fire retardant panel door, often referred to as a “fire door,” is installed in homes, commercial buildings, and industrial plants for preventing the passage or spread of fire from one part of the building to another. In the interest of public safety, standards have been set by governmental agencies; and by municipal, county and state building code authorities and insurance companies for the installation and performance of fire doors. The standards require that the fire retardant doors be installed in wall openings and that they pass industry-wide acceptance tests.
[0003] Standard test methods for fire door assemblies, such as ASTM E-152, UL 10(b) or NFPA 252, measure the ability of a door assembly to remain in an opening during a fire to retard the passage of the fire and evaluate the fire resistant properties of the door. In conducting such tests, doors are mounted in an opening of a fire proof wall. One side of the door is exposed to a predetermined range of temperatures over a predetermined period of time, followed by the application of a high pressure hose stream that causes the door to erode and provides a thermal shock to the assembly. Doors are given a fire rating based on the duration of the heat exposure of 20 minutes, 30 minutes, 45 minutes, one hour, 1½ hours or three hours. The door assembly receives the fire rating when it remains in the opening for the duration of the fire test and hose stream, within certain limitations of movement and without developing openings through the door either at the core or around the edge material.
[0004] A fire door must be made almost entirely of incombustible material. However, since a fire door is part of the interior or exterior of a personal living space or workspace, it must also be aesthetically pleasing. Usually, therefore, a core of incombustible material comprising the main structure of the fire door is overlaid with a thin wood veneer facing that provides the door with an attractive appearance. Fire door assemblies often fail, not because of the fire resistant properties of the fire door, but they fail because of inadequate structural strength of the door such that the fire door buckles. Additionally, the fire resistant blocking material of a core section of the fire door may need supplemental fire resistant materials strategically placed within the fire door to add to its fire door rating.
[0005] There remains a need for a reinforced fire retardant panel door which provides additional structural support, strength and stiffness to the fire retardant panel door in order to prevent buckling of the fire retardant panel door during a fire. Further, the reinforced fire retardant panel door would include supplemental fire resistant materials strategically embedded within the structural components of the fire retardant panel door.
DESCRIPTION OF THE PRIOR ART
[0006] Fire retardant doors, and fire doors of various designs, configurations, structures and materials of construction have been disclosed in the prior art. For example, U.S. Pat. No. 6,115,976 to Gomez discloses an assembly for sealing a fire resistant door within a door frame during a fire event. The door edge assembly includes a plurality of door edges for receiving an intumescent strip within a slot on each door edge. The intumescent strip is constructed and designed to expand upon reaching a certain reaction temperature when exposed to a fire event or other extreme heat source. This prior art patent does not disclose or teach the particular door structure having steel insert washers and having steel joint plates for door reinforcement, nor the use of intumescent material in the door joints in order to provide for a reinforced fire retardant panel door that prevents buckling of the door during a fire, as well as prevent the spread of fire through the door and door frame for at least 90 minutes.
[0007] U.S. Pat. No. 5,816,017 to Hunt et al. discloses a fire retardant door and exit device for the fire retardant door. The fire retardant door includes a core of fire resistant blocking material being Tectonite™ for providing the door with a fire rating of at least 90 minutes. The fire door uses intumescent material which expands when heated to fill the void in the channel between the channel walls and the vertical extending rods within the latch stile of the door. This prior art patent does not disclose or teach the particular door structure having steel insert washers and having steel joint plates for door reinforcement, nor the use of intumescent material in the door joints in order to provide for a reinforced fire retardant panel door that prevents buckling of the door during a fire, as well as prevents the spread of fire through the door and door frame.
[0008] U.S. Pat. No. 5,417,024 to San Paolo discloses a fire resistant panel door. The fire resistant panel door is constructed from panels, stiles, mullion and rails having a core of fire resistant material. The door components are joined together so that the fire resistant material extends substantially continuously from side to side and from top to bottom of the finished door. The fire resistant core of each door panel is recessed within the fire resistant core of the associated rails and stiles to reduce air infiltration through the door which can compromise the door's fire resistance. This prior art patent does not disclose or teach the particular door structure having steel insert washers and having steel joint plates for door reinforcement, nor the use of intumescent material in the door joints in order to provide for a reinforced fire retardant panel door that prevents buckling of the door during a fire.
[0009] U.S. Pat. No. 4,930,276 to Bawa et al. discloses a fire door window construction. The fire door includes a trim strip having inner and outer members. The inner member is of a high density incombustible mineral material or ceramic and is nailed in position to securely and uniformly hold the pane of glass in the door opening. The outer trim member is of a fire retardant particle board and has an exposed wood veneer facing throughout. An intumescent caulking compound is applied between an inner portion of the outer trim member and the pane of glass. This prior art patent does not disclose or teach the particular door structure having steel insert washers and having steel joint plates for door reinforcement, nor the use of intumescent material in the door joints in order to provide for a reinforced fire retardant panel door that prevents buckling of the door during a fire, as well as prevents the spread of fire through the door and door frame for at least 90 minutes.
[0010] U.S. Pat. No. 4,441,296 to Grabendike et al. discloses a fire resistant wood door structure designed to pass code and testing laboratories' requirements. The fire resistant wood door structure includes a door assembly having a support frame assembly with a panel assembly connected to the support frame assembly. The support frame assembly includes top, bottom, side, central and transverse frame members. The panel members include a main body connected through a peripheral edge by a double connector assembly. The double connector assembly functions to only remove about ⅓ of the door's normal 1¾ inch thickness during the burn testing procedure, thus passing the fire resistant testing of 20 minutes. This prior art patent does not disclose or teach the particular door structure having steel insert washers and having steel joint plates for door reinforcement, nor the use of intumescent material in the door joints in order to provide for a reinforced fire retardant panel door that prevents buckling of the door during a fire, as well as prevents the spread of fire through the door and door frame for at least 90 minutes.
[0011] U.S. Pat. Nos. 4,529,742; 6,031,040; and 6,153,674 all disclose the use of intumescent compounds/fire barrier materials within door construction to reduce or eliminate the passage of smoke and fire through the door and door frame. These prior art patents do not disclose or teach the particular door structure having steel insert washers and having steel joint plates for door reinforcement, nor the use of intumescent material in the door joints in order to provide for a reinforced fire retardant panel door that prevents buckling of the door during a fire, as well as prevents the spread of fire through the door and door frame for at least 90 minutes.
[0012] In addition, the aforementioned prior art patents do not disclose or teach the particular structure and configuration of the reinforced fire retardant panel door of the present invention that provides additional structural support, strength and stiffness to the door in order to prevent the buckling of the door during a fire.
[0013] Accordingly, it is an object of the present invention to provide a reinforced fire retardant panel door that prevents buckling of the door during a fire.
[0014] Another object of the present invention is to provide a reinforced fire retardant panel door that has additional structural support, strength and stiffness with the use of a plurality of joint steel washers and a plurality of joint steel plates which are embedded within the fire resistant blocking material (core section) of the door for preventing the buckling of the fire door during a fire.
[0015] Another object of the present invention is to provide a reinforced fire retardant panel door that has supplemental fire resistant materials strategically embedded and placed within the tongue and groove joints of the fire resistant panel door, as well as supplemental fire resistant materials placed on the perimeter edges of the fire resistant panel door for preventing the spread of fire through the door and door frame.
[0016] Another object of the present invention is to provide a reinforced fire retardant panel door that has fire resistant materials being intumescent material that expands in the presence of fire such that the intumescent material closes and seals the component tongue and groove joints, as well as the perimeter edges of the fire retardant panel door for preventing the spread of fire through the door and door frame.
[0017] Another object of the present invention is to provide a reinforced fire retardant panel door that is used as part of an interior or exterior personal living space, or workspace being installed within home dwellings, commercial buildings or industrial plants.
[0018] Another object of the present invention is to provide a reinforced fire retardant panel door that is aesthetically pleasing having the appearance of natural wood, and has achieved a successful fire rating of at least 90 minutes and passes a positive pressure test, and is easily installed in a building.
[0019] A further object of the present invention is to provide a reinforced fire retardant panel door that can be mass produced in an automated and economical matter and is readily affordable to the builder or consumer.
SUMMARY OF THE INVENTION
[0020] In accordance with the prevention, there is provided a reinforced fire retardant panel door that prevents buckling of the door during a fire. The reinforced fire retardant panel door includes a door having at least one door panel and stiles and rails. The reinforced fire retardant panel door also includes at least four (4) steel washer inserts embedded within the door for reinforcing the connection between the door panel and the stiles and rails. Further, the reinforced fire retardant panel door includes at least four (4) steel joint plates embedded within the door member for reinforcing the connection between the stiles and rails for providing increased structural strength and stiffness to the door in order to prevent buckling of the fire retardant panel door during a fire.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] Further objects, features and advantages of the present invention will become apparent upon the consideration of the following detailed description of the presently-preferred embodiment when taken in conjunction with the accompanying drawings, wherein:
[0022] [0022]FIG. 1 is a front perspective view of the reinforced fire retardant panel door of the preferred embodiment of the present invention showing its major component parts thereof;
[0023] [0023]FIG. 2 a is a cross-sectional view of the reinforced fire retardant panel door of the present invention taken along lines 2 a - 2 a of FIG. 1 in the direction of the arrows showing a pair of joint plates connecting a stile to an upper rail and a lower rail and a joint washer;
[0024] [0024]FIG. 2 b is a cross-sectional view of the reinforced fire retardant panel door of the present invention taken along lines 2 b - 2 b of FIG. 1 in the direction of the arrows showing a pair of joint washers connecting the right panel to the upper rail and the lower rail, respectively;
[0025] [0025]FIG. 3 a is a cross-sectional view of the reinforced fire retardant panel door of the present invention taken along lines 3 a - 3 a of FIG. 1 in the direction of the arrows showing a pair of joint washers connecting the upper rail to a pair of panels;
[0026] [0026]FIG. 3 b is a cross-sectional view of the reinforced fire retardant panel door of the present invention taken along lines 3 b - 3 b of FIG. 1 in the direction of the arrows showing a plurality of joint washers being connected to opposing stiles, opposing panels and a center panel;
[0027] [0027]FIG. 4 is an enlarged sectional view of the reinforced fire retardant panel door of the present invention taken along lines 4 - 4 of FIG. 1 in the direction of the arrows showing the joint plate embedded into the core and held into place by screws for reinforcing a tongue and groove joint between the stile and rail; and
[0028] [0028]FIG. 5 is an enlarged sectional view of the reinforced fire retardant panel door of the present invention of FIG. 3 b showing intumescent material embedded within the tongue and groove joint.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0029] The reinforced fire retardant panel door 10 of the preferred embodiment of the present invention is represented in detail by FIGS. 1 through 5 of the patent drawings. The fire retardant panel door 10 is used to fireproof an area and to prevent fire from spreading to other areas within a home dwelling, commercial building or industrial plant.
[0030] Fire retardant panel door 10 includes stiles 12 and 14 , rails 16 and 18 , a center panel 20 , a first panel 30 and a second panel 50 , as shown in FIGS. 1 to 4 . The fire retardant panel door 10 is hingedly connected between a left or right door jamb 22 or 24 and positioned below an upper header 26 , as depicted in FIGS. 2 a and 3 a . Panel 30 has edges 32 , 34 , 36 and 38 and panel 50 has edges 52 , 54 , 56 and 58 . Stiles 12 and 14 , rails 16 and 18 , and panels 20 , 30 and 50 have a core section 40 formed of Tectonite material. Wood applique 42 and molding 44 are applied to the exterior surface of stiles 12 and 14 , rails 16 and 18 , and panels 20 , 30 and 50 , as shown in FIGS. 1, 2 a , 2 b , 3 a and 3 b of the drawings.
[0031] Tongue and groove joints 60 and 62 are used to connect panel 30 to the door 10 , and tongue and groove joints 64 and 66 are used to connect panel 30 to the door 10 . Tongue and groove joints 68 and 70 are used to connect panel 50 to the door 10 , and tongue and groove joints 72 and 74 are used to connect panel 50 to the door 10 . To reinforce the tongue and groove joints 60 , 62 , 64 , 66 , 68 , 70 , 72 and 74 , the present invention employs eight (8) steel joint washers 80 , 82 , 84 , 86 , 88 , 90 , 92 and 94 that are 2½ inches in diameter and ⅛ inch thick. As shown in FIGS. 1, 2 a , 2 b , 3 a and 3 b , the eight (8) joint washers reinforce the joints between the panels 30 and 50 , and the stiles 12 and 14 , the rails 16 and 18 , and the center panel 20 . One of the steel joint washers 80 to 94 is placed on each of the four (4) edges 32 to 38 and 52 to 58 of panels 30 and 50 , respectively. Each of the joint washers 80 to 94 is embedded within the core section 40 of the stiles 12 , 14 , the rails 16 , 18 , center panel 20 and the panels 30 , 50 , as shown in FIGS. 2 a , 2 b , 3 a and 3 b . The joint washers 80 to 94 can be made of metal materials, such as steel, stainless steel alloys, tantalum and titanium alloys. Additional washers may be employed for additional strength, if desired.
[0032] To reinforce the connection between the stiles 12 and 14 and the rails 16 and 18 , the present invention employs four (4) joint plates 100 , 102 , 104 and 106 that are each 3 inches by 6 inches, and ⅛ inch thick. Preferably, they are rectangular in shape and each have two (2) screw hole openings 110 and 112 for receiving screws 114 and 116 to hold the joint plates 100 to 106 in place, as shown in FIGS. 1, 2 and 4 of the patent drawings. Each of the joint plates are embedded within the core section 40 of the stiles 12 , 14 and the rails 16 , 18 , as shown in FIGS. 2 a and 4 of the drawings. The joint plates 100 to 106 can be made of metal materials, such as steel, stainless steel alloys, tantalum and titanium alloys.
[0033] To further reinforce door 10 , intumescent material 120 is embedded in each of the tongue and groove joints 60 to 74 , and is also applied to outer perimeter edges 12 a , 14 a , 16 a , 18 a of the stiles 12 , 14 and the rails 16 , 18 , respectively, as shown in FIGS. 1 to 4 of the drawings. The intumescent material 120 expands in the presence of excessive heat and/or fire such that the intumescent material 120 closes and seals each of the tongue and groove points 60 to 74 to prevent the spread of the excessive heat and/or fire through the fire retardant panel door 10 . Additionally, the intumescent material 120 on the outer perimeter edges 12 a , 14 a , 16 a and 18 a of the stiles and rails 12 , 14 , 16 and 18 , respectively, also expands in the presence of excessive heat and/or fire such that the intumescent material 120 closes and seals the perimeter of the fire retardant panel door 10 within the jambs 22 , 24 and header 26 of the door frame (not shown) to also prevent the spread of the excessive heat and/or fire through the fire retardant panel door 10 and door frame.
[0034] The core section 40 is made from Tectonite™ material which is manufactured by and is available from Warm Springs Composite Products Company of Warm Springs, Oreg. of the United States. The core section 40 is a fire resistant, insulative composite blocking material suitable for use in door 10 of the present invention. The Tectonite™ material has a fire rating above 90 minutes and is used for the core section 40 as a single component construction. The core section (blocking material) 40 , the joint washers 80 to 94 , and the joint plates 102 to 106 all provide structural support, strength and stiffness to the door 10 construction. It is understood that the core (blocking material) section 40 can be made of any fire resistant blocking material approved for fire door applications which has a proven fire door rating.
[0035] In operation, when fire or excessive heat occurs, the intumescent material 120 expands and provides closing and sealing of all the tongue and groove joints 60 to 74 and also provides closing and sealing of the perimeter of the fire retardant panel door 10 within its door frame (not shown), thus preventing the spread of the fire through the fire retardant panel door. Further, the core section 40 , the steel joint washers 80 to 94 , and the steel joint plates 100 to 106 in combination with each other, all cooperate to provide additional structural support, strength and stiffness to the door 10 construction, thus preventing the door 10 from buckling in the presence of excessive heat and/or fire.
ADVANTAGES OF THE PRESENT INVENTION
[0036] Accordingly, it is an advantage of the present invention that it provides for a reinforced fire retardant panel door that prevents buckling of the door during a fire.
[0037] Another advantage of the present invention is that it provides for a reinforced fire retardant panel door that has additional structural support, strength and stiffness with the use of a plurality of joint steel washers and a plurality of joint steel plates which are embedded within the fire resistant blocking material (core section) of the door for preventing the buckling of the fire door during a fire.
[0038] Another advantage of the present invention is that it provides for a reinforced fire retardant panel door that has supplemental fire resistant materials strategically embedded and placed within the tongue and groove joints of the fire resistant panel door, as well as supplemental fire resistant materials placed on the perimeter edges of the fire resistant panel door for preventing the spread of fire through the door and door frame.
[0039] Another advantage of the present invention is that it provides for a reinforced fire retardant panel door that has fire resistant materials being intumescent material that expands in the presence of fire such that the intumescent material closes and seals the component tongue and groove joints, as well as the perimeter edges of the fire retardant panel door for preventing the spread of fire through the door and door frame.
[0040] Another advantage of the present invention is that it provides for a reinforced fire retardant panel door that is used as part of an interior or exterior personal living space, or workspace being installed within home dwellings, commercial buildings or industrial plants.
[0041] Another advantage of the present invention is that it provides for a reinforced fire retardant panel door that is aesthetically pleasing having the appearance of natural wood, and has achieved a successful fire rating of at least 90 minutes and passes a positive pressure test, and is easily installed in a building.
[0042] A further advantage of the present invention is that it provides for a reinforced fire retardant panel door that can be mass produced in an automated and economical matter and is readily affordable to the builder or consumer.
[0043] A latitude of modification, change, and substitution is intended in the foregoing disclosure, and in some instances, some features of the invention will be employed without a corresponding use of other features. Accordingly, it is appropriate that the appended claims be construed broadly and in a manner consistent with the spirit and scope of the invention herein.
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A reinforced fire retardant panel door that prevents buckling of the door during a fire. The reinforced fire retardant panel door includes a door member having at least one door panel and stiles and rails. The reinforced fire retardant panel door also includes at least four (4) steel washer inserts embedded within the door member for connecting at least one door panel to the stiles and rails. Further, the reinforced fire retardant panel door includes at least four (4) steel joint plates embedded within the door member for connecting said stiles and rails together more securely for providing increased structural strength and stiffness to the door in order to prevent buckling of the fire retardant panel door during a fire.
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BACKGROUND OF THE INVENTION
The proper and efficient operation of a sewage treatment plant is dependent upon the rate at which activated return sludge is cycled in the system. The return sludge carries the necessary operating bacteria back into the system to control the rate of treatment. The best operation is obtained when one knows continuously the condition of the return sludge which is determined by measuring the amount of solids suspended in the fluid and the settling rate of the activated sludge. In the prior art the only known way to determine these factors involves a manual test in which an operator must take a sample of the sludge and the mixed liquor and run them through a prolonged settling test in which the amount of solids and the settling rate are observed by eye and recorded by hand. This operation is slow and expensive since it requires the labor of the operator. Frequently the tests simply are not performed often enough to maintain a good operating picture of the system and consequently the sewage plant never quite operates at its optimum level but is always in the process of being corrected back from extreme conditions of too much or too little activated sludge. The present invention corrects these difficulties.
SUMMARY OF THE INVENTION
Briefly, my invention comprises an automatic sampling system which operates without an operator to sample the activated sludge and the mixed liquor and determine the relevant ratios of activated sludge and solids to provide either a printed record or an automatic control signal which can control the return sludge flow rate. The arrangement of the valves, testing equipment, control circuits, and readouts is described in detail hereinafter. However, the main advantages of my invention include a low cost operation which results from freeing the operator from routine manual tests and plant adjustments. Also, if the testing is done continuously, trends can be established and process upsets detected at an early stage so that correcting adjustments can be introduced before the sewage treatment facility reaches an extreme condition of imbalance. The optical readout mechanisms utilized in the present invention are highly accurate and therefore less prone to errors found in the prior art visual checks. The rugged construction can be simply maintained and eliminates the necessity of specialized service so that the plant operators can maintain the machinery themselves. No manual adjustments are necessary and the system is completely automatic providing a printed record that can be used by operators of ordinary skill.
It may therefore be seen that it is an object of my invention to provide an automatic activated sludge control system for sewage treatment plants which provides improved operation through lower cost, more accurate control, and elimination of the need for highly skilled operators. Further objects and advantages will become apparent from the following detailed description and drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic flow diagram showing how the automatic control system of the present invention operates in conjunction with a typical sewage treatment facility.
FIGS. 2 and 3 show the two halves of the testing station with the settleometer jar test and the centrifuge test respectively.
FIG. 4 is a schematic diagram of the typical sequence of operations effected by the automatic circuits of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
In FIG. 1 the sewage input 10 is directed to an aerator tank 12 in which the activated sludge and mixed liquor are continuously circulated with air to maintain the treatment process. Additional aerator tanks 14 may also be used depending upon the size of the facility. The treated effluent is drawn off to a final settling tank 16 where the sludge settles out to eventually be discharged through a waste valve 17. This sludge contains the necessary bacteria to maintain the treatment operation and a portion of it may be returned through line 18 by a return sludge pump 20 to the aerator tanks 12 and 14. The amounts of waste and return sludge primarily determine if the process in the aerator tanks is proceeding efficiently. With the present invention the fluid in the aerator tanks 12 and 14 can be delivered to an automatic control system 26 by means of sample valves 30 or 32 and sample pumps 34. The return sludge is sampled through a valve 28. The result of the testing can be displayed on a keyboard printer 38 or used to develop control signals 39 to operate the return sludge pump 20 and the waste valve 17. Before samples are tested, the line 35 from the treatment facility is purged through a purge valve 36 as will be explained with respect to FIG. 4.
Basically, two tests are performed by the present invention. The aerator tank mixed liquor is directed to a settleometer jar 42 shown in FIG. 2 and allowed to settle. The mixed liquor and the return sludge are directed to a centrifuge 68 and caused to forcibly settle out to determine the ratio of solids therein. The centrifuge 68 is shown in FIG. 3. However, it is contemplated that both portions of the testing apparatus will be mounted on a common testing station console which is divided into console 40A in FIG. 2 and 40B in FIG. 3 for the sake of clarity in the drawings. The settleometer jar 42 in FIG. 2 is filled through a fill pipe 56. An overflow hole 44 ensures that jar 42 will be filled to a precise level from which one can accurately measure the level of settled out sludge. Jar 42 rests on a platform 46 which is secured to a shaft 48 and rotated by a motor in a jar positioner 50. At the conclusion of the test, jar 42 is tilted by positioner 50 to drain into drain pan 52. In the tilted position water is directed into the jar 42 through a nozzle 54 to clean out the jar in preparation for the subsequent test. The measurement of the interface level between the clear supernatant liquid and the settled sludge is measured optically by means of a photo transistor sensing device 60 which measures infrared or other frequency light transmitted through jar 42 from a source 58. A rack and pinion drive 62 operates in conjunction with a stepping motor 64 to slowly lower the probe 60 from an uppermost zero position, determined by a limit switch 66, until the change in transmitted light indicates that the top of the sludge layer has been reached. An electronic computing system knows the distance traveled by detector 60 in comparison to the known total height of the jar and thus calculates the settled position of the activated sludge.
In the preferred embodiment, measurement of the sludge interface is taken at 5 minute intervals for the first 30 minutes and at 10 minute intervals for the last 30 minutes of the test and the results printed out on printer 38 in the form of a graph which the plant operator can examine at his convenience. It would of course be equally possible to use the measurement directly to develop a control signal which varies the quantitites of return sludge and waste discharged from the final settling tank 16.
Turning to FIG. 3 the other half of the testing apparatus is shown. Mounted on the console 40B is a conventional centrifuge 68 which contains a number of test tubes 70 positioned for rotation therein. In the center of the rotor of the centrifuge is a code disk 92 which permits the system to determine the position of the centrifuge by means of a light emitting diode 93 and a photo transistor 94 which are mounted on a cover 95 which is positioned over the centrifuge during operation. Thus, the electronic computing means in the system can determine which test tubes are being measured, filled, or washed. The actual positioning of the test tubes is accomplished electronically by pulsing the drive motor of the centrifuge and comparing the desired position to the actual position as measured by the binary code disk 92 and the photo transistor 94. To clean each test tube after a test has been completed a vaccum probe 72 is pushed downward by an air cylinder 78 through an opening 96 in cap 95 to extract the contents from the test tube. Simultaneously therewith a mixture of air and water is sprayed into the test tube through a tube 74 mounted to the side of vacuum probe 72. The tube is thoroughly cleaned by the spray which is then extracted through vacuum tube 76. The test sample is introduced into the test tubes by another probe 84 which is lowered by an air cylinder 86. The test sample flows in through tube 85 and again a suitable hole is provided in cap 95 to allow probe 84 to enter the test tube. Since an initial purge step is necessary during which fluid in line 85 is removed to ensure that the sample being tested is from a new batch, a suitable cup shaped drain 90 is moved under probe 84 by means of an air cylinder 88. This allows the purged fluid to be directed to a drain rather than into the test tube for the first few minutes of the purging operation. After a test tube has been filled, the centrifuge is run for a period of about 15 minutes causing the solids to precipitate to the bottom of the tube 70. At this time a third probe 83 is lowered through a hole in cap 95 to take an optical measurement of the interface between the clear fluid and the settled solids. A zero position determined by a limit switch 81 is used as a starting point for the measurement. Again, a stepping motor 82 lowers probe 83 through a known distance until the light from a diode source 79 is no longer detected by a photo transistor 80. This indicates the interface between the light blocking solids in the bottom of the test tube and the clear fluid above. Again a ratio is calculated by a computer and the information printed out in the form of a graph by printer 38.
All measurements, calculations, and program steps are controlled according to a predetermined sequence stored in a computer 97 as shown in FIG. 4. Computer 97 operates in a manner well known to those skilled in the art to carry the testing equipment through a preplanned series of steps in accordance with an internal clock that repeats the testing procedure throughout the day at set times. It is also contemplated that the present invention could simply be operated on demand by a start signal delivered to computer 97. A typical sequence is shown in FIG. 4 with the steps proceeding from top to bottom in a logical but not necessarily the only arrangement. The computer first signals motor 82 to raise the centrifuge sensor probe 83. Limit switch 81 signals the computer when a zero position has been reached. Computer 97 then initiates a cleaning of the centrifuge tubes by activating a vacuum pump 77 which operates through tube 76 and an air and water pump 73 which operates through tube 74. At the same time, air cylinder 78 is operated to move the probe into the test tube. According to its program, the computer raises the settleometer probe by activating motor 64 until limit switch 66 indicates that the probe has reached its uppermost or zero position. Computer 97 then signals the system to flush jar 42 signaling jar positioner 50 to rotate jar 42 into the lowered cleaning position discussed earlier and operating a suitable pump 53 to deliver water through nozzle 54. Before introducing samples for measurement it is desirable to purge the lines. Thus it is contemplated that computer 97 will send a "purge sample lines" signal to valve 36, sample pumps 34, and the desired sample valve 28, 30, or 32 depending upon which sample is being selected. Likewise, the fill line 85 at the test apparatus of the centrifuge should be purged. Accordingly, the computer 97 next operates air cylinder 88 to push drain cup 90 underneath probe 84 to receive fluid therefrom for a short interval. To fill a test tube the computer 97 operates a suitable pump 34 and a suitable valve, such as sample valve 32, to bring in a sample from aerator 12 to the test tube in centrifuge 68. Air cylinder 86 is also operated to lower probe 84 into the test tube for the filling procedure. In the present invention a metering pump is used so that the amount of fluid delivered to test tube 70 can be accurately controlled which, of course, is essential to the proper determination of the ratio of solids in the test tube.
The settleometer jar is also filled with a "fill settleometer jar" signal from computer 97 which operates valve 32 to permit the mixed liquor to be delivered by the proper sample pump 34 through fill tube 56. At the selected intervals the computer operates motor 64 to slowly lower probe 60 until the change in detected radiation from source 58 indicates that the interface between the sludge and the supernatant fluid has been reached. The computer knows the distance moved by motor 64 and therefore can calculate the ratio of settled sludge. In a similar manner the computer 97 can determine the percent of solids in the test tubes by operating motor 82 until the probe 83 lowers to the point where detector 80 senses the top surface of the layer of solids in test tube 70. Rotor position decoder 94 in conjunction with decoding ring 92 indicates to computer 97 which test tube is being read.
Clearly the exact sequence of the steps is not essential to the proper operation of the invention nor for that matter the precise arrangement of mechanisms shown in FIGS. 2 and 3 and accordingly I do not intend to be limited to the exact embodiments shown except as defined by the appended claims.
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A system for automatically extracting samples of sludge and mixed liquor from a sewage treatment plant, delivering them to a testing settleometer jar and centrifuge and measuring the rate of settling of sludge and suspended solids in the test samples.
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BACKGROUND
The present invention relates to scaffolding, and more particularly to scaffolding that is adapted for supporting studio lighting, grip and sound components.
Studio sound stages are typically equipped with heavy wooden scaffolding known as "greenbeds" that form hanging catwalks as aerial lamp platforms above studio sets. These typical scaffolds have a standard width of 42 inches and have a load rating of 19 lb/ft. In an exemplary form of such construction, decks are made using spaced 1×2" to 1×6" lattice boards that extend between parallel-spaced 2×4" or heavier beams, longitudinal stringers being fastened on the boards near the beams. A longitudinal spaced series of holes are drilled vertically through the stringers and some of the boards for receiving yoke stems of fixtures such as stage lamps. Reinforcing rings can be fastened to the stringers at some hole locations. Some decks have longitudinal planks on the boards and spaced between the stringers, and some decks have wire mesh nailed to the undersides of the boards for collecting fallen objects. The decks are supported between hanger frames that are suspended from chains, each frame including a pair of 2×4" wooden columns, a 2×4" top cross member and top corner braces, and a pair of bottom cross members fastened to opposite sides of the columns. Inside surfaces of the columns can have straps fastened thereto for receiving 2×4" handrails and the like, the straps having holes therein for nailing the handrails in place. The scaffolding is braced laterally by 2×4" lumber that is nailed between the columns and wall cleats.
There are significant shortcomings associated with the existing scaffolding of the prior art, for example:
1. Set-up and adjustment is difficult and labor-intensive in that the components are undesirably heavy, weighing typically 43 lb/ft to 51.3 lb/ft;
2. Maintenance is increasingly expensive, requiring repeated purchases of scarce clear lumber that is mandated for wooden greenbeds, and rebuilding of the greenbeds requires excessive time;
3. They are dangerous to use in that things can fall through or off of them, and they are subject to structural failure increasingly as the lumber material degrades; and
4. Utility is restricted by the presence of bulky handrails, so that an elaborate scaffold can support only few fixtures.
Thus there is a need for stage scaffolding that overcomes the disadvantages of the prior art.
SUMMARY
The present invention meets this need by providing a modular construction of lightweight, versatile and safe scaffolding in a number of configurations. In one aspect of the invention, a scaffold hanger includes a frame having a horizontally spaced pair of tubular column members, and an upwardly facing channel member rigidly connected horizontally between the column members proximate lower extremities thereof; means associated with each of the column members for connecting a support element for vertically transmitting load forces between the support element and the respective column member; a pair of retainer modules, each retainer module slidingly engaging a respective column member and having a collar portion for slidingly guiding and retaining the retainer module on the column member; a vertically oriented face portion; and a dog portion projecting horizontally outwardly relative to the column member, the face portion having a plurality of fastener openings formed therein for connecting a structural member; and means for holding each retainer module in a lowered position with the dog portion thereof fixedly spaced above the channel member.
The means for connecting can include a pair of support elements axially engaging respective ones of the column members, each of the support elements being secured by a respective support fastener, the support fastener transversely projecting through one of the column member and the support element and at least partly through the other of the column member and the support element. The column members can be tubular, opposite walls thereof having respective transversely oriented support fastener openings formed therein proximate upper and lower extremities of the column members for securing respective pairs of the support elements to the column members.
The frame can further include a top cross member rigidly connected between upper extremities of the column members. The means for holding can include each of the retainer modules having a set-screw threadingly engaging the collar element, or the collar element including a movable jaw member, for clamping the column member.
At least one of the retainer modules can include a gusset portion that is vertically oriented perpendicular to the face portion and having a further plurality of the fastener openings formed therein. The scaffold hanger can further include a shelf portion projecting horizontally perpendicular to a bottom extremity of the gusset portion for temporarily supporting a structural member to be fastened to the gusset portion. The gusset portion can be one of a horizontally spaced pair of gusset portions.
At least one of the dog portions can form a foot plate, opposite ends of the foot plate projecting horizontally beyond opposite sides of the column member, the foot plate having a further plurality of the fastener openings formed therein for fastening the dog portion to the bed. A side extremity of the foot plate can extend proximate a bottom extremity of the face portion and parallel thereto. The scaffold hanger can further include a horizontal boot bar rigidly extending between the column members and spaced below the channel member.
In another aspect of the invention, a scaffold assembly incorporates a spaced pair of the scaffold hangers, and further includes a scaffold bed having a deck surface, transversely oriented downwardly projecting retainer members proximate opposite ends of the bed for engaging respective ones of the channel members, and opposite longitudinal edge deck portions being spaced apart sufficiently for engagement by each of the dog portions of the scaffold hangers for holding the scaffold bed connected between the channel members. The scaffold bed can include a plurality of rigid rectangular panel members for forming the deck surface, each panel member having opposite end and side edges; a parallel-spaced pair of beam members, upper surfaces of the beam members forming the edge deck portions of the bed; and fastener means for rigidly connecting the panel members in adjacent coplanar relation between the beam members. The beam members can project above the deck surface, inside portions of the beam members forming respective edge barriers of the bed. Each panel member can include a shell member, a pair of rigidly downwardly projecting retainer flange portions extending along respective ones of the end edges, a pair of the retainer flange portions forming the retainer members, and the fastener means including a spaced plurality of beam fastener openings being formed in each of the side edges. The fastener means can include a pair of threaded deck fasteners connecting each beam member to respective side edges of each of the panel members, the beam members projecting above the panel members and spacing the edge deck portions above the deck surface for forming respective edge barriers.
Preferably the bed further includes a socket member having a cylindrical opening therethrough for receiving a fixture yoke shank on a socket axis, the socket member being located proximate an edge of the deck surface, the socket axis being inclined outwardly and upwardly relative to the deck surface. The socket axis can be inclined at an angle φ from being normal to the deck surface, the angle φ being between approximately 20 degrees and approximately 35 degrees. Preferably the angle φ is approximately 24 degrees.
The scaffold assembly can further include a deck extension cantilevered from one of the hangers and abutting the bed. The deck extension can be supported by the channel member of one of the hangers, being tied to the bed by the retainer modules thereof. The scaffold assembly can further include a handrail member connected between the hangers in spaced relation above the bed. Preferably a pair of the column members has respective projections formed thereon for supporting the handrail, the handrail having respective hook members rigidly formed on opposite ends thereof for partially enclosing the columns, a pair slidingly supported latch members for releasably securing the corresponding hook members on the respective column members, and closure members for releasably holding the latch members in closed positions thereof, nose portions of the latch members projecting into respective openings of the hook members in the closed positions for supporting the latch members on opposite sides of the column members, thereby strengthening the connection of the handrail to the column members.
The scaffold assembly can include an auxiliary scaffold hanger connected in depending relation to the bed by extension members that project into a pair of the tubular column members, the auxiliary hanger including an upwardly facing auxiliary channel member connecting a spaced pair of auxiliary column members, the extension members forming upper extremities of the auxiliary column members. The auxiliary hanger is used when vertical offset is desired between adjacent scaffold decks, the connection being effected by fasteners engaging auxiliary fastener openings of the extension members and transverse column fastener openings of the tubular column members. The extension members are preferably formed with vertically spaced counterparts of the auxiliary fastener openings for permitting adjustment of the vertical offset.
In another aspect of the invention, a scaffold assembly includes a pair of frames, each frame comprising a horizontally spaced pair of column members and an upwardly facing channel member rigidly connected horizontally between the column members proximate lower extremities thereof; a pair of retainer modules for each of the frames, each retainer module being slidingly engagable with a respective column member and having a U-shaped body for slidingly guiding and retaining the retainer module on the column member, and a jaw member pivotally connected to the body portion for contacting the column member opposite the body; a clamp element for clamping the column member between the body and the jaw member, a dog portion of the retainer module projecting horizontally outwardly relative to the column member; and a scaffold bed having a deck surface, transversely oriented downwardly projecting retainer members proximate opposite ends of the bed for engaging respective ones of the channel members, and opposite longitudinal edge deck portions being spaced apart sufficiently for engagement by each of the dog portions of the retainer modules for holding the scaffold bed connected between the channel members. The scaffold assembly can further include a pair of ball joints, a wall brace being connected between the ball joints for stabilizing the scaffold assembly relative to an external structure.
In a further aspect of the invention a scaffold deck includes a plurality of rigid rectangular panel members, each panel member having opposite end and side edges, a pair of rigidly downwardly projecting flange portions extending along respective ones of the end edges, the flange portions being formed for projecting into corresponding laterally extending channel members when the deck is supported on the channel members, the flange portions longitudinally retaining the deck relative to the channel members; a parallel-spaced pair of beam members, upper surfaces of the beam members forming respective edge deck portions of the bed; and fastener means for rigidly connecting the panel members in adjacent coplanar relation between the beam members, upper surfaces of the panel members forming a deck surface, the deck surface being offset below the edge deck portions, upper portions of the beam members forming respective edge barriers.
The scaffold deck can further include an accessory socket rigidly supported relative to the panel members, the socket having a cylindrical opening extending therethrough on a socket axis, the socket axis being inclined non-perpendicular to the deck surface. The accessory socket can include a socket flange portion and a sleeve portion, the cylindrical opening extending through the socket flange and sleeve portions, the sleeve portion projecting through a panel member, the socket flange portion engaging adjacent portions of the deck surface and one of the beam members. The socket axis can extend over one of the beam members perpendicular to a longitudinal direction thereof. Preferably the socket flange portion extends above the beam member for clearing outward projections of accessories that might otherwise be caught on the beam member, the flange portion also having a fastener opening against the beam member for permitting the accessory socket to be more securely anchored by fastening to the beam member.
In still another aspect of the invention, a scaffold deck panel includes a rectangular shell member having opposite end and side edges, a generally planar deck wall extending between the end and side edges, a pair of rigidly downwardly projecting flange portions extending along respective ones of the end edges, each of the flange portions being formed for projecting into a corresponding channel member when the deck panel is supported on the channel member with the channel member extending beyond the side edges, the flange portion longitudinally retaining the deck panel relative to the channel member; a resilient pad supported on the deck wall and forming a generally planar deck surface portion; a shear-resistant core member bonded to the deck wall for reinforcing the shell member, the core member extending to proximate the end and side edges; and a socket member projecting through the shell member proximate one of the side edges thereof and having a cylindrical socket opening formed therethrough on a socket axis, the socket axis extending beyond the one side edge above the deck surface. Preferably the socket member is flush with the side edge and projecting approximately 1.5 inches above the deck surface for supporting an accessory engaging the socket member is spaced relation to a beam member when the beam member is located against the side edge.
DRAWINGS
These and other features, aspects, and advantages of the present invention will become better understood with reference to the following description, appended claims, and accompanying drawings, where:
FIG. 1 is a perspective view of a modular scaffold assembly according to the present invention;
FIG. 2 is a fragmentary sectional elevational view of a portion of the assembly of FIG. 1;
FIG. 3 is an elevational view as in FIG. 2, at reduced scale, and showing a lighting fixture supported by the assembly of FIG. 1;
FIG. 4 is a fragmentary sectional elevational view of the assembly of FIG. 1 on line 3--3 of FIG. 2;
FIG. 5 is a perspective view of a handrail portion of the assembly of FIG. 1;
FIG. 6 is a plan view of the handrail portion of FIG. 5;
FIG. 7 is a perspective view showing an alternative configuration of a retainer module portion of the assembly of FIG. 1;
FIG. 8 is a fragmentary elevational view showing another alternative configuration of the assembly of FIG. 1;
FIG. 9 is a fragmentary sectional view of a retainer portion of the assembly of FIG. 8; and
FIG. 10 is a fragmentary elevational view of a wall attachment to the assembly of FIG. 8.
DESCRIPTION
The present invention is directed to modular scaffolding construction that is particularly effective for supporting lighting fixtures, grip and sound equipment in studio environments. With reference to FIGS. 1-4 of the drawings, a scaffold system 10 includes a bed 12 that is supported between a pair of suspended hangers 14, the hangers also supporting handrails 15 as appropriate. Each of the hangers 14 includes a spaced pair of column members 16, an upwardly facing channel member 18 connecting the column members proximate lower extremities thereof for engaging opposite ends of the bed 12 as described below. A top cross member 20 is connected between upper extremities of the column members 16, and a bottom cross member 21 is connected between lower extremities of the column members 16 by respective pairs of gusset plates 22, the connections being made by suitable means such as welding. Thus each of the hangers 14 preferably forms a rigid structure, thereby enhancing stability of the system 10. In addition to stiffening the hanger 14, the bottom cross member 21 also serves as a "boot bar" for supporting the feet of workers erecting the scaffold system 10. In an exemplary and preferred configuration as shown in the drawings, the column members 16 and the top and bottom cross members 20 and 21 are formed of high strength structural aluminum alloy tubing. The channel member 18 and the gusset plates 22 are also formed of suitable high strength aluminum alloys; further, the alloys are selected for weldability, the connections being made by welding.
The hangers 14 also each include a pair of retainer modules 24 that slidably engage respective ones of the column members for securing the bed 12 engaged with the channel members 18, and for other purposes indicated below. Each retainer module 24 includes a collar member 26 that slidably engages the corresponding column member, a face member for optionally securing lumber to stage walls, a dog flange 30 for holding the bed downwardly engaged with a corresponding channel member, and a gusset member 32 for receiving wall brace lumber, the gusset member 32 having a gusset flange 34 projecting horizontally at a bottom extremity thereof for temporarily supporting the wall brace lumber during fastening thereof. A retainer set-screw 36 threadingly engages a boss 37 that forms an enlargement of the collar member 26 for clamping the retainer module with the dog flange 30 fixedly spaced above the channel member 18, thereby preventing the bed 12 from being lifted away from the channel member. Each of the face member 28, the dog flange 30, and the gusset member 32 is formed with a plurality of fastener openings 38 extending therethrough for receiving suitable fasteners thereby to secure the dog flange 30 to the bed 12, and to fasten lumber as desired to the face member and to the gusset member. The retainer module 24 is preferably fabricated of a lightweight high strength alloy such as aluminum for facilitating handling of the hangers 14, and for limiting the required load-carrying capacity of the tension members 41.
In the exemplary configuration of the scaffold hanger 14 as shown in the drawings, a support element 40 is secured to the upper extremity of each of the column members 16, axially projecting therefrom and being formed for receiving a clevis pin or other hardware of a tension member 41 such as a chain or cable. The support element 40 is secured to the column member 16 by a pair of transversely oriented support fasteners 42 that project through the element, opposite walls of the column member 16, and colocated ones of the gusset plates 22. Preferably, counterpart support fastener openings 43 are provided proximate both ends of each column member 16 for receiving further support fasteners 42, thereby permitting a stacked configuration of scaffold hangers 14, optionally using further tension members 41 that extend between the scaffold hangers 14 for obtaining a desired spacing between the hangers 14. Further, each of the column members 16 has one or a spaced plurality of enlargements 44 formed thereon for supporting the handrails 15 as described below. The enlargements 44 are formed, for example, as ring members 45 that are welded onto the column members 16.
As best shown in FIG. 2, the retainer modules 24 are particularly suitable for attaching timbers, such as for lateral wall bracing, as indicated at 46, and longitudinal members, as indicated at 47. The lateral wall bracing can extend horizontally or inclined as shown in FIG. 2.
As further shown in the drawings, the bed 12 is preferably an assembly including a rectangular panel member 50 having opposite side edges 51 and end edges 52, respective retainer flange portions 53 downwardly projecting along the end edges 52 for engagement into corresponding channel members 18 of the hangers 14. The panel member 50 has a substantially planar deck surface 54, a resilient mat 55 being inlaid approximately flush with the deck surface 54 and secured to the panel member 50 by a suitable adhesive. Typically, several panel members 50 are disposed in adjacent coplanar relation end-to-end in the bed 12, a pair of beam members 56 being fastened along respective side edges thereof by pairs of deck fasteners 58 for transmitting loading of the bed 12 to opposite ends thereof. The deck fasteners 58 each project through one beam member 56 and into a panel member 50, each panel member 50 having a longitudinally spaced pair of deck fastener openings 59 formed in each of the side edges 51 thereof.
A preferred configuration of the panel member 50 includes a shell member 60 that incorporates the retainer flange portion 53, a deck panel portion 62 that forms a portion of the deck surface 54, and side flange portions 63 in which the deck fastener openings 59 are located. The shell member 50 can be fabricated as a lightweight reinforced plastic structure, using glass or carbon fibers in epoxy resin, for example. A shear-resistant core element 64 is bonded to the underside of the deck panel portion 62, the core element extending between the retainer flanges 53 and between the side flange portions 63 for efficient load transfer from the deck surface 54 thereto. Further, a bottom panel portion 65 of the shell member 60 is bonded to the underside of the core element 64, the bottom panel portion 65 being integrally formed with the retainer flanges 53 and the side flange portions 63. The core element 64 can be formed of a cellular structure of thin sheet material such as aluminum or stiff paper, such being commercially available from a variety of sources.
A particularly convenient and effective implementation of the panel members 50 has a deck width D between the side edges 51 being approximately 39 inches and a panel length l between the end edges 52 being approximately 24 inches. Thus the bed 12 has a length L between the hangers 14 (center to center) being a multiple of the panel length l. Typically, the bed 12 includes five of the panel members 50 as shown in FIG. 1, the length L being approximately 10 feet. As further shown in FIG. 4, the retainer flange portions 53 at opposite ends of the bed 12 can extend downwardly fully to the bottom inside surface of the channel members 18 for support thereby. Also, end portions of the beam members 56 can be formed for resting on top of respective ones of the channel members 18. Thus the support of each end of the bed 12 by the corresponding channel member 18 can be through one or both of the retainer flanges 53 and end portions of the beam members 56. Preferably, upper surfaces beam members 56 form respective edge deck portions 66 that are raised above the panel members 50 by a distance B, inside edges of the beam members above the deck surface 55 forming respective edge barriers 68 for safely confining objects within the deck surface 55.
An optional yet important feature of the present invention is that the bed 12 is provided with a spaced plurality of inclined socket members 70 for receiving respective yoke stems 71 of fixtures such as lighting fixtures 72 as shown in FIG. 3. The inclination of the socket members 70 facilitates placement of fixture heads 73 laterally outside of the column members 16 and handrails 15 that may extend therebetween. Thus the handrails 15 do not interfere with light transmission from the fixture heads 73 to stage sets being illuminated thereby. Further, the socket members 70 support the fixtures 72 out of the way of grip personnel that may be on the deck surface 54. More particularly, the socket members 70 are preferably located proximate the beam members 56, each having a cylindrical opening 74 therethrough on a socket axis 75, the socket axis 75 being inclined outwardly at a socket angle φ relative to the side edge 51 as shown in FIG. 2. Typically, the socket axis 75 is normal to the deck surface 54 in a direction parallel to the beam members 56 as shown in FIG. 4. However, it is contemplated within the present invention that the axis 75 can be inclined both laterally and longitudinally, or longitudinally alone, relative to the scaffold bed 12. As further shown in the drawings, the socket member 70 has a sleeve portion 76 that extends through the panel member 50, and a flange portion 77 that abuts the deck surface 54 and the edge barrier 68 (at the intersection of the deck panel portion 62 and the beam member 56). The socket member 70 is anchored in place by a pair of socket fasteners 78 that threadingly engage the corresponding beam member. A fixture set screw 79 threadingly engages the flange portion 77 for fixably clamping the yoke stem 71. Preferably, the flange portion 77, being flush with the side edge 51, extends thereat a distance C above the beam member 56 sufficiently to insure that portions of the fixture 72 that might project outwardly from the yoke stem 71 do not jam against the beam member 56 when the fixture 72 is being adjusted. The distance C is preferably at least 0.25 inch, more preferably approximately 0.5 inch. Thus, the distance B being typically approximately 1.0 inch, the total of the distances B and C is approximately 1.5 inch.
The scaffold system 10 preferably includes a suitable combination of the handrails 15 being selectably connectable between the column members 16 of the hangers 14 as indicated above. As best shown in FIGS. 5 and 6, each handrail 15 includes a tubular rail member 80 having a hook member 82 rigidly connected to each end thereof for partially enclosing one of the column members 16, and a pair of latch members 84, each latch member projecting through a portion of the corresponding hook member, being movably supported between respective open and closed positions, the open position (depicted by solid lines in FIG. 5) permitting entry of the column member 16 into engagement with the corresponding hook member, the closed position (broken lines in FIG. 5) being effective for locking the hook member 82 onto the column member 16. More particularly, the hook member 82 extends into the rail member 80, being fastened thereto by a pair of rail fasteners 85, which can be drive screws. The latch member 84 is formed of an elongate bar, one end thereof being formed as a handle portion 86 that substantially encircles the rail member 80, one of the fasteners 85 blocking movement of the latch member beyond the closed position. An additional one of the fasteners 85 is located for blocking movement of the latch member 84 beyond the open position, the latch member slidingly engaging the hook member 82 and/or the rail member 80. A nose portion 87 of the latch member 84 extends in the closed position into an opening 88 that is formed proximate an end extremity of the hook member 82 for positively supporting the latch member on opposite sides of the column member 16, thereby securing the handrail 15 on the column member 16. The latch member 84 is provided with a device such as a spring ball 89 as a detent for yieldably maintaining the closed position. It will be understood that the latch member 84 can alternatively be provided with a spring for biasingly maintaining the closed position. As indicated above, the handrails 15 rest on selected ones of the ring members 45 that are vertically spaced on the column members 16. Optionally, one or more auxiliary column members 16' can be located between the hangers 14 for supporting different lengths of the handrails 15. As shown in FIG. 1, an auxiliary column member 16' includes a tubular post 90 having a C-shaped foot member 91 for engaging one of the beam members 56, a ring member 45, and counterparts of the hook member 82, the latch member 84, and the fastener 86 at an upper extremity thereof for engaging a handrail 15 that extends between the hangers 14. Thus the handrails 15 are supplied in various lengths, for connection between the column members 16 of one hanger 14, between the hangers 14, and between a hanger 14 and the auxiliary column member 16'.
Optionally, the scaffold system 10 includes a crossover unit 92 for supporting planks that bridge between assemblies of the system. As best shown in FIG. 3, the crossover unit 92 includes a solid member 93 that is formed of a material such as wood being suitable for receiving and holding nails, and a pair of angle members 94 fastened thereto in spaced relation for engaging opposite sides of one flange of the channel member 18, the member 93 abutting one end of the bed 12. The solid member 93 has a depth for forming flush extensions of the deck edge portions 66 at opposite ends of the member 93 as indicated at 95, a main center portion 96 being of reduced depth for forming a flush extension of the deck surface 54.
With further reference to FIG. 7, an alternative configuration of the retainer module, designated 24', includes counterparts of the gusset plates, designated 32', connected by a pair of collar straps 98 to a rectangularly formed face strap 100, the face strap forming a counterpart of the face member 28 of FIGS. 1-4. A counterpart of the retainer boss, designated 37' is fixed (by welding) to the top of the face strap 100, and a counterpart of the dog flange, designated 30', is welded to the bottom of the face strap 100.
With further reference to FIGS. 8-10, another alternative configuration of the scaffold system 10 includes a base 110 having counterparts of the column members, designated 16", and the channel member 18. The base 110 corresponds to the hanger 14, but without the top cross member 20. Optionally, the base 110 includes the bottom cross member 21, omission thereof being appropriate when the base 110 is intended to be placed on supporting structure as an alternative to being suspended by the tension members 41. Thus the column members 16" can be shorter than the column members 16 of FIGS. 1-4, in that head clearance under top cross members 20 is not required. When the bottom cross member 21 is omitted, the gusset plates 22 can be inverted. As further shown in FIG. 8, a pair of extension members 111 form upper portions of the column members 16", being of reduced diameter for fitting into the column members 16 of another hanger 14. The extension members 111 have vertically spaced counterparts of the support fastener openings 43 formed therein for alignment with corresponding openings 43 of the hanger 14, the base 110 being thus adjustably supportable in depending relation to the hanger 14 as an auxiliary hanger, using counterparts of the support fasteners 42. Thus one end of another bed 12 can be supported in vertically offset relation to the bed 12 in the scaffold system 10 of the present invention. The extension members 111 can be separate cylindrical tubes that fit within the column members 16", being fastened thereto by further counterparts of the support fasteners 42 that extend also through the gusset plates 22.
As also shown in FIGS. 8-10, respective dog clamp assemblies 112 can be used in place of the retainer modules 24, each clamp assembly including a U-shaped body 114 having a jaw member 116 pivotally connected thereto, a preferably captive clamp screw 118 extending through the jaw member for threaded engagement with the body 114, thereby providing clamped engagement with the associated column member 16" (or 16). The jaw member 116 thus provides a counter part of the dog flange 30 for retaining the bed 12 engaged with the channel member 18 as described above. As best shown in FIG. 9, a ball joint 120 can be attached to the clamp assembly 112 for receiving a wall brace 122, the ball joint 120 including a ball member 121 and a retainer block 123 that is rigidly connected to the body 114 by threaded fasteners 124, a stem portion 125 of the ball member projecting through the block 123 and threadingly engaging a tube fitting 126 of the wall brace 122. Thus the ball joint 120 replaces the gusset members 32 of the retainer module 24. The retainer block 123 is formed for permitting pivotal movement of the ball member 121, the ball member being captured between the block 123 and the body 114.
The tube fitting 126 is formed for axially engaging a brace tube 128 of the wall brace 122, being affixed thereto by a pair of the rail fasteners 85. Counterparts of the brace tube 128 and the tube fitting 126 are adjustably clamped in close proximity and opposing end to end relation by a pair of tube clamps 129, the counterpart tube fitting 126 forming an opposite end of the wall brace 122. As shown in FIG. 10, the opposite end of the wall brace 122 is attached by a counterpart of the ball joint 120 to a wall bracket 130 that can be anchored to a timber wall plate or other stationary structural member. The tube clamps 129 include pivotally connected jaws 134 that are doubly contoured correspondingly with the body 114 and jaw member 116 of the dog clamp assembly, for receiving the brace tubes 128 in side-by-side relationship, clamping being effected by an enlarged counterpart of the clamp screw, designated 118'.
Although the present invention has been described in considerable detail with reference to certain preferred versions thereof, other versions are possible. For example, the panel members 50 can be provided in different lengths such as multiples of a base panel length, and when the bed 12 has a single panel member only, the beam members can be integrally formed with the panel member. Also, panel members can be pie-shaped for forming deck intersections at 45°, 22.50, or other angles. Therefore, the spirit and scope of the appended claims should not necessarily be limited to the description of the preferred versions contained herein.
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A scaffold system in which a scaffold bed is suspended between a pair of channel members. The channel members are horizontally disposed in respective frames that include a spaced pair of column members. The bed is modular and provides a deck surface that is formed by a plurality of panel members that are joined by a pair of beam members. The panel members have retainer flanges at opposite ends thereof, the end most retainer flanges of the bed engaging respective ones of the channel members. Each of the column members is provided with a retainer for holding the bed engaged with the channel members. Handrails are selectively connectable between the column members in elevated relation to the deck surface. The retainers are adopted for connecting wall braces for laterally stabilizing the system. The frames can rest on stationary supports, or they can be configured as hangers for suspension by tension members.
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CROSS REFERENCE TO RELATED APPLICATION
The present application claims priority from U.S. Provisional Patent Application Ser. No. 60/648,013, filed Jan. 27, 2005.
TECHNICAL FIELD
The invention relates to thin films, methods of making the films, and structures including the films.
BACKGROUND
A variety of structures can have their native surfaces modified to provide desired effect. For example, visual displays, such as computer monitors and touchscreens, may be treated with an antireflective layer of oxide to reduce glare and reflection. Medical devices, such as orthopedic implants, may be coated with an osteoconductive layer that promotes bone growth to the implant and integration of the implant into the body. Certain devices can be passivated or be made more hydrophilic or hydrophobic, to protect the devices from ill effects (such as corrosion, wear, or water permeation) caused by the environment in which the devices are used. Surface modifications of substrates are described, for example, in U.S. Pat. No. 6,146,767; U.S. Pat. No. 6,645,644; US 2004/0001959; US 2004/0023048; and PCT/US/2003/034909, all hereby incorporated by reference.
SUMMARY
The invention relates to structures comprising an organic substrate, preferably, a substrate capable of accepting a proton from an organophosphorous compound and a film of the organophosphorous compound bonded to the substrate, the film being characterized such that the organic groups associated with the organophosphorous compound are exposed to the atmosphere and preferably are oriented away from the substrate.
Embodiments may include one or more of the following features. The organophosphorous compound is an organophosphorous acid or derivative thereof such as an organophosphonic acid. The substrate includes oxygen. The substrate includes a hydroxyl group, an oxo group, and/or a carboxyl group. The substrate includes a nitrogen-hydrogen bond. The substrate is a polymer such as a polycarbonate, an epoxy resin or a resin derived from an epoxy resin. The substrate may be flexible, such as a film or rigid such as a structural plastic. The organophosphorous acid or derivative thereof includes an aliphatic group or an olefinic group. The acid includes an aryl-substitute group. The film can be a monolayer or a multilayer structure. The film may have a contact angle equal to or greater than about 75°.
In another aspect, the invention features a structure in which the organophosphorous compound is chemically bonded to the substrate by phosphorus-oxygen bonds.
Other aspects, features and advantages will be apparent from the description of the embodiments and from the claims.
DESCRIPTION OF DRAWING
FIG. 1A illustrates a method of making a thin film; and FIG. 1B is a detailed view of a substrate having a thin film.
FIG. 2 is a schematic diagram showing a mechanism of thin film formation.
DETAILED DESCRIPTION
Referring to FIGS. 1A and 1B , a method 20 of making a thin film is shown. As shown, method 20 includes applying a solution 22 containing an organophosphorous compound to a surface of a substrate 24 to form a layer of the solution. The organophosphorous compound (such as an aliphatic phosphonic acid) includes an organic component (such as an aliphatic chain) and an acidic functional group (such as phosphonic acid). Subsequently, the layer of solution 22 is treated (e.g., cured) by exposing the solution to heat and/or electromagnetic radiation to form an adherent thin film 26 (for example, a monolayer) on substrate 24 ( FIG. 1B ). Thin film 26 includes a plurality of organic components from the organic acid chemically bonded directly to substrate 24 , for example, via a phosphorus-oxygen bond.
The thin film can be used to modify the surface properties of substrate 24 . For example, solution 22 can include a material (such as an aliphatic phosphonic acid) adapted to bond with substrate 24 . In this example, when the acid group of the material bonds with the substrate, the aliphatic group preferably extends away from the surface of the substrate, thereby enhancing the hydrophobicity the surface. The enhanced hydrophobicity can increase the substrate's resistance to water, fogging, and smudging. The modified substrate can also have altered interactions with other materials or interfaces. For example, the organic components can make the surface of the substrate more non-stick and/or more lubricious, which can be beneficial for certain applications. Certain organic components can also enhance the non-fouling characteristics of a surface so that cells (e.g., from bacteria, scar tissue, mildew, mold, and other unwanted organisms) do not adhere well to the treated surface.
Examples of organophosphorous acid or derivative thereof are organophosphoric acids, organophosphonic acids and/or organophosphinic acids including derivatives thereof. Examples of derivatives are materials that perform similarly as the acid precursors such as acid salts, acid esters and acid complexes. The organo group of the phosphorous acid may be a monomeric, oligomeric or polymeric group. Examples of monomeric phosphorous acids are phosphoric acids, phosphonic acids and phosphinic acids including derivatives thereof.
Examples of monomeric phosphoric acids are compounds or a mixture of compounds having the following structure:
(RO) x P(O)(OR′)
wherein x is 1-2, y is 1-2 and x+y=3, R is a radical having a total of 1-30, preferably 6-18 carbons, where R′ is H, a metal such as an alkali metal, for example, sodium or potassium or lower alkyl having 1 to 4 carbons, such as methyl or ethyl. Preferably, a portion of R′ is H. The organic component of the phosphoric acid (R) can be aliphatic (e.g., alkyl having 2-20, preferably 6-18 carbon atoms) including an unsaturated carbon chain (e.g., an olefin), or can be aryl or aryl-substituted moiety.
Example of monomeric phosphonic acids are compounds or mixture of compounds having the formula:
wherein x is 0-1, y is 1, z is 1-2 and x+y+z is 3. R and R″ are each independently a radical having a total of 1-30, preferably 6-18 carbons. R′ is H, a metal, such as an alkali metal, for example, sodium or potassium or lower alkyl having 1-4 carbons such as methyl or ethyl. Preferably at least a portion of R′ is H. The organic component of the phosphonic acid (R and R″) can be aliphatic (e.g., alkyl having 2-20, preferably 6-18 carbon atoms) including an unsaturated carbon chain (e.g., an olefin), or can be an aryl or aryl-substituted moiety.
Example of monomeric phosphinic acids are compounds or mixture of compounds having the formula:
wherein x is 0-2, y is 0-2, z is 1 and x+y+z is 3. R and R″ are each independently radicals having a total of 1-30, preferably 6-18 carbons. R′ is H, a metal, such as an alkali metal, for example, sodium or potassium or lower alkyl having 1-4 carbons, such as methyl or ethyl. Preferably a portion of R′ is H. The organic component of the phosphinic acid (R, R″) can be aliphatic (e.g., alkyl having 2-20, preferably 6-18 carbon atoms) including an unsaturated carbon chain (e.g., an olefin), or can be an aryl or aryl-substituted moiety.
Examples of organo groups which may comprise R and R″ include long and short chain aliphatic hydrocarbons, aromatic hydrocarbons and substituted aliphatic hydrocarbons and substituted aromatic hydrocarbons. Examples of substituents include carboxyl such as carboxylic acid, hydroxyl, amino, imino, amido, thio, cyano, fluoro such as CF 3 (C n F 2n )CH 2 CH 2 PO 3 H 2 where n=3-15, CF 3 (CF 2 ) n O(CF 2 CF 2 ) y —CH 2 CH 2 —PO 3 H 2 where x is 0 to 7, y is 1 to 20 and x+y≦27, phosphonate, phosphinate, sulfonate, carbonate and mixed substituents.
Representative of the organophosphorous acids are as follows: amino trismethylene phosphonic acid, aminobenzylphosphonic acid, 3-amino propyl phosphonic acid, O-aminophenyl phosphonic acid, 4-methoxyphenyl phosphonic acid, aminophenylphosphonic acid, aminophosphonobutyric acid, aminopropylphosphonic acid, benzhydrylphosphonic acid, benzylphosphonic acid, butylphosphonic acid, carboxyethylphosphonic acid, diphenylphosphinic acid, dodecylphosphonic acid, ethylidenediphosphonic acid, heptadecylphosphonic acid, methylbenzylphosphonic acid, naphthylmethylphosphonic acid, octadecylphosphonic acid, octylphosphonic acid, pentylphosphonic acid, phenylphosphinic acid, phenylphosphonic acid, bis-(perfluoroheptyl) phosphinic acid, perfluorohexyl phosphonic acid, styrene phosphonic acid, dodecyl bis-1,12-phosphonic acid.
In addition to the monomeric organophosphorous acids, oligomeric or polymeric organophosphorous acids resulting from self-condensation of the respective monomeric acids may be used.
Solution 22 can further include a suitable solvent for the organophosphorous compound, such as an alcohol (e.g., ethanol), tetrahydrofuran, dichloromethane, 2:1 by volume ethanol:toluene, and acetonitrile. The concentration of the organophosphorous compound can range from about 0.1 micromolar to as high as the upper limit of the solubility of the organophosphorous compound in a specific solvent, for example, from about 0.1 micromolar to about 100 micromolar, from about 0.1 micromolar to about 10.0 millimolar, for example, about 1.0 millimolar.
Substrate 24 is comprised of an organic material and may include a composite having an organic component and an inorganic component. The substrate 24 , preferably, is capable of accepting protons from the organophosphorous compound such as an organophosphorous acid to chemically bond with the organic component of the organophosphorous compound. Substrate 24 can include one or more functional groups that are reactive (will form a chemical bond) with the organophosphorous compound applied to the substrate. In some embodiments, the surface of substrate 24 to be treated with the organophosphorous compound includes hydroxyl groups, oxo groups (for example, carboxylate groups, carboxylate anions, or μ-oxo groups), amide groups, and/or amine groups. In some embodiments, substrate 24 includes oxygen. Examples of organic substrates include polymers, such as epoxy resins, resins derived from epoxy resins, cured or uncured epoxies (such as UV curable epoxy resins, e.g., SU-8, or a mixture of organoepoxide and an organic amine), polyvinyl alcohol, nylon, and polycarbonates. An example of a composite substrate is wood coated with a polymer derived from an epoxy resin. The substrate can be flexible such as a free film or can be rigid such as a structural plastic.
Solution 22 can be applied to substrate 24 using one or more techniques, and allowing the solution to evaporate. For example, solution 22 can sprayed (e.g., a few microgram per square centimeter) onto, dropped on, and/or painted on substrate 24 . Substrate 24 can be dipped into solution 22 . Solution 22 can be applied using an elongated instrument capable of applying the solution across the surface of substrate 24 to form a uniform layer of the solution. Examples of elongated instruments include Mayer rods (which are rods with wires helically wrapped around the rods), wiping blades or blocks (e.g., Teflon blades or blocks), a doctor blade, a reverse roll, a die coater, a wire bar, a knife, and a blade coaters. Direct gravure, micro gravure and reverse gravure techniques can also be used. For Mayer rods, the size of the rods (or gauge of the wire on the rods) can be selected to control the amount of the solution that is applied on substrate 24 . Mayer rod sizes of M0, #3, #5, or #10 can be used. In some embodiments, about 0.02 ml/cm 2 of solution is applied. Solution 22 can be applied to substrate 24 by drawing the elongated instrument across the surface of the substrate. Other methods of applying solution 22 to substrate 24 are described in US 2004/0023048 and PCT/US/2003/034909, both hereby incorporated by reference. Application of solution 22 may deposit one or multiple layers of the acid, and the amount of acid deposited can be determined by infrared analysis. In some embodiments, when multiple layers are deposited, rinsing the applied layers can decrease the layers to one monolayer.
After solution 22 is applied to substrate 24 and the solvent is allowed to evaporate, the applied layer on the substrate is treated to enhance bonding directly to the substrate. The applied layer can be treated with heat and/or electromagnetic radiation, such as microwave radiation (e.g., 2450 MHz or a wavelength of about 12 cm). In some embodiments, the applied layer is exposed to radiant and/or induction heating, for example, to a temperature of 50° C. to about 200° C. (e.g., about 150° C.) for about 30-120 seconds. The heating time may be a function of the temperature used, and the temperature used may be restricted by design considerations and/or materials limitations, such as the melting point of the substrate. Heat can also be applied by pressing a standard clothes iron (e.g., set at the highest setting) back and forth over the applied layer for 30-60 seconds, or by using a heat gun, convection oven, or a heat plate. Alternatively or additionally, the applied layer can be applied to microwave radiation (e.g., in a 700 Watt microwave oven) for about 30 seconds to about 120 seconds. After the heat treatment, the substrate and film can be rinsed with a solvent, such as ethanol and toluene.
Without wishing to be bound by theory, it is believed that treatment of the applied layer of an organophosphorous acid causes a dehydration reaction that forms a bond between the organic components of the applied acid and substrate 24 . Referring to FIG. 2 , which shows application of an aliphatic phosphonic acid to a surface including hydroxyl groups, application of the acid results in proton transfer from the acid to the surface. Next, water is eliminated, and the phosphonate is bonded to the surface via a first phosphorus-oxygen bond. Another proton is transferred from the acid to the surface, water is eliminated, and the phosphonate is further bonded to the surface via a second phosphorus-oxygen bond.
The treated film is well adhered to the substrate and, as described above, is capable of altering the surface chemistry of the substrate. The thin film is resistant to mechanical removal (e.g., the film does not delaminate after 100 wipes with a cellulose tissue paper (e.g., a Kimwipe), or solvent rinsing (e.g., sonication and/or heating in ethanol, tetrahydrofuran, or acetonitrile). As another indication of the properties of the treated film, an ink mark (e.g., from a Sharpie marker) can be applied to the film, and the ink mark can be wiped with a Kimwipe or similar cloth or tissue to remove the mark. For very hydrophobic surfaces, the mark can be removed with a few low force wipes. For hydrophilic surfaces, the mark can be difficult to remove, even with many wipes and using high forces. Another test to determine the adhesion of the thin film is a tape test in which a piece of Scotch tape is pressed onto the film, and the tape is removed. The steps of pressing and removing the tape can be repeated a few time, and any changes in the water contact angle can be observed. No changes in the water contact angle may suggest that the thin film is well bonded to the substrate.
In some embodiments, a hydrophobic thin film has a high water contact angle, such as from about 75 degrees to about 130 degrees. The contact angle can be greater than or equal to about 75°, about 80°, about 90°, about 100°, about 110°, or about 120°, and/or less than or equal to about 130°, about 120°, about 110°, about 100°, about 90°, or about 80°. The contact angle is determined using a contact angle goniometer, such as a TANTEC Contact Angle Meter, Model: CAM-Micro.
While a number of embodiments have been described, the invention is not so limited. For example, in other embodiments, multiple applications of solution 22 and subsequent bonding treatments can be performed to form a desired thin film.
The methods and materials described herein can be applied to a number of structures and devices, as discussed above. As one example, certain inkjet cartridges are packaged with a piece of tape adhered to a portion of the cartridge. The tape, which is removed prior to using the cartridge, blocks one or more openings or nozzles on the cartridges through which ink is delivered, for example, to prevent dust or other contamination from entering the cartridge. The surface of the cartridge defining the nozzles may include a polymer derived from an epoxy resin, such as SU-8. In some cases, removing the tape may damage the nozzle because the tape is too strongly adhered to the cartridge. By forming a thin film as described herein on the cartridge (e.g., by applying octadecylphosphonic acid to the polymer surface), the adherence of the tape to the cartridge can be reduced. As a result, the tape can be removed without damaging the nozzles.
The following example is illustrative and not intended to be limiting.
EXAMPLE
A one millimolar solution of octadecylphosphonic acid (in a solvent of ethanol, methanol, or isopropyl alcohol) is sprayed on the surface of the SU-8 substrate. The solvent is allowed to evaporate from the surface and the mask is removed. A standard household iron at ˜150° C. is held in contact with the treated surface for about 30 seconds.
The substrate is cooled. The entire surface is then cleaned with ethanol and a tissue.
Other embodiments are within the claims.
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Structures comprising substrates comprised of an organic material capable of accepting a proton from an organophosphorous compound and a film of the organophosphorous compound bonded to the substrate are disclosed. The structures are useful in a variety of applications such as visual display devices.
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BACKGROUND OF THE INVENTION
[0001] Machines incorporating intermeshing rotors have been described. See Chomyszak U.S. Pat. No. 5,233,954, issued Aug. 10, 1993 and Tomcyzk, U.S. patent application Publication 2003/0111040, published Jun. 19, 2003. The contents of the patent and publication are incorporated herein by reference in their entirety. In order for intersecting vane machines to function as compressors or expanders, chambers holding gas must be sealed. Sealing such machines has proven to be difficult. Vane seals often break or wear at an undesirable rate. Thus, a need exists to improve sealing intersecting vane machines.
SUMMARY OF THE INVENTION
[0002] Accordingly, it is an object of this invention to provide an intersecting vane machine, such as a toroidal intersecting vane machine, incorporating intersecting rotors to form primary and secondary chambers whose porting configurations minimize friction and maximize efficiency. Specifically, it is an object of the invention to provide a toroidal intersecting vane machine that greatly reduces the frictional losses through the meshing surfaces without the need for external gearing by modifying the function of one or the other of the rotors from that of “fluid moving” to that of “valving” thereby reducing the pressure loads and associated inefficiencies at the interface of the meshing surfaces. The inventions described herein relate to these improvements.
BRIEF DESCRIPTION OF THE DRAWINGS
[0003] The foregoing and other objects, features and advantages of the invention will be apparent from the following more particular description of preferred embodiments of the invention, as illustrated in the accompanying drawings in which like reference characters refer to the same parts throughout the different views. The drawings are not necessarily to scale, emphasis instead being placed upon illustrating the principles of the invention.
[0004] FIG. 1 shows a schematic of the prior art invention wherein the tracks of the first rotor and second rotor are substantially constant in their widths.
[0005] FIG. 2A shows a schematic of an embodiment of a compressor of the present invention wherein one track is wider at the point of intersection.
[0006] FIG. 2B shows a schematic of an embodiment of an expander of the present invention wherein one track is wider at the point of intersection.
[0007] FIG. 2C shows a schematic of an embodiment of a compressor/expander of the present invention wherein selected tracks are wider at the point of intersection.
DETAILED DESCRIPTION OF THE INVENTION
[0008] The invention provides a substantially improved intersecting vane machine, such as a toroidal intersecting vane machine, herein disclosed. The invention has two or more rotors rotatably mounted within a supporting structure so that the vanes of each of the rotors pass through a common region or intersection. Between the vanes of each primary rotor exists chambers which contain and exchange a working fluid. Changes in volume of the chambers are made possible by the interaction of the vanes. Because the rotors and their vanes continuously rotate, they create a cyclic positive displacement pumping action which enables the processing of a working fluid. If heat is added to the process then the machine can be used as an engine. If heat is removed from the process then the machine can be used as a refrigeration device.
[0009] Toroidal geometry, on which this invention and its following embodiments are preferably based, provides a very flexible design platform. Not only does it allow for a very compact mechanical package but provides numerous attributes which can be adjusted so as to optimize the pumping action and benefit the thermodynamic cycles which the invention may utilize. A key feature of this invention is its ability to allow configurable volumetric ratios between the initial and final volume of its working fluid with less frictional losses.
[0010] FIG. 1 shows a schematic of a prior invention wherein both the first and second rotor possess uniform width of track. Secondary vanes 120 intersect with primary vanes 122 ; secondary chamber 202 is in fluid communication with an outlet port 232 ; primary chamber 208 is in fluid communication with an inlet port 240 . This machine had the disadvantage of maintaining frictional losses during the entire cycle, not just when the chamber was under pressure. The frictional losses not only resulted in decreased efficiency for the machine, but also unnecessary wear on the seals.
[0011] FIG. 2A shows a schematic of a compressor embodiment of the present invention. The widths of track 302 are wider at and proximal to the points of intersection (or those lengths of track where sealing is not desired) than the widths of the track 304 where the chamber is to be sealed. This configuration reduces frictional losses and increases the life of the seal. Further preferred embodiments illustrated in this figure include selective porting of the primary chamber, thereby eliminating selected ports. That is, compressor inlet port 242 is in fluid communication with primary chamber 208 . Compressor outlet port 240 exhausts the compressed fluid. Secondary chamber 202 is not pressurized in this embodiment. Secondary vanes 120 intermesh with the primary vanes 122 .
[0012] FIG. 2B shows a schematic of an expander embodiment of the present invention. The widths of track 302 are wider at and proximal to the points of intersection (or those lengths of track where sealing is not desired) than the widths of the track 304 where the chamber is to be sealed. This configuration also reduces frictional losses and increases the life of the seal. Further preferred embodiments illustrated in this figure include selective porting of the primary chamber, thereby eliminating selected ports. That is, expander inlet port 252 is in fluid communication with primary chamber 208 . Expander outlet port 250 exhausts the compressed fluid. Secondary chamber 202 is not pressurized in this embodiment. Secondary vanes 120 intermesh with the primary vanes 122 .
[0013] FIG. 2C depicts a combination of the compressor and expanders depicted in FIG. 2A and 2B . The numbering convention of the previous figures has been preserved.
[0014] The vanes of the rotors only need to maintain a seal during the compression and expansion phases. Because these phases occur in a relatively short time and within a small amount of actual rotor rotation, the friction due to sealing can be greatly reduced.
[0015] The invention relates to an intersecting vane machine, preferably a toroidal intersecting vane machine, which comprises a supporting structure, a first rotor and at least one intersecting second rotor rotatably mounted, wherein:
(a) said first rotor has a plurality of first vanes positioned on a radial surface of said first rotor, with spaces between said first vanes and said surface defining a plurality of primary chambers, which said first vanes and said primary chambers travel in a primary track; (b) said second rotor has a plurality of secondary vanes positioned on a radial surface of said second rotor, with spaces between said secondary vanes and said surface defining a plurality of secondary chambers, which said secondary vanes and said secondary chambers travel in a secondary track; (c) one or more intake ports which each permit flow of a fluid into a primary chamber or secondary chamber and one or more exhaust ports which each permit flow of a fluid out of said primary or secondary chamber; and (d) wherein a first width of said primary track and/or said secondary track at each point of intersection is greater than a second width of said track between each point of intersection, thereby permitting sealing between the vanes and said track at said second width but not at said first width.
[0020] In another embodiment, the invention relates to an intersecting vane machine, which comprises a supporting structure having an inside surface, a first rotor and at least one intersecting second rotor rotatably mounted in said supporting structure, wherein:
(a) said first rotor has a plurality of first vanes positioned on a radially inner peripheral surface of said first rotor, with spaces between said first vanes and said surface defining a plurality of primary chambers, which said first vanes and said primary chambers travel in a primary track and wherein said vanes have a seal; (b) an intake port which permits flow of a fluid into said primary chamber and an exhaust port which permits exhaust of the fluid out of said primary chamber; (c) said second rotor has a plurality of secondary vanes positioned on a radially outer peripheral surface of said second rotor, with spaces between said secondary vanes and said surface defining a plurality of secondary chambers, which said secondary vanes and said secondary chambers travel in a secondary track; (d) a first axis of rotation of said first rotor and a second axis of rotation of said second rotor arranged so that said axes of rotation do not intersect, said first rotor, second rotor, first vanes and secondary vanes being arranged so that said first vanes and said secondary vanes intersect at only one location during their rotation; and (e) wherein a first width of said primary track at a point proximal to the point of intersection is greater than a second width of said primary track between each point of intersection and the primary chamber, thereby permitting sealing between said primary vanes and said primary track at said second width but not at said first width.
[0026] Where both tracks are to be used to compress or expand fluid, the track configuration of the invention can be used in both tracks and both sets of vanes can have seals. The seal can be disposed within the vane, on the vane or in the track. The seal can be one seal which is in contact with all surfaces of the track or two or three or more seals which are independently in contact with the surfaces, or walls, of the track. The seals should be disposed such that they provide a seal when in contact with the narrower lengths of the track.
[0027] Where only one of the tracks is to be used to compress or expand fluid, the track configuration need be only along the track that is to compress or expand the fluid. Thus, where the primary track compresses or expands the fluid, then the width of said secondary track can be substantially the same along the length of said secondary track. The secondary track need not be sealed at all. Thus, seals can be avoided for the secondary vanes. Of course, the opposite configuration is also possible, whereby the secondary vanes have the seal and the secondary track has the track configuration of the invention.
[0028] The difference in the width of said primary track along the length of said track is not necessarily critical. Generally, it will differ between about 2% and 10%.
[0029] The widths of the tracks are defined by sidewalls. Generally, the sidewalls will be substantially perpendicular to the peripheral surface. The walls can be manufactured from a single material, such as a molded plastic or a metal. The walls can be a single piece of material or, for example, interlocking separate materials. The change in width is preferably accomplished by a gradual change to reduce the shear forces upon the seal during engagement. This can be accomplished, for example, by presenting the wall in a convex curve, relative to the inside of the track. Alternatively, the wall can present an obtuse angle. Often, the angle, including the tangential angle in the case of a curve, will be greater than 90°, preferably greater than 100°, such as about 135°.
[0030] In one embodiment, the machine can be self-synchronized via a leading meshing surface of a vane of one rotor driving the trailing meshing surface of a vane of another rotor or abutment, with the spacing of the vanes such that they are geometrically synchronized, thereby eliminating the use of an external gear train. For example, the leading surfaces of at least two consecutive primary vanes are in contact with the trailing surfaces of at least two consecutive secondary vanes. The embodiment relies upon the inherent design of the intersecting vane mechanism to provide related duties.
[0031] The advantage of self-synchronization is that the extra apparatus needed for external gearing can be eliminated with a savings in complexity and cost. The advantage of external gearing is that the driving loads between rotors are transmitted through the gears as opposed to the meshing surfaces of the vanes. In Applicants' work with a self-synchronized toroidal intersecting vane machine that was configured as an integral compressor and expander, testing showed that the frictional losses experienced via the meshing surfaces were a significant source of inefficiency but that the addition of external gearing to alleviate this problem was prohibitively complex and expensive.
[0032] The machine can have a wide range of gear ratios. In one embodiment, the second rotors have a number of said secondary vanes equal to (1/GEAR RATIO) X (number of said primary vanes on said first rotor) where GEAR RATIO equals revolutions of each of said second rotors per revolution of said first rotor. Preferably, the gear ratio is at least 1:1, preferably at least 1.5:1.
[0033] Further, the machine can accommodate a large range of fluid flow rates and/or rotational speeds for each rotor. Of course, the fluid flow rate will be dependent upon the volume of each chamber and the rotational speed of the rotors. For example, the fluid flow rate can be greater than 0.005 cubic feet per minute (CFM), such as at least about 30 CFM, preferably at least about 250 CFM, or at least about 1000 CFM. Generally, the fluid flow rate will be less than 5 million CFM. The rotational speed of the rotors can also be varied widely. For example, the first rotor can rotate at a rate of less than 1 rotation per minute (RPM). However, it will generally rotate at much higher speeds, such as at least about 500 RPMs, preferably at least about 1000 RPMs, more preferably at least about 1500 RPMs. Similarly, the second rotors can rotate at a rate of less than 1 rotation per minute (RPM). However, it will generally rotate at much higher speeds, such as at least about 500 RPMs, preferably at least about 1000 RPMs, more preferably at least about 2000 RPMs.
[0034] In one embodiment, the total flow rate of fluid through the primary chambers can be at least 250 cubic feet per minute with a primary speed of said first rotor of at least 1700 rotations per minute. In one embodiment, the speed of said second rotors can be at least 3000 rotations per minute. In this preferred configuration, the ratio of the width of said secondary vanes to the width of said primary vanes can be less than 1:1, preferably less than 0.5:1. The primary chamber volume can be at least about 0.75 cubic inches, and/or the secondary chamber volume can be less than about 0.5 cubic inches.
[0035] In another embodiment, the porting configuration is reversed, as compared to the above. Thus, the secondary chambers are ported, allowing pressurization of the secondary chambers, and the primary chambers are not ported and are not pressurized. Porting of the chambers can also be done in multiple configurations. For example, the exhaust port can be located in or along the primary and/or secondary track (generally, in the track which is not working as a compressor or expander) or in a separate conduit opening into the primary chambers. Likewise, the input port can be via a separate conduit. Usually, the intake port is located proximally to the point of intersection of the primary vanes and secondary vanes and the input port is not in fluid communication with a pressurized exhaust port.
[0036] The machine can be configured as a compressor or pump with an external means for supplying input power connected to drive said first and/or second rotors or can be configured as an expander with an external means for using output power connected to said first and/or second rotors or combination thereof. Further, it can be configured as a combustion engine by including a fuel igniter.
[0037] The application of the improvements described herein can be applied to the machines described in U.S. Pat. No. 5,233,954 issued Aug. 10, 1993 and Tomcyzk, U.S. patent application Publication 2003/0111040, published Jun. 19, 2003 and other toroidal and/or cylindrical vane machines. The contents of the patent and publication are incorporated herein by reference in their entirety. It should now be readily apparent to those skilled in the art that a novel toroidal intersecting vane machine capable of achieving the stated objects of the invention has been provided.
[0038] The foregoing dimensions and ranges are set forth solely for the purpose of illustrating typical device dimensions. The actual dimensions of a device constructed according to the principles of the present invention may obviously vary outside of the listed ranges without departing from those basic principles. It should further be apparent to those skilled in the art that various changes in form and details of the invention as shown and described may be made. It is intended that such changes be included within the spirit and scope of the claims appended hereto.
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The invention provides a toroidal intersecting vane machine incorporating intersecting rotors to form primary and secondary chambers whose porting configurations minimize friction and maximize efficiency. Specifically, it is an object of the invention to provide a toroidal intersecting vane machine that greatly reduces the frictional losses through intersecting surfaces without the need for external gearing by modifying the width of one or both tracks at the point of intermeshing. The inventions described herein relate to these improvements.
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FIELD OF THE INVENTION
The invention relates to novel substituted 3-thiazolines (isothiazolines), processes for their preparation and their use as a flavoring for foods and drinks.
BACKGROUND OF THE INVENTION
In the flavor industry, there is still a strong demand for compounds which give foods and drinks an olfactory impression such as that formed in the thermal treatment during the cooking, baking and roasting treatment of foods. The resultant aromatizing compounds have especially roasted flavor notes. Compounds of this type have hitherto been only scarcely available for industrial use.
The most important reaction which proceeds during the thermal treatment of foods is the reaction between reducing sugars and amino acids, which is termed the Maillard reaction. During this Maillard reaction, flavorings, particularly, heterocyclic substances, are formed. These compounds contain one or more heteroatoms, such as sulphur, nitrogen and oxygen, various side chains and are aromatic or partially hydrogenated.
In the 2-thiazoline class of substances, especially 2-acetyl-2-thiazoline is a known and industrially used flavoring which is used, owing to its flavor properties, in particular, where roasted flavor properties are desired. Thus, 2-acetyl-2-thiazoline is used, for example, for chicken flavors, where it imparts the typical roasted flavor. The threshold value for this 2-thiazoline is reported in the literature at 0.016 to 0.022 ng/l in air (M. Rychlik, P. Schieberle, W. Grosch, Compilation of Odor Thresholds, Odor Qualities and Retention Indices of Key Food Odorants, Deutsche Forschungsanstalt für Lebensmittelchemie und Institut fur Lebensmittelchemie der Technischen Universität Muinchen, Garching, 1998). The threshold value is taken to mean the lowest concentration at which a compound can be detected by sensory means.
SUMMARY OF THE INVENTION
The present invention provides for a 4-alkanoyl-3-thiazolines of the formula
where R 1 , R 2 and R 3 are identical or different and denote hydrogen or a lower alkyl for use in a flavoring and/or odorant composition.
DETAILED DESCRIPTION OF THE INVENTION
A lower alkyl denotes an unbranched or branched hydrocarbon having 1 to 3, more preferably 1 or 2, carbon atoms.
The thiazolines of the invention, in particular, 4-acetyl-3-thiazoline, surprisingly have very low threshold values. For example, the 4-acetyl-3-thiazoline (R 1 ,R 2 ,R 3 ═H) of the present invention has a threshold value which is 0.005 ng/l in air. This threshold value is, thus, markedly lower than the case for 2-acetyl-2-thiazoline. The compound 4-acetyl-3-thiazoline is, thus, one of the most aroma-intensive compounds.
4-Acetyl-3-thiazoline was identified in a reaction mixture of fructose as the amino acid 4-carboxy-3-thiazolidine (Example 1).
The compound was identified by fractionating the extract from the reaction mixture by multi-dimensional gas chromatography and subsequent mass-spectrometric analysis. 4-Acetyl-3-thiazoline was unambiguously identified by comparison with the analytical data of an authentic sample.
In addition, systematic experiments were also carried out using a cbromatographic method which is termed gaschromatography-olfactometry (GC-O). In this method, the compounds separated during the chromatographic process are sniffed individually using the nose at the end of the capillary column.
Using these methods, the olfactory and gustatory qualities of 4-acetyl-3-thiazoline were determined.
4-Acetyl-3-thiazoline smells and tastes like popcorn and bread crust and has intensely roasted aroma properties.
The structure of the thiazolines of the present invention was demonstrated by comparison with synthesized 4-acetyl-3-thiazoline. 4-Acetyl-3-thiazoline can be prepared starting from diacetyl. Diacetyl is first brominated. The resultant bromodiacetyl is converted by sodium hydrogen sulphide into 1-mercaptodiacetyl. After reaction with formaldehyde solution and ammonia solution and also chromatographic purification, 4-acetyl-3-thiazoline is obtained (Example 2).
The compounds of the invention, because of their excellent organoleptic character, are particularly suitable as odorants and flavorings for use in flavoring compositions and reaction flavors. It is particularly surprising that the 4-acetyl-3-thiazoline imparts to the compositions a highly intense popcorn-like roasted note at extremely low concentrations.
In flavor compositions, the amount of the inventive compound used is preferably between 0.0005 and 1% by weight, in particular between 0.001 and 0.5% by weight, based on the total composition. Flavor compositions of this type can be used in the entire food and drink sector. In particular, they are suitable for aromatizing snacks, soups, sauces, instant meals, fat compositions, bakery products, yogurt, ice cream and confectionery. The dosage of flavor compositions of this type is preferably 0.005 to 2% by weight, and more preferably between 0.01 and 1% by weight, based on the final food or drink.
The flavors can be used in a liquid form, a spray-dried form or an encapsulated form. Whereas, in liquid form, they are used in a solvent which is customary in practice, such as ethanol, propylene glycol, vegetable oil triglycerides or triacetin. The dry flavors are produced by spray-drying or by encapsulation according to one of the processes which are conventional in the flavor industry. These are, in particular, extrusion and spray granulation.
The invention is further illustrated but is not intended to be limited by the following examples in which all parts and percentages are by weight unless otherwise specified.
EXAMPLES
Example 1
Model Reaction Fructose and 4-carboxy-3-thiazolidine
1.8 g of fructose and 0.44 g of 4-carboxy-3-thiazolidine were dissolved in 2.1 g of water and ground with 19.1 g of silica gel. This mixture was heated for 10 min. at 150° C. on an aluminum block under the air atmosphere. After cooling, the mixture was extracted with diethyl ether, the organic phase was washed with sodium hydrogen carbonate solution and with sodium chloride solution, dried over sodium sulphate and concentrated.
The reaction mixture was fractionated by column chromatography on silica gel. The individual fractions were sniffed on the sniffing gas chromatograph, separated by multi-dimensional gas chromatography and then studied by GC/MS. 4-Acetyl-3-thiazoline was unambiguously identified by comparison with the analytical data of an authentic sample.
Example 2
Preparation of 4-acetyl-3-thiazoline
10 mmol of (x-bromocarbonyl compound (prepared by bromination of the corresponding ox-dicarbonyl compound as reported by P. Ruggli, M. Herzog, J. Wegmann, H. Dahn, Helv. Chim. Acta, 1946, 29(1), 95-101 using half the amount of bromine) are added dropwise at 0° C. to a solution of 30 mmol of sodium hydrogen sulfide in 20 ml of 5% sodium hydroxide solution. The mixture is then heated to room temperature and stirred for 1 hour. It is then acidified to pH 3 with 20% citric acid and the mercaptodiketo compound is extracted with ether.
This ether phase is admixed with 10 mmol of aldehyde (formaldehyde as aqueous, 35% solution) and 10 mmol of ammonia solution (aqueous, 25%). The mixture is stirred at room temperature and the course of the reaction is followed by GC/MS. After 1 to 10 hours, the ether phase is concentrated and the mixture is purified by column chromatography using pentane-ether gradients on silica gel. Pure 4-alkanoyl-3-thiazolines are obtained in yields of 5 to 20%.
Mass spectrum of 4-aceltyl-3-thiazoline
TABLE 1
m/z
Intensity %
41
15
42
19
43
91
45
29
46
19
59
19
60
19
86
20
128
100
129
66
Example 3
Preparation of a Roasted Flavor
The following are mixed (all figures in g):
TABLE 2
3-Methylthiopropanal (1% in vegetable oil triglycerides)
1.0
2,3-Diethyl-5-methylpyrazine
1.0
Isoamyl caprylate
1.0
Diacetyl (10% in triacetin)
2.0
2-Methylbutyric acid
5.0
Isoamyl alcohol
10.0
Delta-dodecalactone
10.0
2-Phenylethanol
15.0
2-Methylbutanal
20.0
Caprylic acid (10% in triacetin)
25.0
Dimethyloxyfurone (1% in propylene glycol)
100.0
2,5-Dimethyl-4-hydroxy-3(2H)-furanone (15% in propylene
500.0
glycol)
Vegetable oil triglycerides
9310.0
Total
10000.0
If 0.1 to 0.5 of the solvent vegetable oil triglycerides was replaced by 0.1 to 0.5 g of 4-acetyl-3-thiazoline, the flavor became markedly more typical of popcorn and bread crust.
Although the invention has been described in detail in the foregoing for the purpose of illustration, it is to be understood that such detail is solely for that purpose and that variations can be made therein by those skilled in the art without departing from the spirit and scope of the invention except as it may be limited by the claims.
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The present invention provides for novel 3-thiazolines comprising the formula
where R 1 , R 2 and R 3 are identical or different and denote hydrogen or a lower alkyl, wherein said lower alkyl denotes an unbranched or branched hydrocarbon having 1 to 3 carbon atoms. These novel 3-thiazolines can be used as odorants and flavorings having an olfactory impression.
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RELATED APPLICATION
This application is a continuation of U.S. patent application Ser. No. 11/757,304, filed Jun. 1, 2007, which is hereby incorporated herein by referenced in its entirety.
BACKGROUND
1. Field of the Invention
The present invention relates to a method and apparatus for controlling a lifting magnet of a materials handling machine for which the source of DC electrical power is a DC generator. It finds particular application in conjunction with lifting magnets used on crawlers in the scrap metal industries.
2. Prior Art
Lifting magnets are commonly attached to crawler booms to load, unload, and otherwise move scrap steel and other ferrous metals.
While lifting magnets have been in common use for many years, the systems used to control these lifting magnets remain relatively primitive. During the “Lift”, a DC current energizes the lifting magnet in order to attract and retain the magnetic materials to be displaced. At the end of the “Lift”, when the materials need to be separated from the lifting magnet, most of the controllers automatically apply a reversed voltage across the lifting magnet for a short period of time to allow the consequently reversed current to reach a fraction of the “Lift” current. This phase is known as the “Drop” phase, during which a magnetic field in the lifting magnet of the same magnitude but in an opposite direction of the residual magnetic field is produced that the two fields cancel each other. When the lifting magnet is free of residual magnetic field, all scrap metal detaches freely from the lifting magnet. This is known as a “Clean Drop”.
Some known control systems operate to selectively open and close contacts that, when closed, complete a “Lift” or “Drop” circuit between the DC generator and the lifting magnet. At the end of the “Lift”, which is called the “discharge” and at the end of the “Drop”, which is called the “secondary discharge”, these systems generally use either a resistor or a varistor to discharge the lifting magnet's energy. The higher the resistor's resistance value or varistor breakdown voltage, the faster the lifting magnet discharges, but also the higher the voltage spike across the lifting magnet. High voltage spikes cause arcing between the contacts. In addition, fast rising voltage spikes also eventually wear out the DC generator collector and its winding insulation, the lifting magnet insulation, and the insulation of the cables connected to the lifting magnet and the generator. To withstand these voltage spikes, generally in the magnitude of 750 V DC with systems using DC generators rated 240 V DC, the lifting magnet, cables, and the control system contacts and other components must be constructed of more expensive materials, and must also be made larger in size. These systems waste lifting magnet's energy. Lifting magnet's energy is transformed into heat, dissipated through a voltage suppressor or resistor bank. This results in poor system efficiency and oversized components to dissipate the heat.
To avoid these issues, some other known control systems connect directly to DC generator excitation shunt field. They eliminate arcing across contacts and minimize voltage spikes in the lifting magnet circuit but at the expense of a slower response time, caused by the induced DC generator time constant.
SUMMARY
A new and improved method and apparatus for controlling a lifting magnet is provided.
In one embodiment, the lifting magnet energy produced during the “Lift” phase is returned to the DC generator which in turn converts it back into mechanical energy.
In one embodiment, a Transient Voltage Suppressor (TVS) is provided to control DC generator maximum voltage when current is reversed in the DC generator.
In one embodiment, a circuit is provided to protect the TVS against overload. TVS overload can occur, for example, by accidental disconnection between the controller and the DC generator such that energy stored in the lifting magnet cannot be returned to the DC generator.
In one embodiment, at least a portion of the energy stored in the lifting magnet is returned to the source rather than being dissipated in resistor, varistor, or other lossy elements.
In one embodiment, switching of current for the magnet is provided by solid-state devices.
In one embodiment, the control system is configured to reduce voltage spikes in the lifting magnet circuit.
In one embodiment, the control system is configured to increase the useful life of the lifting magnet, the generator supplying power to the lifting magnet, and/or the associated circuitry.
In one embodiment, the control system is configured to reduce the “Drop” time. Shorter “Drops” helps to increase production by reducing lifting magnet cycle times. Some existing systems are using a resistor, which causes voltage to decay with the current leading to a longer discharge time. This invention uses a constant voltage source provided by the DC generator to discharge the lifting magnet energy, allowing a faster discharge.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 schematically illustrates a lifting magnet controller circuit.
FIG. 2 graphically shows a voltage and current signals as the lifting magnet is operated through “Lift” and “Drop” cycle.
FIG. 3 shows the circuit of FIG. 1 during the “Lift” mode.
FIG. 4 shows the circuit of FIG. 1 during the “Lift” off mode.
FIG. 5 shows the circuit of FIG. 1 during the Discharge mode.
FIG. 6 shows the circuit of FIG. 1 during the “Drop” mode.
FIG. 7 shows the circuit of FIG. 1 during the “Drop” off mode.
FIG. 8 shows the circuit of FIG. 1 during the secondary discharge mode.
FIG. 9 shows the circuit of FIG. 1 during an open circuit in the “Lift” mode.
FIG. 10 shows the circuit of FIG. 1 during the Freewheel TVS protection mode after the “Lift” mode.
FIG. 11 shows the circuit of FIG. 1 during an Open circuit in the “Drop” mode.
FIG. 12 shows the circuit of FIG. 1 during the Freewheel TVS protection mode after the “Drop” mode.
FIG. 13 , consisting of FIGS. 13A-13K , is a schematic diagram of one embodiment of the logic controller.
DETAILED DESCRIPTION
FIG. 1 schematically illustrates a lifting magnet controller circuit that includes a logic controller 108 . Outputs from the logic controller 108 are provided to respective switches 101 , 102 , 103 and 104 . One of ordinary skill in the art will recognize that logic controller 108 can be a Printed Circuit Board, Programmable Logic Controller, etc. The switches 101 - 104 are configured in an “H” bridge arrangement to provide current to a magnet 150 . The switches 101 - 104 can be any type of mechanical or solid-state switch device so long as the devices are capable of switching at a desired speed and can withstand the desired current and voltage. For convenience, and not by way of limitation, FIG. 1 shows the switches 101 - 104 as insulated gate bipolar transistors. One of ordinary skill in the art will recognize that the switches 101 - 104 can be bipolar transistors, insulated gate bipolar transistors, field-effect transistors, MOSFETs, etc.
In FIG. 1 , a first output from the logic controller 108 is provided to a gate of the switch 101 , a second output from the logic controller 108 is provided to a gate of the switch 102 , a third output from the logic controller 108 is provided to a gate of the switch 103 , a fourth output from the logic controller 108 is provided to a gate of the switch 104 . An emitter from the switch 101 is provided to a first terminal of the magnet 150 and to a collector of the switch 102 . An emitter from the switch 103 is provided to a second terminal of the magnet 150 and to a collector of the switch 104 . Flyback diodes 111 - 114 are provided to respective collectors and emitters of the switches 101 - 104 .
A positive output from a DC generator 101 is provided through a fuse 130 to a first terminal of a current sensor 121 . A second terminal of the current sensor 121 is provided to a first terminal of a transient voltage suppressor (TVS) 123 , and to the collectors of the switches 101 and 103 . A negative output from the DC generator 101 is provided through a current sensor 122 to a first terminal of a resistor 124 and to the emitters of the switches 102 and 104 . A second terminal of the resistor 124 is provided to a second terminal of the TVS 123 .
The transistors, 103 and 102 form the “Lift” circuit, and transistors 101 and 104 form the “Drop” circuit. One of ordinary skill in the art will recognize that when any of the diodes 111 - 114 are forward biased, the switch 101 - 104 can be closed to provide a current path in parallel with the diode (e.g., to protect the diode, to provide a lower impedance path for current, etc.) Thus, for example, during discharge and/or drop, the switches 104 and 101 can be closed to provide current through the switches, or open to allow current to flow through the respective diodes. The current sensors 121 , 122 can be configured as Hall Effects sensors, current shunts, resistors, current transformers, etc. The current sensors 121 , 122 monitor current and detect “Drop current threshold” current, short-circuits, and ground faults. The system 100 (shown in FIGS. 1 and 3 - 12 as the system 100 with the addition of the generator 101 , the fuse 130 and the magnet 150 ). controls the maximum voltage when current reverses direction in the generator. The resistor 124 is provided to monitor energy dissipated in the TVS 123 .
FIG. 2 shows voltage and current during the lift mode. When the operator activates “Lift” at time “L”, the logic controller 108 closes the switches 103 and 102 . Current flows from the generator 101 to the magnet 150 . Current from the DC generator 101 is applied to the lifting magnet through the switches 103 and 102 as shown in FIG. 3 , and the current ramps to the lifting magnet rated current value. The operator ends “Lift” at time “D 1 ”, whereupon the circuit is configured shown in FIG. 4 , the voltage rises to the TVS breakdown value, and the current in the lifting magnet decays. When the current direction reverses in the DC generator (at time D 2 ), the circuit is as shown in FIG. 5 where the lifting magnet energy discharges into the DC generator. When the lifting magnet energy is released (at time D 3 ), current in the lifting magnet reaches zero and then starts to ramp in the reverse direction as shown in FIG. 6 . When the current value becomes equal to the “Drop current threshold” (at time D 4 ), the circuit is in the configuration shown in FIG. 7 , the voltage steps to TVS breakdown value, and the current in the lifting magnet decays. When the current direction reverses in the DC generator (at time D 5 ), the circuit is as shown in FIG. 8 , the lifting magnet energy discharges into the DC generator, and the current decays until substantially all lifting magnet energy is released (at time D 6 ).
FIG. 3 shows current in the system 100 during the “Lift” mode. During lift, the logic controller 108 keeps the switches 101 and 104 open (e.g., off), and closes (e.g., turns on) the switches 103 and 102 . Current flows from the positive terminal of the DC generator 101 through the switch 103 , through the lifting magnet 150 , through the switch 102 and back to the generator 101 . Rated current establishes in the lifting magnet 150 after a few seconds, based on the time constant of the circuit, which is primarily due to the inductance to resistance ratio (L/R) of the lifting magnet 150 .
FIG. 4 shows current in the system 100 during the “Lift” off mode. When operator needs to release the material being lifted by the magnet, the operator instructs the logic controller 108 to start the drop process. The drop process includes lift off ( FIG. 4 ), discharge ( FIG. 5 ), drop ( FIG. 6 ), drop off ( FIG. 7 ) and secondary discharge ( FIG. 8 ). During lift off, switches 103 and 102 are turned off and a few milliseconds later switches 101 and 104 are turned on. Due to the inductance of the generator, the generator current is still flowing in the same direction as it was flowing during “Lift”. Because the switches 103 and 102 are off, the generator current flows through the TVS 123 . Due to the inductance of the lifting magnet, the lifting magnet current is still flowing in the same direction as it was flowing during “Lift”. So, if for example, during “Lift”, a current of 100 Amps was flowing through the DC generator 101 and the lifting magnet 150 , at the time 103 and 102 turn off, a current of 200 amperes flows through the TVS 123 , with the DC generator 101 contributing for 100 amperes, and the lifting magnet 150 contributing for 100 amperes.
FIG. 5 shows current in the system 100 during the discharge mode. The lifting magnet 150 has a longer time constant than the DC generator 101 , so the direction of current will reverse in the DC generator 101 before it can reverse in the lifting magnet 150 . When the DC generator 101 allows current to reverse its direction, the lifting magnet current flows back into the DC generator 101 . The difference of potential V M2 -V M1 across the lifting magnet is positive. Therefore, the lifting magnet 150 acts as a source of energy, and energy from the lifting magnet is transferred from the lifting magnet 150 to the DC generator 101 .
FIG. 6 shows current in the system 100 during the “Drop” mode. During drop mode, switches 101 and 104 are closed. When there is insufficient energy left in the lifting magnet 150 to maintain the reverse current flow into the DC generator 101 , the DC generator 101 generates a “reverse” current in the lifting magnet 150 . Based on the time constant of the circuit, the reverse current gradually increases.
In one embodiment, the switches 101 and 104 are closed during the lift-off phase. Since the flyback diodes 114 and 111 are forward biased during the lift-off phase, the switches 101 , 104 need not to be forward biased (in other words, the switches 101 , 104 can be closed by the logic controller 108 but nevertheless not conducting current because they are reversed biased). Once the magnet 150 is discharged, the current through the magnet will reverse during the drop phase and thus the switches 101 , 104 will become forward biased.
FIG. 7 shows current in the system 100 during the “Drop” off mode. When the current measured by the current sensor 121 (and/or the current sensor 122 ) matches the “Drop current threshold”, the logic controller turns the switches 101 and 104 off. Due to the inductance of the generator 101 , the generator current is still flowing in the same direction as it was flowing during “Drop”. Because all of the switches 101 - 104 are off, generator current flows through the TVS 123 . Due to the inductance of the lifting magnet 150 , the lifting magnet current is still flowing in the same direction as it was flowing during “Drop”. If for example, during the “Drop” a “reverse” current of 20 Amps was flowing through the DC generator and the lifting magnet, at the time the switches 101 and 104 turn off, 40 amperes would flow in the TVS 123 , with the DC generator 101 contributing for 20 amperes, and the lifting magnet 150 contributing for 20 amperes.
FIG. 8 shows current in the system 100 during secondary discharge. The lifting magnet 150 has a longer time constant than the DC generator 101 , so the direction of current will reverse in the DC generator 101 before it can reverse in the lifting magnet 150 . When the DC generator 101 allows current to reverse its direction, the lifting magnet current flows back into the DC generator 101 . The difference of potential V M1 -V M2 across the lifting magnet is positive. Therefore the lifting magnet 150 acts as a source of energy, and energy is transferred from the lifting magnet 150 to the DC generator 101 . Then the “reverse” current into the generator 101 gradually decays to zero when all the energy left in the lifting magnet 150 is dissipated.
FIG. 9 shows current in the system 100 during an open circuit in the “Lift” mode. If during “Lift”, the DC generator 101 is accidentally disconnected, such as in the case of a loose connection or if the fuse 130 opens, the path for the lifting magnet current is through the circuit formed by the diodes 111 , 114 and the TVS 123 . In one embodiment, the TVS is not sized to absorb all the lifting magnet energy. The logic controller 108 measures the current in the TVS 123 by sensing a voltage across the resistor 124 . If excess current in the TVS 123 is detected, then the circuit switches into “Freewheel TVS protection” mode to protect the TVS 123 against overload.
FIG. 10 shows current in the system 100 during the “Freewheel TVS protection” mode after an open circuit in the “Lift” mode. In the “Freewheel TVS protection” mode, the switch 103 is closed and the diode 111 is forward biased, thus providing a loop for the current circulating in the lifting magnet 150 to maintain the same direction that it had during “Lift”.
FIG. 11 shows current in the system 100 during an open circuit in the “Drop” mode. If during “Drop”, the generator 101 is accidentally disconnected such as in the case of a loose connection or if the fuse 130 opens, the path for the lifting magnet current is through the circuit formed by the diodes 113 , 112 and the TVS 123 . In one embodiment, the TVS 123 is not sized to absorb all the lifting magnet energy. The logic controller 108 measures the current in the TVS 123 by sensing a voltage across the resistor 124 . If excessive current in the TVS 123 is detected, then the circuit switches into “Freewheel TVS protection” mode to protect the TVS 123 against overload.
FIG. 12 shows current in the system 100 during the Freewheel TVS protection mode after an open circuit in the “Drop” mode. In “Freewheel TVS protection” mode, the switch 101 is closed and the diode 113 is forward biased, thus providing a loop for the current circulating in the lifting magnet 150 to maintain the same direction that it had during “Drop”.
reewheel TVS protection mode is not polarity sensitive. When a TVS overload is detected, Freewheel TVS protection mode is activated by closing switches 101 and 103 to divert the current from the TVS. As described above, the switch 101 can be closed to form a loop with diode 113 , and the switch 103 can be closed to form a loop with diode 111 .
Logic controller 108 monitors currents passing through sensors 121 and 122 . If an unbalance occurs, then the logic controller 108 signals a ground fault alarm. In one embodiment, the logic controller 108 will turn off the switches 101 - 104 if an overload condition is detected.
FIG. 13 , consisting of FIGS. 13A-13E , is a schematic diagram of one example circuit embodiment for the logic controller. In FIG. 13 , a LIFT INPUT is received from a “Lift” user control (e.g., a such as, for example, a lift push button provided to the circuit of FIG. 13 via an opto-isolator). The “Lift” control initiates the “Lift” operation. After the “Lift” push button is released, circuit stays in “Lift”. A thermostat that senses the temperature of the one or more of the switches 101 - 104 (or a heat-sink for the switches 101 - 104 ) can be provided to a THERMOSTAT input shown in FIG. 13 . If the switches get too hot, the thermostat sends a signal to the THERMOSTAT input that prevents initiation of the next Lift operation, however, a lift currently in progress is not terminated (for safety reasons). A “cycle” control (e.g., push button and associated electronics) can be provided to a CYCLE INPUT. The “Cycle” control can be used to replace (or supplement) the lift and drop controls. Activating the cycle control (e.g., pressing the cycle button) causes the status of the Magnet Controller to cycle through “Lift”, then “Drop” and automatically to “OFF”, and then again to “Lift” etc. Basically U301A with its complemented output fed in its data input acts as a divider by 2. A POWER UP RESET line is temporary held ON when control power is applied (or after power has been cycled to reset a fault) to set the status of D Type Flip-Flop (latches) in the circuit. A DROP INPUT receives signals from a “Drop” control (e.g., a “Drop” push button and associated opto-isolator and electronics). The “Drop” push button terminates the “Lift” and initiates the “Drop”. After the “Drop” push button is released, the circuit finishes “Lift” and then automatically goes to “Off”. A NO CONTROL POWER input is configured to receive a signal indicating that the 24V DC power supply has fallen below 18V. A typical 24V to 15V voltage regulator needs at least 18V on its input to guarantee 15V output. So if control power supply is too low, to protect against unexpected behavior, the switches 101 - 104 are turned off when the NO CONTROL POWER signal is received. The “Drop” current can be adjusted by an optional potentiometer P 201 . An HE POS input receives current sensor signals from the current sensor 121 . An HE NEG input receives current sensor signals from the current sensor 122 . A SHORT CIRCUIT input is provided to receive a signal if an overload or short condition is detected. A connector CN 521 provides inputs from the TVS current sensor 124 . The circuit of FIG. 13 is configured to use a 0.1 ohm resistor as the TVS current sensor. If a TVS overload signal is received at the TVS input, the switches 101 and 103 are then turned on to protect 123 .
FIG. 13B shows “LIFT” and “DROP” outputs. The “LIFT” output is provided to drivers that control the switches 102 and 103 . The “DROP” output is provided to drivers that control the switches 101 and 104 . The “LIFT” output is activated to produce the lift function. The “DROP” output is activated to control the drop function.
It will be evident to those skilled in the art that the invention is not limited to the details of the foregoing illustrated embodiments and that the present invention may be embodied in other specific forms without departing from the spirit or essential attributed thereof; furthermore, various omissions, substitutions and changes may be made without departing from the spirit of the inventions. The foregoing description of the embodiments is, therefore, to be considered in all respects as illustrative and not restrictive, with the scope of the invention being delineated by the appended claims and their equivalents.
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A magnet controller supplied by a DC generator controls a lifting magnet. Four transistors, forming an H bridge, allow DC current to flow in both directions in the lifting magnet. During “Lift”, full voltage is applied to the lifting magnet. During “Drop”, reverse voltage is applied briefly to demagnetize the lifting magnet. At the end of the “Lift” and the “Drop”, most of the lifting magnet energy is returned to the DC generator. A transient voltage suppressor protects against voltage spike generated when current reverses in the generator.
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This application is a continuation of application Ser. No. 583,275, filed Feb. 27, 1984, now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a signal communication system, and more particularly to an improved signal communication system which conveys signals between power boards, control boards or other board devices (hereinafter referred to merely as "board devices") with a minimum of wires in a signal communication cable.
2. Description of the Prior Art
A typical example of conventional wiring between board devices of the above mentioned sort is illustrated in FIG. 1. In FIG. 1, there are shown two board devices generally designated the reference numbers 100 and 200. The two board devices 100 and 200 are connected through a communication cable 300. The board devices 100 and 200 each includes a terminal board 150 or 250. The communication cable 300 is connected between the terminal boards 150 and 250. The terminal boards 150 and 250 have terminals P, N, 1, 2 ... n wherein P and N are terminals for power supply. Power supply lines 400 include a positive line P and a negative line N. There are also shown relay coils R 11 , R 12 and R 21 and their corresponding relay contacts C 11 , C 12 , C 21 and C 22 . In the example of FIG. 1, power voltages P and N are fed from one of the board devices to the other through the cable 300.
The system as illustrated in FIG. 1 will operate as follows. Upon closure of the contact C 11 the coil R 21 is energized and upon closure of the contact C 21 the coil R 11 is energized. Furthermore, upon closure of the two contacts C 12 and C 22 the coil R 12 is placed into its energized state. In other words, the two board devices 100 and 200 are rendered operative in association with each other through the terminal boards 150 and 250.
The problems of the system as shown in FIG. 1 are that it requires a number of core wires in the connection cable 300 and becomes expensive correspondingly with increase in the distance between the two devices 100 and 200. One solution to those problems is a system of FIG. 2 by which to reduce the number of connection wires to a minimum.
FIG. 2 schematically illustrates an improved prior art wiring scheme between the board devices for further simplicity of connections between the devices as shown in FIG. 1 and minimization of the signal communication cable. In FIG. 2, components similar to those in FIG. 1 are represented by the same reference numbers. The board devices 100 and 200 include conventional signal communicators 10 and 20 for such wiring. The signal communicators 10 and 20 each are divided into a transmitter side and a receiver side. On the transmitter side of the signal communicator 10 signals are conveyed to a cable 310 in the signal communication cable 300 by way of an input signal terminal board 101, a signal converter circuit 102, a parallel-to-serial conversion logic circuit 103, a modulator 104 and a transmitter/receiver terminal board 120. The signals from the cable 310 are received through a transmitter/receiver terminal board 220, a demodulator 214, a serial-to-parallel conversion logic circuit 213, an output conversion circuit 212 and an output signal terminal board 211 on the receiver side of the signal communicator 20. In a likewise manner, signals are conveyed to a cable 320 in the signal communication cable 300 by way of an input signal terminal board 201, a signal conversion circuit 202, a parallel-to-serial conversion logic circuit 203, a modulator 204 and transmitter/receiver terminals 220 on the transmitter side of the signal communicator 20. The signals from the cable 320 are received through the transmitter/receiver terminal board 120, a demodulator 114, a serial-to-parallel conversion logic circuit 113, an output conversion circuit 112 and an output signal terminal board 111 on the receiver side of the signal communicator 10. The board devices 100 and 200 include individual power supply lines 401 and 402. The signal communicators 10 and 20, respectively, include power supply conversion circuits 131 and 231 which are led to power supply lines 401 and 402 via power terminal boards 130 and 230, for the purposes of generating voltages for logic operations.
Operation of the above described system will now be discussed. The input signal terminal board 101 in the board device 100 of FIG. 1 is fed with a positive power supply voltage P 1 , depending upon whether or not the contacts C 11 , C 12 and so forth are closed. The respective terminals of the input signal terminal board 101 are connected to respective input terminals of the signal conversion circuit 102. The signal conversion circuit 102, when its respective input terminals are connected to the power supply P 1 and supplied with DC 110V, for example, provides a logic "1" voltage (typically, DC 5V) at its output terminals corresponding to the respective input terminals. For those input terminals that are not connected to the power supply P 1 and remain open, the signal conversion circuit provides a logic "0" voltage (typically, DC 0V) at its output terminals corresponding to those input terminals. The logic signals at the respective output terminals of the signal conversion circuit 102 are fed to respective parallel input terminals of the parallel-to-serial conversion logic circuit 103 which in turn converts those signals into bit serial signals which are supplied to the modulator 104 after error detection codes such as parity codes have been added thereto. The modulator 104 modulates a carrier suitable for transmission with the input signals and sends out the same to the signals communication cable 300 via the transmitter/receiver terminal board 120. For example, the carrier is within an audio frequency range and frequency-modulated with the input signals. Typically, 2100 Hz sinewave signals are provided for the logic "0" signals and 1300 Hz sinewave signals for the logic "1" signals. This permits transmission to take place under the condition where signals being transmitted are immune to noise readily induced over the cable.
The modulated carrier conveyed over the signal communication cable 300 are then demodulated through the demodulator 214 into bit serial signals which in turn are converted through the serial-to-parallel conversion circuit 213 into parallel signals and fed to the output conversion circuit 212. Within the output conversion circuit 212, a voltage P 2 is applied to terminals of the serial-to-parallel conversion logic circuit 213 which correspond to logic "1" bits whereas terminals thereof which correspond to logic "0" bits are held in open state. The outputs of the output conversion circuit 212 are connected to the relay coils and contacts through the output signal terminal board 211. Signal transmission from the transmitter side of the signal communicator 20 to the receiver side of the signal communicator 10 takes place in the same manner as with signal transmission from the transmitter side of the signal communicator 10 to the receiver side of the signal communicator 20.
Therefore, should the contact C 11 be brought into a closed position, the power supply voltage P 2 is fed to the terminal 1 of the output signal terminal board 211, thus energizing the coil R 21 . Upon closure of the contact C 21 the power supply voltage P 1 is supplied to the terminal 1 of the output signal terminal board 111 to energize R 11 . Upon closure of the contact C 12 the power supply voltage P 2 is supplied to the terminal 2 of the output signal terminal board 211. If under this circumstance the contact C 22 is placed into a closed position, then the power supply voltage P 2 is fed to the terminal 2 of the input signal terminal board 201, permitting the supplying of the power supply votage P 1 to the terminal 2 of the output signal terminal board 111 and the energizing of the coil R 12 .
With the above described system, it is possible to convey a number of signals through a minimum of communication lines (the lines 310 and 320 in the example of FIG. 2). However, in the device of FIG. 2, there are two kinds of terminal boards, the input signal terminal board and the output signal terminal board, which are separated from each other. The designer of the board devices is required to consider arrangement of various terminals, components and the like in the board deivces while taking into consideration the location of the terminal boards of the signal communicators settled in the board devices. In other words, a limitation is imposed that terminal arrangement in the board devices should be determined in association with the location of the signal communicators, presenting great difficulties in the design of the board devices. Another problem is that great difficulties are experienced in applying the system of FIG. 2 to the board devices designed without consideration of the foregoing limitation.
SUMMARY OF THE INVENTION
This invention is directed to a signal communication system for signal transmission between two board devices via a cable.
According to the present invention, there is provided a signal communication system which comprises a signal input/output terminal board for receiving from and providing signals therethrough to one of said two board devices therethrough, a transmitted section connected between said signal input/output terminal board and said cable for receiving output signals from said one board device and converting the same into desired logic signals of a bit serial format for supply to said cable, a receiver section connected between said signal input/output terminal board and said cable for receiving said logic signals from the other board device of the two via said cable and converting the same into signals of a desired format for supply to said input/output terminal board and means for enabling either said transmitter or receiver section.
Accordingly, it is the primary object of the present invention to provide a signal communication system which is capable of minimizing limitations on the design of arrangement of various components in board devices.
These objects and other objects, features, aspects and advantages of the present invention will become more apparent from the following detailed description of the present invention when taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows an example of conventional wiring between board devices;
FIG. 2 shows an improved example of conventional wiring between board devices;
FIG. 3 is a wiring diagram of a preferred embodiment of the present invention; and
FIG. 4 is a perspective view showing the appearance of a signal communicator as illustrated in FIG. 3.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 3 is a wiring diagram showing a preferred embodiment of the present invention, wherein components similar to those in FIG. 2 are identified by the same reference numbers and description of operation thereof omitted herein. In this alternative embodiment, a single input/output terminal board common to the respective signal communicators provides a substitute for the input signal terminal board and the output signal terminal board. In FIG. 3, a signal communicator in the board device 100 includes a transmitter path including an input/output signal terminal board 110, a signal conversion circuit 102, a parallel-to-serial conversion circuit 103, a modulator 104 and a transmitter/receiver terminal board 120, a receiver path including the transmitter/receiver terminal board 120, a demodulator 114, a serial-to-parallel conversion logic circuit 113, an output conversion circuit 112 and an input/output signal terminal board 110, as well as a power terminal board 130 and a power conversion circuit 131. A signal communicator in the board device 200 likewise includes a transmitter path including an input/output signal terminal board 210, a signal conversion circuit 202, a parallel-to-serial conversion logic circuit 203, a modulator 204 and a transmitter/receiver terminal board 220 and a receiver path including the transmitter/receiver terminal board 220, a demodulator 214, a serial-to-parallel conversion logic circuit 213, an output conversion circuit 212 and an input/output signal terminal board 210, as well as a power terminal board 230 and a power conversion circuit 231.
Referring to the input/output signal terminal board 110, the input/output terminals (respective terminals of relays and coils) of the board device 100 are sequentially connected on a predetermined order (for example, the order of alignment as shown in FIG. 1) to the respective ones of the terminals 1-n of the input/output signal terminal board 110. No particular consideration to signal inputs and outputs is necessary in this form of wiring. On the input/output signal terminal board 110 there are provided a changeover switch S 1 -S n , an output signal terminal and an input signal terminal for each of the input/output terminals. Through proper selection of the changeover switches the respective ones of the input/output terminals 1-n are used as input terminals or output terminals according to wiring in the board device. This is also the case with the input/output signal terminal board 210. Operation after the switches have been set is similar to that described with respect to FIG. 2.
As stated above, even though the terminals in the board device are connected to the signal communicator regardless of its input and output directions, it is easy to distinguish between the input side and output side in the foregoing embodiment through proper selection of the switches on the input/output signal terminal board. In the design of the input and output terminals in the board device, no attention should be drawn as to whether those terminals are for inputs or outputs, thus providing simplicity of the design of the board devices.
FIG. 4 is a perspective view showing the appearance of the signal communicator as discussed with respect to FIG. 3. A signal communicator 70 of a rectangular shape is provided at upper and lower corners with mounting plates having fixing holes 71. On a front panel of the signal communicator 70 there are mounted an input/output signal terminal board 710, a transmitter/receiver terminal board 720, a power terminal board 730 and switches 72 corresponding to respective ones of input/output signal terminals. The directions of arrows, for example, imprinted on the respective switches indicate the settings of those switches, which settings may be modified by means of a screwdriver.
It is evident that the above embodiment allows great flexibility in the design of terminal arrangement in the board devices.
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.
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A signal communication system provided in a board device has a signal input/output terminal board having a plurality of input/output terminals. When a signal is communicated between two board devices, some of the input/output terminals serve as an input signal terminal and the remainder as an output signal terminal in accordance with the manual selection thereof.
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BACKGROUND OF THE INVENTION
The invention relates to an apparatus for coating food products with sauce while simultaneously deep freezing them, with a rotatable drum in a horizontal position, on the inner wall surface of which a driving plate is disposed and which has an opening at an end face.
Previously, it has not been possible satisfactorily to combine different, cooked food products, such as noodles, rice, vegetables, potatoes or meat in the deep frozen state, firmly with a sauce, particularly when the proportion of sauce was to be higher than 4%. However, this would be desirable, since it would offer the possibility of dividing the contents of a package of the product into individual portions, which would always have same consistency and composition. It would then be possible to dispense with mixing all the contents of a package before consumption. In practice, it is therefore customary for the manufacturer either to offer the whole product as a frozen block or to add some larger, frozen pieces of the sauce portion in block form to the package.
Admittedly, attempts have been made to freeze food products in horizontally positioned, relatively long drums with the help of liquid nitrogen or liquid carbon dioxide and, at the same time, to provide them with a sauce coating. Up to now, however, results have been unsatisfactory. It was possible to achieve uniform adhesion of the sauce only to a limited extent. The problems, which arose, obviously were based essentially on the fact that it was not possible to cool the goods quickly enough. For the previously used, relatively long drums with only one filling and discharging opening at an end face, there was an ejector, for ejecting the goods after the cooling process, at the driving plate in the region of the opening. This resulted in relatively confined space relationships, which counteracted particularly the rapid introduction of the coolant. However, if the cooling does not take place quickly enough, not only is the adhesion of the sauce to the products limited, but there may also be agglomeration and adhesion or even breakage of the goods, such as cooked rice or noodles.
SUMMARY OF THE INVENTION
It is an object of the invention to provide an apparatus of the above type, which permits food products to be deep frozen rapidly with an accurately definable temperature-time profile and, at the same time, to provide such food products with a firmly adhering coating of sauce.
Pursuant to the invention, this objective is accomplished by an apparatus of the initially named type, which is characterized by a second opening on the opposite end face, an ejector, which is provided at the driving plate and disposed in front of the second opening, a nozzle, mounted in the first opening, for feeding a coolant, particularly in the form of liquid nitrogen or liquid carbon dioxide, into the drum, a further nozzle, mounted next to the first opening, for injecting sauce into the drum, an exhaust pipe, which occupies essentially the whole cross sectional area of the first opening and is intended to exhaust gaseous coolant, as well as a movable holding device, which accommodates a section of the exhaust pipe and permits the exhaust pipe to be moved between a position immediately in front of the first opening and a retracted position.
Since the drum has two openings on two opposite sides, both openings can be tailor-made particularly for the functions of filling and discharging the products. The ejector, provided in front of the second opening, enables the products to be delivered rapidly after the treatment, but does not impede the rapid injection of coolant and sauce on the opposite side.
An important advantage of the invention lies in the arrangement of the exhaust pipe which, in the interest of rapid exhaustion of the gaseous coolant, has large dimensions, on a movable holding device in front of the first opening. With this holding device, the exhaust pipe, at the end of an operating cycle, can be moved to the side, so that the working space in front of the drum is free and new material can be filled into the drum. A movable carriage, a swiveling arm, a lifting device or the like comes into consideration as the holding device.
The nozzles or lances for injecting coolant and sauce are mounted, pursuant to the invention, readily accessibly at the exhaust pipe or at a collar surrounding the end of the exhaust pipe. This enables the nozzles to be exchanged easily and handled readily. The food products are tumbled continuously in the drum by the driving plate and, at the same time, coated uniformly with sauce (coating) and deep frozen.
Largely conventional nozzles are used for the injection of liquid nitrogen as coolant and also for the injection of sauces. On the other hand, when carbon dioxide is used as coolant, a so-called snow pipe is used, into one end of which liquid carbon dioxide enters and which is open at the other end for discharging carbon dioxide snow into the interior of the drum.
BRIEF DESCRIPTION OF THE DRAWINGS
In the following, preferred examples of the invention are described in greater detail by means of the attached drawing, in which
FIG. 1 is a diagrammatic representation of an inventive apparatus within a partially indicated production building,
FIG. 2 shows a different embodiment of a similar plant,
FIGS. 3 and 4 illustrate the supply of the coolant supply system in some detail,
FIGS. 5 and 6 are a diagrammatic side view and a plan view of an inventive drum with a movable opening and an exhaust system,
FIG. 7 is a diagrammatic partial representation and shows a view into the open end of the exhaust pipe,
FIG. 8 is a partial side view of the drum and of the exhaust pipe in a partially sectional representation and
FIG. 9 corresponds to FIG. 8, but shows a different embodiment.
DETAILED DESCRIPTION
In FIG. 1, an inventive drum is labeled 10. The drum stands on the floor 12 of a production building and is supported by a frame 14, which is provided, in a manner not shown, with supporting and driving rollers for the drum, which permit the drum to be rotated. On the left side and on the right side, the drum 10 has end openings 16 and 18 at both ends, which should be referred to as the first and the second openings. The second opening forms the discharging opening for finished product, as indicated by arrow 20.
To further illustrate the production building, an outer wall 22 is shown, which supports a false ceiling 24 as well as a roof 26. The left opening 16 of the drum 10, which is on the left in FIG. 1, serves, on the one hand, for filling material into the drum and, on the other, during the operating process, for exhausting evaporating coolant, particularly nitrogen or carbon dioxide. Since rapid and intensive exhausting is necessary in order to avoid an overpressure in the drum, the opening 16 is connected with an exhaust pipe 28 of relatively large cross section during the operating process. For the example shown, this exhaust pipe passes through the false ceiling 24 upwards and then sideways to a blower 30, the outlet pipe 32 of which emerges upwards from the roof 26.
During the exhausting process, the exhaust pipe 28, which runs perpendicularly downwards through the false ceiling 24, is connected at its lower end with a pipe elbow 34, one end of which is surrounded by a collar 36. During the exhaustion, this collar 36 lies in the funnel-shaped opening 16 with clearance all around. The connection between the exhaust pipe 28 and the pipe elbow 34 during an exhaustion process can be brought about by a sliding sleeve 38 on the lower end of the exhaust pipe 28. After clamping screws 40 have been loosened, the sliding sleeve 38 can be lowered so far in relation to the exhaust pipe, that it laps over the outwardly directed section of the pipe elbow 34.
The pipe elbow 34, together with the collar 36, is supported on a frame 42, which can be moved on a carriage 44. After a batch of material is finished, the pipe sleeve 38 is pushed up on the exhaust pipe 28 and clamped and, subsequently, the carriage 44, together with the frame 42, the pipe elbow 34 and the collar 36 can be moved to the side, so that the opening 16 is freely accessible and a new batch of material can be introduced. The accessibility, moreover, is also advantageous for cleaning, maintenance and repair work.
A similar overall solution is shown diagrammatically in FIG. 2. Those parts, which were described already in conjunction with FIG. 1, have the same reference numbers. In FIG. 2, the arrangement of the drum is the opposite to that of FIG. 1, the discharging opening 18 being on the left side and the filler opening 16 on the right side. Within the drum 10, the material to be treated is shown diagrammatically. Outside of the building, there is a cylindrical pressure vessel 46, which contains the liquid coolant, that is, nitrogen or carbon dioxide. After valves 50 and 52 are opened on the outside and the inside of the building, the coolant passes through pipeline 48, a hose section 54 and a pipe section 56 into the interior of the drum 10.
At the underside of the false ceiling 24, a spray pipe 58 is suspended, with which a coolant can be sprayed from the outside onto the drum 10. Above the false ceiling 24, the guidance of the exhaust pipe has been modified from that of the embodiment of FIG. 1. The exhaust pipe 28, emerging vertically upwards through the false ceiling 24, is connected T-shaped with a further pipe section 60, in which there are two blowers 62 and 64, which are disposed one behind the other and transport the gas, which is to be exhausted, from the exhaust pipe 28 above the false ceiling 24 first to the left and then vertically upwards through the roof 26 and finally to the right in FIG. 2. At the right end of the horizontal part of the pipe section 60, there is a vacuum-controlled supplementary air valve 66.
It can, moreover, be seen in FIG. 2 that the drum 10 lies on supporting and driving rollers 68, 70, which are on a common shaft 72, which can be rotated as indicated by arrow 74. Such shafts and rollers are on either side of the drum, so that the drum is supported securely and can be rotated corresponding to the rotation of the shafts.
FIGS. 3 and 4 show two highly diagrammatic representations of the area of the inlet opening 16 of the drum 10. Moreover, FIGS. 3 and 4 show the pipe elbow 34 of the exhaust system and the collar 36.
FIG. 3 shows a so-called snow pipe 76, which enters the drum through the collar 36 in the upper region of the pipe elbow and is slightly inclined downwards from the right to the left in FIG. 3 and closed at the right end. A pipeline 78, at the end of which there is a nozzle 80 within the snow pipe, enters this closed end. Liquid carbon dioxide is emitted through this nozzle 80 and solidifies immediately to carbon dioxide snow within the snow pipe.
In the embodiment of FIG. 4, this system for supplying coolant is formed by a pipeline 82, which changes over into two nozzles 84, 86 within the drum 10, through which liquid nitrogen is emitted as coolant.
FIGS. 5 and 6 serve to supplement the explanation of some details, which have not been shown previously. On the one hand, FIG. 6 shows the frame 42 together with the carriage 44 in plan view. Moreover, the drum 10 in FIG. 6 is shown partially cut open, so that driving plates 88, which are formed on the inner surface shell and carry along the goods to be processed as the drum is rotated, can be recognized within the drum. An ejector blade is provided at driving plates 88 and is disposed in front of second opening 18.
In addition to the feeding devices for a coolant, such as carbon dioxide or nitrogen, shown in FIGS. 3 and 4, there is, in the region of the first opening 16, a feed pipe, which ends in a nozzle, for feeding the sauce into the drum. This feed pipe will be described later on.
It can be inferred from the previously explained drawings, that the front collar 36 is formed essentially only by a ring surrounding the corresponding end of the pipe elbow 34 of the exhaust pipe. Compared to the open area of the first opening 16, a considerable gap is left free. The apparatus thus works as an open system. Since an overpressure is avoided in every case in the drum due to the strong exhaustion of the evaporating coolant and moreover, due to the gap on the inlet side, the required liquids, that is, the coolant and the sauce, can be injected without hindrance.
To begin with, according to FIG. 7, the pipe elbow 34 of the exhaust pipe 28, in deviation from the previously described Figures, is mounted not on a carriage 44, but on a vertical post 90, with which the pipe elbow is connected over horizontal swiveling arms 92. The overall arrangement of exhaust pipe and/or pipe elbow and nozzles can therefore be swung to the side at the end of a cycle. In FIG. 7, a pipeline for supplying coolant is labeled 94. In this pipeline, there is a valve 96. As already indicated in FIGS. 3 and 4, the pipeline 94 is taken to an upper indentation 98 of the exhaust pipe, so that it arrives directly in the cross sectional area of the exhaust pipe through the opening in the drum 10. FIG. 7 moreover shows a pipeline 100, with a valve 102 for supplying sauce. This pipeline 100 enters the drum in the 10 o'clock position through a collar 36.
The two pipelines are shown in side view in FIGS. 8 and 9. The two pipelines for coolant and sauce are also labeled 94 and 100 in these Figures. At the end of the pipeline, there is a so-called three-finger nozzle 104 for feeding in the liquid nitrogen. A similar three-finger nozzle 106 is provided at the end of the pipeline 100. Such a nozzle is suitable for feeding in viscous sauces.
FIG. 9 differs from FIG. 8 inasmuch as a lance 108 is provided instead of the three-finger nozzle 106. The front end region of the lance 108 is bent downwards at an angle. At the underside of the lance 108, there is a number of fan nozzles 110.
Admittedly, the inventive apparatus also offers the possibility of merely freezing the food products, which are to be processed. However, the special advantage lies therein that the apparatus permits a freezing process as well as a mixing process, during which the products are coated with sauce and the coating, while constantly being distributed, adheres in a frozen state to all solid parts.
In contrast to conventional drums, the drum is relatively short, so that the coolant, sprayed in from the inlet side, very rapidly comes into contact with all of the filling material. For example, the cylindrical middle part of the drum may have a diameter of 1,000 mm and a length of only 600 mm. The small length of the drum, the intensive exhausting and the correspondingly rapid supply of coolant offer the possibility of controlling the treatment and freezing relatively accurately and, with that, maintaining an accurately definable temperature-time profile.
It was already pointed out that, for example, an excessively long freezing time can be responsible for the individual product parts sticking, agglomerating or even breaking. Moreover, a shock-like freezing process is advantageous for the adhesion of the sauce to the individual parts of the product. However, this presupposes that the sauce is fed in very rapidly. The feeding in of the sauce can take place without hindrance. On the other hand, in the case of conventional apparatuses, for which only one opening is provided and an ejector blade is required in the region of this one opening, such feeding of sauce can occasionally be hindered by this ejector blade.
The inventive apparatus offers the advantage that, in a single plant, loose foods, frozen while rolling, can be produced, which can be coated with any adjustable amount of sauce, marinade, oil emulsion and/or seasoning emulsion and similar materials in such a manner that, in the end, the individual pieces of the respective food, as before, do not adhere together, that largely the same proportion of coating adheres to each piece and that the individual pieces are not damaged. The freezing process and the coating process can take place timewise independently of one another with respect to time, that is, for example, simultaneously or in any sequence alternately.
A coherent arrangement of an exhaust pipe, a nozzle for feeding a coolant, particularly liquid nitrogen or carbon dioxide, and a nozzle or lance for feeding sauce, can be swiveled or moved in front of one of the two openings of the drum. The entry area of the exhaust pipe occupies essentially the whole cross sectional area of the corresponding opening of the drum, so that coolant, which has gone over into the gaseous state, can be exhausted rapidly. In the feed line for the sauce, there may be a sauce pump, which is connected with a reservoir container for sauce or also with a sauce mixer or cooker. The nozzles and/or lances for feeding the coolant and the sauce can easily be exchanged and can therefore be exchanged readily for cleaning purpose or for changing over to a different working program.
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An apparatus for coating food products with sauce while simultaneously deep freezing them comprises a rotatable drum (10) in a horizontal position, on the inner wall surface of which a driving plate is disposed and which has an opening (16) at an end face. The apparatus furthermore comprises a second opening (18) on the opposite end face, an ejector, which is provided at the driving plate (88) and disposed in front of the second opening (18), a nozzle (80, 84, 86), mounted in the first opening (16), for feeding a coolant, particularly in the form of liquid nitrogen or liquid carbon dioxide, into the drum, a further nozzle, mounted in the first opening (16), for injecting sauce into the drum, an exhaust pipe, which occupies essentially the whole cross sectional area of the first opening (16) and is intended to exhaust gaseous coolant, as well as a movable holding device (42, 44), which accommodates the exhaust pipe (34, 28) and permits the exhaust pipe to be moved between a position immediately in front of the first opening and a retracted position.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to new semiconductor films made of metal oxide with large bandgaps formed on substrates.
The new semiconductor films are very useful to be used in electronic and photonic devices.
The present invention relates to also a new method to form said new semiconductor films on substrates made of material which has been used in usual electronic and photonic devices.
2. Related Background Art
Recently so-called power devices such as bipolar transistors, field effect transistors, and thyristors are used in various fields such as domestic electronic articles, cars, machine tools, and illumination. With increase of application, conversion and control of electric power with high efficiency and with a high speed are requested to power devices. Although power devices have been fabricated using silicon (Si) for a long time, limits of silicon devices are predicted. The limits come from the fact that the bandgap of silicon, about 1 electron volt (eV), is small. Research to realize power devices made up of semiconductors with large bandgaps, that is, so-called widegap semiconductors to overcome the limits has been widely done. In particular, development of power devices using gallium nitride (GaN) whose bandgap is about 3.43 eV or silicon carbide (SiC) whose bandgap is about 3.2 eV has been done extensively.
On the other hand, error or trouble of electronic devices due to noise which comes from the cosmic rays or cars and heat has been serious problems. It has been made clear that so-called hostile-environment devices which are proof against a severe environment with noise or heat should be made of semiconductors with large bandgaps. Development of electronic devices using GaN or SiC has been done from these points. However there are many problems to be solved to realize electronic devices made of GaN or SiC.
The most serious problem is that bulk crystal of GaN has not been obtained because an equilibrium vapor pressure of nitorogen is very high relative to that of gallium. Therefore, substrates made up of sapphire or silicon carbide (SiC) are used. GaN can not be formed directly on a sapphire substrate because there is lattice mismatch of 16% between sapphire and GaN. Therefore a buffer layer of aluminum nitride (AlN) is formed on a sapphire substrate before growth of GaN. AlN is resistive because it is difficult to dope impurities into AlN. Use of sapphire substrate in a device which includes multi-layers of semiconductor such as a bipolar transistor and a thyristor is very disadvantageous to their structures and fabrication process. On the other hand, SiC substrate is very expensive because bulk crystal of SiC can be grown at a very high temperature of 2200˜2400° C. GaN devices using SiC substrate or SiC devices are very expensive.
The second serious problem is to realize new devices which can be grown at a lower temperature than that at which GaN or SiC layers are formed. It is necessary to form layers of GaN or SiC at a temperature higher than 1000° C. Large energy is necessary to form semiconductor layers at a high temperature. In addition, there are possibilities that atoms move between layers and a composition is disturbed or dopants move near the interface between layers.
The problems described above can be solved by using molybdenum oxide for such devices. The inventor of the present invention discovered that high quality molybdenum oxide crystal has a large bandgap larger than 3.2 eV and is very useful to be used in photonic and electronic devices (U.S. patent application Ser. No. 10/848,145 and Ser. No. 10/863,288).
However, in the patent application described above, the molybdenum oxide crystal was formed by oxidation of a metallic molybdenum plate. Because the molybdenum plate was not crystal, some fabrication technologies such as cleavage could not used. In addition, it was impossible to integrate the devices formed of molybdenum oxide with those formed of silicon. Furthermore, precise control of a thickness of the molybdenum oxide layer was difficult when it was formed by oxidation of a molybdenum plate.
Therefore it is required to form a layer of semiconductor crystal whose bandgap is larger than 3.2 eV on a substrate made of material which is used in usual devices. The semiconductor layer should be formed at a relatively low temperature such that device structures are not damaged during the formation of the layer. Electronic devices with high withstand voltages and photonic and electronic hostile-environment devices will be made at a relatively low temperature on substrates which are used in devices at present.
SUMMARY OF THE INVENTION
The present invention is directed to a new semiconductor film comprising of metal oxide grown on a substrate and its fabrication method.
The metal oxide is comprised of molybdenum oxide which has a bandgap larger than 3.2 eV and is very useful to fabricate electronic devices with high withstand voltages and photonic and electronic hostile-environment devices. Molybdenum oxide is useful also to fabricate a light emitting diode or a laser diode which emit light with a wavelength shorter than 387 nm.
An important aspect of the present invention is that the molybdenum oxide film is formed on a substrate made of material which has been used in usual electronic and photonic devices. The most popular material is silicon.
Another important aspect of the present invention is to provide a new method to form a molybdenum oxide film on a substrate. This method comprises the following steps: A substrate and source material are set in a deposition chamber, at the first step. Typical source material is molybdenum plate and a typical substrate is silicon. A temperature profile is formed in the growth chamber such that a temperature at the source material is higher than that at the substrate at the second step. After the temperature profile is formed, oxygen gas is flowed for a period which depends on a thickness of the molybdenum oxide which is required to form a particular device at the third step.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic view of one example of an equipment to be used to form metal oxide layer according to the method of the present invention.
FIG. 2 is a flow diagram which shows steps to form metal oxide layer by deposition on a substrate according to the present invention.
FIG. 3 shows one example of the temperature profile in a furnace and a position of a substrate during formation of a metal oxide layer by the method according to the present invention.
FIG. 4 shows one example of the more preferable temperature profile in a furnace in an area of a target substrate.
FIG. 5 is a schematic view of the metal oxide layer formed on a substrate made of material which is used in usual devices at present.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Reference will now be made in greater detail to preferred embodiments of the invention.
The First Embodiment
FIG. 1 shows schematically one example of an equipment to be used to form high-purity molybdenum oxide according to the method of the present invention. The equipment ( 100 ) to be used to form molybdenum oxide includes a quartz tube ( 101 ) in which molybdenum oxide is deposited, a source holder ( 104 ), a substrate holder ( 105 ), a furnace ( 102 ) and heaters ( 103 ) which can form a temperature profile in the furnace ( 102 ). A thermometer ( 106 ) which monitors a temperature of the source and a thermometer ( 107 ) which monitors a temperature of the substrate are also included. The thermometers ( 106 ) and ( 107 ) were thermo-couple in this case. Means to introduce and control oxygen gas ( 108 ) and nitrogen gas are included although they are not shown in the figure. Inside of the quartz tube ( 101 ) can be evacuated by a vacuum pump (not shown in the figure). The source holder ( 104 ) and the substrate holder ( 105 ) were made of quartz because it does not change at a temperature at which molybdenum oxide is formed and does not react with a substrate, oxygen and molybdenum oxide. Although the equipment shown in FIG. 1 was used in a typical embodiment, it is not restricted as far as a preferred temperature profile is formed including source and substrate zones and inside of the deposition chamber can be made oxygen atmosphere.
The new method to form molybdenum oxide according to the present invention will be described with reference to the flow diagram shown in FIG. 2 . A molybdenum (Mo) plate was used as source and a silicon (Si) substrate were used in this example. At first, the molybdenum plate and the silicon substrate were rinsed with acetone, methanol and high-purity water in this sequence (step 201 ). A molybdenum plate is rinsed with sulfuric acid and high-purity water following to the step 201 if necessary. Naturally grown oxide on a silicon substrate is removed with hydrofluoric acid or other methods with hydrogen or hydrogen radical if necessary.
At the next step (step 202 ), a pre-treated source molybdenum plate or a molybdenum plate whose surface had been oxidized previously (10 mm×10 mm×0.1 mm) was set on the source holder ( 104 ) and a silicon substrate (10 mm×10 mm×0.1 mm) was set on the substrate holder ( 105 ) which was set at a position 20 cm apart from the source holder ( 104 ) to the downstream.
As the next step (step 203 ), inside of the quartz tube was evacuated to 10 −3 Torr with a rotary pump and was filled with nitrogen (or inert gas such as argon).
After air inside of the quartz tube was replaced with nitrogen or inert gas, the furnace was heated so that a temperature profile shown in FIG. 3 is formed (step 204 ). In the temperature profile, a temperature at the source zone was 650° C. and that at the substrate zone was 450° C. The temperature profile was formed by heating for about 45 minutes under control of a temperature controller (not shown in the figure). In embodiments of the present invention, a temperature of the source zone was 550˜850° C., preferably 650° C. and that of the substrate zone was 350˜650° C., preferably 450° C. A slope of temperature was formed from the source zone to the substrate zone. A temperature over 850° C. at the source zone was not preferable because oxygen is likely to leave molybdenum oxide and molybdenum nitride is likely to be formed. It is important that the temperature at the substrate zone is lower than that at the source zone.
After the desired temperature profile was formed in the furnace ( 102 ), oxygen gas ( 108 ) was introduced into the quartz tube ( 101 ) (step 206 ). The oxygen gas ( 108 ) flowed in a direction from the source holder ( 104 ) to the substrate holder ( 105 ). A flow rate of the oxygen gas ( 108 ) was 50 to 450 SCCM, preferably 250 SCCM. Although oxygen flow was used to make inside of the quartz tube to be oxygen atmosphere, other oxygen atmosphere, oxygen radical or oxygen plasma can be used as far as the molybdenum plate is oxidized at a desired temperature and molecules of molybdenum oxide desorb the source.
The temperature profile shown above and oxygen flow were kept for six hours (step 207 ). After then the furnace was cooled to room temperature keeping oxygen flow (step 208 ). As a result a layer of high quality single crystalline molybdenum oxide was deposited on a silicon substrate to a thickness of 6 μm as shown in FIG. 5 . Although a growth rate of the molybdenum oxide was about 1 μm/h in the embodiment, it can be changed by selecting a size of the molybdenum source, a flow rate of oxygen and temperature profile. In addition, deposition rate depends also on many factors such as a diameter of the quartz tube, a distance between the source and the substrate and a size of the substrate. Therefore it is desirable to measure a growth rate previously for some sets of growth parameters. A thickness of the layer can be measured with optical methods or direct measurement.
The Second Embodiment
Strictly speaking, a thin layer of silicon oxide is likely to be formed between a silicon substrate ( 501 ) and a layer of molybdenum oxide ( 502 ). This is because the surface of the silicon substrate is oxidized at the early stage of growth of molybdenum oxide. If it is desired that the silicon oxide is not formed, growth of silicon oxide is prohibited by adding a step (step 205 ) to flow hydrogen for 5 minutes between the steps ( 204 ) and ( 206 ) in the flow diagram shown in FIG. 2 (other steps are similar to those shown above for the first embodiment). Although growth of silicon oxide was prevented by flowing hydrogen gas in the second embodiment, it can be prevented by other methods using reduction agents.
A temperature profile in a furnace as shown in FIG. 3 is simple one. However it is preferred that a temperature in the substrate zone is flat because more substrates can be set at the same temperature.
In the embodiments of the present invention, silicon substrates with various surface orientations such as (100) and (111) were used. High quality crystalline layers of molybdenum oxide could be formed on any such substrates. The method to deposit high quality films of metal oxide according to the present invention can be applied to form high quality metal oxide films on substrate other than silicon such as germanium, gallium arsenide, indium phosphide, gallium phoshpide, gallium nitride, silicon carbide, organic semiconductors or their derivatives, plastic substrates, polyimide and insulators such as glass. Similarly, the method of the present invention can be applied to form metal oxide films using metals such as zinc, titanium, tantalum, aluminum, ruthenium, indium, tin, iridium, palladium, tungsten, copper and chromium as their sources. It was shown by analysis using X-ray and Raman spectroscopy that molybdenum oxide films formed by the method according to the present invention have superior quality of crystal and more uniform composition relative to those formed by known methods CVD or sputtering. The reason is considered that molecules of molybdenum oxide desorb the source molybdenum plate without breaking their chemical bonds and molybdenum oxide deposits in a quartz tube which is kept at a relatively lower temperature. It was made clear from analysis using X-ray and Raman spectroscopy that the main composition of the molybdenum oxide film formed by the present method is MoO 3 . It is known that the crystal structure of MoO 3 has different lattice constants depending on a direction of lattice. The fact is considered to be favorable to lessen problems due to difference of lattice constants when molybdenum oxide is deposited on a substrate of different material. A bandgap of molybdenum oxide formed by the present method was characterized larger than about 3.2 eV from reflection spectra measurement. It is possible to make molybdenum oxide having a bandgap larger than 3.2 eV by changing growth conditions such as a source temperature, a substrate temperature and a flow rate of oxygen, pre-treatment process of a source plate or a substrate or pre-treatment of a growth chamber. The fact that molybdenum oxide has a bandgap larger than 3.2 eV means that the material has possibility that it is possible to be used in devices instead of GaN or SiC. The molybdenum oxide formed by the present method was n-type and resistivities were 1.5×10 7 Ω·cm and 2.0×10 5 Ω·cm when the source temperatures were 650 and 750° C., respectively.
The molybdenum oxide made by the method according to the present invention can be used in usual ways in which other semiconductor materials are used in semiconductor industry. The molybdenum oxide made by the present method is high resistive when it is made without intentional doping and the source temperature is lower than 650° C. It is possible, however, to change electronic properties of the molybdenum oxide by doping donors (for example, P, As, Sb, Se et al.) or acceptors (for example, Zn, Ga, Mg et al.). When the molybdenum oxide is formed by the present method without intentional doping, it is possible to change its resistivity by changing the source temperature. For example, the resistivity of the molybdenum oxide grown by setting the source temperature at 750° C. is much less than that of the molybdenum oxide by setting the source temperature at 650° C. The reason is considered that oxygen vacancies in the molybdenum oxide have a role of donors and its concentration in the molybdenum oxide formed by setting the source temperature at a higher one is larger than that in the oxide formed by setting the source temperature at a lower one. The fact is remarkable point of the present method. In addition, it is possible to control local electronic properties of the molybdenum oxide formed by the present method, by introducing donors or acceptors in the local area by, for example, ion implantation.
Metal oxide films with a high resistivity formed by the method according to the present invention with, for example, setting the source temperature at a lower temperature can be used to separate devices on a substrate. Furthermore the method to form metal oxide films according to the present invention can be used to form such metal oxide films to be used as insulators in devices at present.
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The present invention is directed to a new semiconductor film comprising of metal oxide grown on a substrate and its fabrication method.
The metal oxide is comprised of molybdenum oxide which is very useful to fabricate electronic devices with high withstand voltages and photonic and electronic hostile-environment devices. An important aspect of the present invention is that the molybdenum oxide film is formed on a substrate made of material which has been used in usual electronic and photonic devices. The most popular material is silicon. Another important aspect of the present invention is a new method to form a molybdenum oxide film on a substrate.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of prior application Ser. No. 14/600,601, filed on Jan. 20, 2015, which is a continuation of prior application Ser. No. 14/335,174, filed on Jul. 18, 2014, which is a continuation of prior application Ser. No. 14/243,453, filed on Apr. 2, 2014, which is a continuation of prior application Ser. No. 13/347,961, filed on Jan. 11, 2012, which claimed the benefit under 35 U.S.C. §119(e) of a U.S. Provisional application filed on Jan. 11, 2011 in the U.S. Patent and Trademark Office and assigned Ser. No. 61/431,635, and under 35 U.S.C. §119(a) of a Korean patent application filed on Dec. 26, 2011 in the Korean Intellectual Property Office and assigned Serial number 10-2011-0141875, the entire disclosure of each of which is hereby incorporated by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to a mobile communication system. More particularly, the present invention relates to a method for activating/deactivating secondary carrier(s) in addition to a primary carrier for the mobile communication system supporting carrier aggregation.
[0004] 2. Description of the Related Art
[0005] With the rapid development of wireless communication technologies, Long Term Evolution (LTE) is taking a strong position in 4 th Generation (4G) mobile communication technology. Various techniques have been introduced to meet the high capacity requirements of LTE. Carrier aggregation is a technique to increase the peak data rate and capacity, as compared to single carrier transmission, by aggregating one or more secondary carriers with a primary carrier between User Equipment (UE) and an evolved Node B (eNB). In LTE, the primary carrier is referred to as Primary Cell (PCell) and the secondary carrier as Secondary Cell (SCell).
[0006] The carrier aggregation technique causes additional control complexity for the PCell to control the SCells. This means that the PCell should be able to determine whether to use SCell and, if so, determine the SCell to be used. There is also a need for a method of activating and deactivating SCells. This means that the actual operations of the UE in receipt of SCell activation/deactivation command from the eNB should be specified in detail.
SUMMARY OF THE INVENTION
[0007] Aspects of the present invention are to address at least the above-mentioned problems and/or disadvantages and to provide at least the advantages described below. Accordingly, an aspect of the present invention is to provide a method for activating and deactivating SCell in the mobile communication system supporting carrier aggregation.
[0008] Another aspect of the present invention is to provide a method for activating and deactivating SCell in a mobile communication system that is capable of initiating some operations with delay in activation of a SCell, terminating some operations in advance in deactivation of the SCell, and terminating some operations at a predetermined time.
[0009] In another aspect of the present invention, a method for activating/deactivating secondary carriers of a User Equipment (UE) in a mobile communication system supporting carrier aggregation is provided. The method comprises receiving a control message including an activation/deactivation Control Element (CE) in a first sub-frame from a Base station, identifying an activation command or a deactivation command of at least one secondary carrier based on the control message, determining whether a current sub-frame is a second sub-frame or not, performing at least one first operation for the at least one secondary carrier in a second sub-frame, and performing, when the activation/deactivation CE indicates deactivation of the at least one secondary carrier, at least one second operation for the at least one secondary carrier no later than the second sub-frame
[0010] In yet another aspect of the present invention, a User Equipment (UE) for controlling activation/deactivation of secondary carriers in a mobile communication system supporting carrier aggregation is provided. The UE comprises a transceiver configured to communicate signals with a base station, and a controller configured to receive a control message including an activation/deactivation Control Element (CE) in a first sub-frame from a Base station, to identify an activation command or a deactivation command of at least one secondary carrier based on the control message, to determine whether a current sub-frame is a second sub-frame or not, to perform at least one first operation for the at least one secondary carrier in a second sub-frame, and to perform, when the activation/deactivation CE indicates deactivation of the at least one secondary carrier, at least one a second operation for the at least one secondary carrier no later than the second sub-frame.
[0011] In still another aspect of the present invention, a method for activating/deactivating secondary carriers in a base station in a mobile communication system supporting carrier aggregation is provided. The method comprises configuring a control message including an activation/deactivation Control Element (CE), the activation/deactivation CE corresponding to activation/deactivation of at least one secondary carrier, transmitting to the UE the secondary carrier control message in a first subframe, receiving, when the activation/deactivation CE indicates activation of the at least one secondary carrier, a Channel State Information (CSI) report on the at least one carrier in a second subframe, and receiving, when the activation/deactivation CE indicates deactivation of the at least one secondary carrier, a CSI report for the at least one secondary carrier no later than the second subframe.
[0012] In still another aspect of the present invention, a base station for controlling activation/deactivation of secondary carriers in a mobile communication system supporting carrier aggregation is provided. The base station comprises a transceiver configured to communicate signals with a base station, and a controller configured to configure a control message including an activation/deactivation Control Element (CE), the activation/deactivation CE corresponding to activation/deactivation of at least one secondary carrier, to transmit to the UE the control message in a first subframe, to receive, when the activation/deactivation CE indicates activation of the at least one secondary carrier, a Channel State Information (CSI) report on the at least one secondary carrier in a second subframe, and to receive, when the activation/deactivation CE indicates deactivation of the at least one secondary carrier, a CSI report for the at least one carrier no later than the second subframe.
[0013] Other aspects, advantages, and salient features of the invention will become apparent to those skilled in the art from the following detailed description, which, taken in conjunction with the annexed drawings, discloses exemplary embodiments of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] The above and other aspects, features, and advantages of certain exemplary embodiments of the present invention will be more apparent from the following description taken in conjunction with the accompanying drawings, in which:
[0015] FIG. 1 is a diagram illustrating the architecture of a mobile communication system according to an exemplary embodiment of the present invention;
[0016] FIG. 2 is a diagram illustrating a protocol stack of the mobile communication system according to an exemplary embodiment of the present invention;
[0017] FIG. 3 is a diagram illustrating an exemplary situation of carrier aggregation in the mobile communication system according to an exemplary embodiment of the present invention;
[0018] FIG. 4 is a signaling diagram illustrating message flows between a User Equipment (UE) and an evolved Node B (eNB) for a secondary carry activation/deactivation method according to an exemplary embodiment of the present invention;
[0019] FIG. 5 is a flowchart illustrating a UE procedure for performing first operations in a secondary carrier activation/deactivation method according to an exemplary embodiment of the present invention;
[0020] FIG. 6 is a flowchart illustrating a UE procedure for performing second operations in a secondary carrier activation/deactivation method according to an exemplary embodiment of the present invention; and
[0021] FIG. 7 is a block diagram illustrating a configuration of a UE according to an exemplary embodiment of the present invention.
[0022] Throughout the drawings, it should be noted that like reference numbers are used to depict the same or similar elements, features, and structures.
DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS
[0023] The following description with reference to the accompanying drawings is provided to assist in a comprehensive understanding of exemplary embodiments of the invention as defined by the claims and their equivalents. It includes various specific details to assist in that understanding, but these are to be regarded as merely exemplary. Accordingly, those of ordinary skill in the art will recognize that various changes and modifications of the embodiments described herein can be made without departing from the scope and spirit of the invention. In addition, descriptions of well-known functions and constructions may be omitted for clarity and conciseness.
[0024] The terms and words used in the following description and claims are not limited to the bibliographical meanings, but are merely used by the inventor to enable a clear and consistent understanding of the invention. Accordingly, it should be apparent to those skilled in the art that the following description of exemplary embodiments of the present invention is provided for illustration purposes only and not for the purpose of limiting the invention as defined by the appended claims and their equivalents.
[0025] It is to be understood that the singular forms “a,” “an,” and “the” include plural referents unless the context clearly dictates otherwise. Thus, for example, reference to “a component surface” includes reference to one or more of such surfaces.
[0026] Exemplary embodiments of the present invention relate to a secondary carrier activation/deactivation method and apparatus of a UE in a mobile communication system supporting carrier aggregation.
[0027] FIG. 1 is a diagram illustrating the architecture of a mobile communication system according to an exemplary embodiment of the present invention.
[0028] Referring to FIG. 1 , the radio access network of the mobile communication system includes evolved Node Bs (eNBs) 105 , 110 , 115 , and 120 , a Mobility Management Entity (MME) 125 , and a Serving-Gateway (S-GW) 130 . The User Equipment (hereinafter, referred to as UE) 135 connects to an external network via eNBs 105 , 110 , 115 , and 120 and the S-GW 130 .
[0029] The eNBs 105 , 110 , 115 , and 120 correspond to legacy node Bs of Universal Mobile Communications System (UMTS). The eNBs 105 , 110 , 115 , and 120 allow the UE establish a radio link and are responsible for more complicated functions than a legacy node B. In the LTE system, all the user traffic including real time services such as Voice over Internet Protocol (VoIP) are provided through a shared channel. Accordingly, there is a need of a device which is located in the eNB to schedule data based on the state information such as UE buffer conditions, power headroom state, and channel state. Typically, one eNB controls a plurality of cells. In order to secure a data rate of up to 100 Mbps, the LTE system adopts Orthogonal Frequency Division Multiplexing (OFDM) as a radio access technology on 20 MHz bandwidth. The LTE system also adopts Adaptive Modulation and Coding (AMC) to determine the modulation scheme and channel coding rate in adaptation to the channel condition of the UE. S-GW 130 is an entity to provide data bearers so as to establish and release data bearers under the control of the MME 125 . MME 125 is responsible for various control functions and connected to a plurality of eNBs 105 , 110 , 115 , and 120 .
[0030] FIG. 2 is a diagram illustrating a protocol stack of the mobile communication system according to an exemplary embodiment of the present invention.
[0031] Referring to FIG. 2 , the protocol stack of the LTE system includes Packet Data Convergence Protocol (PDCP) 205 and 240 , Radio Link Control (RLC) 210 and 235 , Medium Access Control (MAC) 215 and 230 , and Physical (PHY) 220 and 225 . The PDCP 205 and 240 is responsible for IP header compression/decompression. The RLC 210 and 235 is responsible for segmenting the PDCP Protocol Data Unit (PDU) into segments in a size appropriate for Automatic Repeat Request (ARQ) operation. The MAC 215 and 230 is responsible for establishing connection to a plurality of RLC entities so as to multiplex the RLC PDUs into MAC PDUs and demultiplex the MAC PDUs into RLC PDUs. The PHY 220 and 225 performs channel coding on the MAC PDU and modulates the MAC PDU into OFDM symbols to transmit over radio channel or performs demodulating and channel-decoding on the received OFDM symbols and delivers the decoded data to the higher layer.
[0032] FIG. 3 is a diagram illustrating an exemplary situation of carrier aggregation in the mobile communication system according to an exemplary embodiment of the present invention.
[0033] Referring to FIG. 3 , an eNB typically uses multiple carriers transmitted and received in different frequency bands. For example, the eNB 305 may be configured to use the carrier 315 with center frequency f 1 and the carrier 310 with center frequency f 3 . If carrier aggregation is not supported, the UE 330 has to transmit/receive data using only one of the carriers 310 and 315 . However, the UE 330 having the carrier aggregation capability may transmit/receive data using both the carriers 310 and 315 . The eNB may increase the amount of resources to be allocated to the UE having the carrier aggregation capability in adaptation to the channel condition of the UE so as to improve the data rate of the UE.
[0034] When a cell is configured with one downlink carrier and one uplink carrier, the carrier aggregation may be understood as if the UE communicates data via multiple cells. With the use of carrier aggregation, the maximum data rate increases in proportion to the number of aggregated carriers.
[0035] In the following description, the phrase “the UE receives data through a certain downlink carrier or transmits data through a certain uplink carrier” denotes transmitting or receiving data through control and data channels provided in a cell corresponding to center frequencies and frequency bands of the downlink and uplink carriers. Although an LTE mobile communication system is described for convenience of explanation, exemplary embodiments of the present invention may be applied to other types of wireless communication systems supporting carrier aggregation.
[0036] Exemplary embodiments of the present invention propose UE procedure in receipt of SCell activation/deactivation command from the eNB. The UE starts some operations after a predetermined time elapses from the receipt of an activation command, ends some operations before a predetermined time from the receipt of a deactivation command, and ends some other operations after a predetermined time elapses from the receipt of the deactivation command. The time point for executing or ending a certain operation may differ from the time point for executing or ending another operation, because the activation and deactivation delay increases when the time points are determined in order of start or end processing delay of the operations. The UE should not start data transmission/reception in a SCell immediately upon receipt of the command from the eNB. This is because it takes additional time to activate the function blocks for communication in the SCell. Although the function blocks are activated, there may be some delay before the function blocks operate normally.
[0037] FIG. 4 is a signaling diagram illustrating message flows between UE and eNB for secondary carry activation/deactivation method according to an exemplary embodiment of the present invention.
[0038] Referring to FIG. 4 , the eNB 403 sends the UE 401 a secondary carrier control message (hereinafter, Activation/Deactivation MAC Control Element (CE) is used interchangeably with secondary carrier control message) including information on the SCell cells to be activated/deactivated among the configured SCells in N th subframe in step 405 . The Activation/Deactivation MAC CE is a MAC CE fixed in size of 8 bits and includes seven C fields and one R field. R field denotes a reserved field. The C fields are referred to as C7, C6, C5, C4, C3, C2, and C1 (i.e. Ci). Each C field is set to 1 for activation and 0 for deactivation of SCell i, i.e. secondary carrier. i is an integer selected in the range between 1 and 7 as the secondary carrier identifier and transmitted by the eNB to the UE along with the secondary carrier when new secondary carriers are configured.
[0039] Upon receipt of the Activation/Deactivation MAC CE, the UE identifies the SCell(s) to be activated/deactivated in step 407 and, if a certain cell is to be activated, identifies a first time point in step 409 . The first time point indicates an (N+m) th subframe, where m is an integer greater than 1 (e.g. 8). The first time point is for executing operations to be performed before other operations. m is determined in consideration of the time taken to decode the received Activation/Deactivation MAC CE and analyzes the meaning of the decoded Activation/Deactivation MAC CE and may have a value large enough for terminals having relatively low processing capability. At the first time point, i.e. (N+m) th subframe, the UE performs the first operations to be executed at the first time point in step 411 . These operations may include:
[0040] Start Channel State Information (CSI) report: the CSI report includes CQI/PMI/RI/PTI necessary for eNB's link adaptation and scheduling.
[0041] CQI (Channel Quality Indicator): transmission format recommended to fulfill a bit error rate of 10%.
[0042] PMI (Precoding Matrix Index): Index for use in closed-loop spatial multiplexing.
[0043] RI (Rank Indicator): recommended Transmission Rank
[0044] PTI (Precoder Type Indicator): recommended precoder type
[0045] Start monitoring PDCCH (Physical Downlink Control Channel in SCell
[0046] Start transmission of SRS (Sounding Reference Symbol) (only when sounding reference signal is configured)
[0047] The eNB sends the UE an Activation/Deactivation MAC CE indicating the SCells to be activated/deactivated among the SCells configured for the UE in P th subframe in step 413 .
[0048] Upon receipt of the Activation/Deactivation MAC CE, the UE identifies the SCell(s) to be activated/deactivated in step 415 and, if a certain cell is to be activated, identifies a second time point in step 417 . The second time point indicates a (P+o) th subframe, where o is an integer greater than 1 (e.g. 8). The second time point may be equal to the first time point. The UE performs the second operations before the second time point, i.e. (P+o) th subframe in step 419 . Since these operations are not associated with the interaction between the UE and eNB, it is not necessary for the UE to stop the operations at a predetermined time point. The operations include:
[0049] Stop monitoring PHCCH (Physical Downlink Control Channel) in SCell
[0050] Stop transmitting SRS (Sounding Reference Symbol)
[0051] The UE executes third operations to be performed at the second time point, i.e. (P+o) th subframe, in step 421 . These operations include stopping a reporting of CSI. Since this operation is associated with the interaction between the UE and eNB, the UE should stop the operations at a predetermined time point to avoid performance degradation of the eNB caused by not stopping the corresponding operations. For example, if the eNB is not aware that the UE has stopped reporting channel state information, the eNB may fail scheduling due to the misjudgment on the UE's channel state.
[0052] All of the operations may be performed by following the above described procedure.
[0053] FIG. 5 is a flowchart illustrating UE procedure for performing first operations in a secondary carrier activation/deactivation method according to an exemplary embodiment of the present invention.
[0054] Referring to FIG. 5 , the UE receives Activation/Deactivation MAC CE having an 8-bit bitmap in N th subframe in step 501 . Each bit of the bitmap of MAC CE indicates whether to activate or deactivate the corresponding SCell.
[0055] Upon receipt of the Activation/Deactivation MAC CE, the UE determines whether there is any SCell to be newly activated and, if so, identifies the SCell to be activated in step 503 . The UE identifies the deactivated SCells before the receipt of a MAC CE and, when the MAC CE is received, searches the bitmap of the MAC CE for bits representing the deactivated SCells but marked for activation.
[0056] If there is any SCell to be activated, the UE determines the first time point and performs the first operations when the first time point arrives in step 505 . As described with reference to FIG. 4 , the first time point may correspond to an (N+m) th subframe after the time duration of m subframes elapses from the N th subframe in which the UE receives the Activation/Deactivation MAC CE. The UE executes the operations to be performed at the first time point in step 507 , i.e. in the (N+n) th subframe. As described with reference to FIG. 4 , these operations include:
[0057] Start channel State Information (CSI) report
[0058] Start monitoring PDCCH (Physical Downlink Control Channel) in SCell
[0059] Start transmission of SRS (Sounding Reference Symbol) (only when sounding reference signal is configured)
[0060] The value of m is known to both the UE and eNB (e.g. m=8).
[0061] FIG. 6 is a flowchart illustrating a UE procedure for performing second operations in a secondary carrier activation/deactivation method according to an exemplary embodiment of the present invention.
[0062] Referring to FIG. 6 , the UE receives the Activation/Deactivation MAC CE including 8-bit bitmap in the N th subframe in step 601 . Each bit of the bitmap of MAC CE indicates whether to activate or deactivate the corresponding SCell.
[0063] Upon receipt of the Activation/Deactivation MAC CE, the UE determines whether there is any SCell to be deactivated and, if so, identifies the SCell to be deactivated in step 603 . The UE identifies the activated SCells before the receipt of a MAC CE and, when the MAC CE is received, searches the bitmap of the MAC CE for bits representing the activated SCells but marked for activation.
[0064] If there is any SCell to be deactivated, the UE identifies the second time point and executes the second operations supposed to be performed before the second time point arrives in step 605 . As described with reference to FIG. 4 , the second operations include:
[0065] Stop monitoring PHCCH (Physical Downlink Control Channel) in SCell
[0066] Stop transmitting SRS (Sounding Reference Symbol)
[0067] The UE waits for the arrival of the second time point in step 607 . As described with reference to FIG. 4 , the first time point corresponds to the (P+o) th subframe after the time duration of o subframes elapses from P th subframe in which the UE receives the Activation/Deactivation MAC CE. The UE executes the third operations supposed to be performed at the second time point in step 609 , i.e. in the (P+o) th subframe As described with reference to FIG. 4 , the third operations include stopping the reporting of CSI. The value of o is known to both the UE and eNB (e.g. o=8).
[0068] FIG. 7 is a block diagram illustrating a configuration of a UE according to an exemplary embodiment of the present invention.
[0069] Referring to FIG. 7 , the UE includes a higher layer device 750 for generating data to be transmitted and processing the received data, a control message processor 707 for processing control messages received and to be transmitted, a multiplexer/demultiplexer 703 for multiplexing data and control signals to be transmitted via the transceiver 701 and for demultiplexing the received data and controls signals to be delivered to the control message controller 707 and the higher layer device 705 respectively under the control of the control unit 709 .
[0070] According an exemplary embodiment of the present invention, when the Activation/Deactivation MAC CE for activation is received, the control message processor 707 notifies the SCell activation/deactivation processor 711 of the receipt of MAC CE such that the SCell activation/deactivation processor 711 determines the first time point and, when the first time point arrives, notifies the controller 709 and the control message processor 707 of the operations to be executed at the first time point. When the Activation/Deactivation MAC CE for deactivation is received, the control message processor 707 notifies the SCell activation/deactivation processor 711 of the receipt of the MAC CE such that the SCell activation/deactivation processor 711 determines the second time point and notifies the controller 709 and the control message processor 707 of the operations to be executed before and when the second time point arrives.
[0071] Although the description is directed to the UE composed of a plurality of function blocks performing different functions, exemplary embodiments of the present invention is not limited thereto. For example, the UE may be implemented with a transceiver and an integrated controller. In this case, when a secondary carrier control message is received from the eNB, the controller checks the secondary carriers to be activated/deactivated. The controller may monitor the arrival of the first time point and control to perform the first operations when the first time point arrives.
[0072] The first time point is the time after the time duration corresponding to 8 subframes elapses from the receipt of the secondary carrier control message. The first operations may include at least one of CSI report initiation, PDCCH monitoring initiation on secondary carrier, and SRS transmission initiation.
[0073] The controller may also control to perform the second operations before the second time point arrives and the third operations at the second time point when a secondary carrier deactivation command is analyzed.
[0074] According to an exemplary embodiment of the present invention, the second time point may be equal to the first time point, i.e. the time after the time duration corresponding to 8 subframes elapses from the receipt of the secondary carrier control message. The second operations may include at least one of PDCCH monitoring termination on the secondary carrier and SRS transmission termination.
[0075] As described above, the secondary carrier activation/deactivation method and apparatus according to exemplary embodiments of the present invention controls specific operations to be executed at predetermined time points in association with the activation and deactivation of SCells in the mobile communication supporting carrier aggregation, thereby preventing a UE from malfunctioning.
[0076] The secondary carrier activation/deactivation method and apparatus according to exemplary embodiments of the present invention is also capable of guaranteeing the successful execution of operations necessary in activation and deactivation of SCells, resulting in completion of activation and deactivation without error.
[0077] While the invention has been shown and described with reference to certain exemplary embodiments thereof, it will be understood by those skilled in the art that various changes in form and details may be made therein without departing from the spirit and scope of the present invention as defined by the appended claims and their equivalents.
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A method for activating/deactivating secondary carriers of a User Equipment (UE) in a mobile communication system supporting carrier aggregation is provided. The method comprises, receiving a control message including an activation/deactivation Control Element (CE) in a first sub-frame from a Base station, identifying an activation command or a deactivation command of at least one secondary carrier based on the control message, determining whether a current sub-frame is a second sub-frame or not, performing at least one first operation for the at least one secondary carrier in a second sub-frame, and performing, when the activation/deactivation CE indicates deactivation of the at least one secondary carrier, at least one second operation for the at least one secondary carrier no later than the second sub-frame.
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CROSS-REFERENCE TO RELATED APPLICATION
This application claims priority to Provisional Application No. 61/192,891, filed with the United States Patent and Trademark Office on Sep. 22, 2008.
BACKGROUND OF THE INVENTION
In the papermaking industry, substituting inorganic filler for wood fiber in paper and paperboard is advantageous because the inorganic filler is generally less expensive than wood fiber and the substitution lowers costs. Precipitated calcium carbonate is commonly used as a filler in the industry. Although inorganic fillers decrease the total cost of papermaking, increasing concentrations can reduce the overall bulk, strength, and stiffness of the paper—all of which are important end use performance properties.
This decrease in strength and stiffness in the final paper product is a result of the structure of the wood pulp and inorganic filler. During the papermaking process, the long wood pulp fibers become entangled, thus creating a strong web of fiber. The inorganic filler does not have these long fiber chains, so increasing the inorganic filler content can weaken the fiber web in the finished product. In addition, as the inorganic filler content increases, the never-dried strength of the wet web exiting the press section of a paper machine decreases. This strength decrease affects machine runnability and may force the paper machine to run at lower yields because of a lower thru-put or higher downtime because of web breaks in the wet web.
Although the prior art teaches treatments, as part of the papermaking process, for increasing the retention of fine inorganic fillers in the final paper or paperboard product, the prior art does not disclose methods to increase the inorganic filler content of paper while simultaneously maintaining the weight, strength, and runnability of the end product.
For example, dry strength resins are known in the prior art and can increase the strength of the finished paper product when mixed into the initial paper pulp slurry (also called a paper furnish). Amphoteric, water-soluble dry strength resins are known in the prior art. Amphoteric resins are typically made by reacting acrylamide with cationic and anionic monomers (for example, diallyldimethylammonium chloride (“DADMAC”) and acrylic acid) in a free radical copolymerization reaction. These resins are generally limited to 10-15 mol % of each ionic component (20-30 mol % charged polymer total). If the ionic polymer concentration is higher, the solution becomes unstable.
Additionally, separate anionic and cationic polymeric dry strength resins are also known in the prior art. Typically, these resins will be added sequentially—i.e. all the resin of one charge is added, then all the resin of the opposite charge is added. When anionic and cationic resins are added as separate resins, the anionic resin is typically an acrylamide/acrylic acid copolymer. The cationic typically contains either DADMAC, acryloylethyltrimethylammonium chloride (“AETAC”), or a hydrolyzed form of vinyformamide.
For example, the inorganic filler content of paper may be increased by treating the pulp slurry and inorganic filler separately with a charged polymer, then treating the filler with an oppositely charged ionic, and mixing the treated filler and pulp slurry together. Alternatively, one may treat only the inorganic filler with a charged polymer, and then combine the treated filler with the pulp slurry for processing into paper.
Another method to maintain paper bulk as the inorganic filler content of paper is increased is to increase the average inorganic filler particle size. An increase in filler concentration and/or filler particle size can lead to additional abrasion on the paper slurry processing surfaces. This abrasiveness generally manifests itself as additional wear on the wet end of the paper making process, especially on the paper forming fabrics and static drainage elements. Additionally, the increased wear on these parts, slitter knives, and other surfaces may degrade the quality of the final paper product and increase maintenance and servicing costs for the equipment. Previous attempts to mitigate these problems have included addition of surfactants and TEFLON (polytetrafluoroethylene) to the paper slurry.
BRIEF SUMMARY OF THE INVENTION
The invention relates, in general, to the surprising discovery that heterogeneous polymer blends that contain polymers composed of at least one anionic, one cationic, and one nonionic monomer may be used to increase the inorganic filler content of paper without negatively affecting paper strength, weight, or runnability. This discovery allows for the cost-effective production of paper or paperboard. The present invention also relates in one aspect to a novel method of creating the novel heterogeneous polymer blends. Finally, the present invention also relates in another aspect to methods of using the heterogeneous polymer blends with a precipitated calcium carbonate filler to maintain the strength, weight, and runnability of paper or paperboard.
One embodiment of the present invention is a method of making a heterogeneous polymer blend for increasing the inorganic filler content of paper or paperboard, comprising: (a) adding to a non-neutral solution a first amount of polymerization initiator and one or more anionic or cationic monomers, wherein each monomer has the same charge; (b) adding a second amount of the polymerization initiator and one or more non-ionic monomers to the solution; (c) adding a third amount of the polymerization initiator and one or more ionic monomers that are oppositely charged from the monomers of step (a); and (d) adding, stepwise, a fourth amount of the polymerization initiator to react any residual monomer and resulting in the heterogeneous polymer blend, and (e) if necessary, neutralizing the resulting heterogeneous polymer blend, wherein the polymerization initiator is selected from the group consisting of water soluble azo initiators.
The anionic monomer(s) may be: (1) acrylic acid, (2) methacrylic acid, (3) styrenesulfonic acid, (4) vinylsulfonic acid, (5) acrylamidomethylpropane sulfonic acid, or (6) mixtures thereof.
The cationic monomer(s) may be: (1) diallyldimethylammonium chloride, (2) acryloylethyltrimethyl ammonium chloride, (3) methacryloylethyl trimethyl ammonium chloride, (4) acryloylethyltrimethylammonium sulfate, (5) methacryloylethyl trimethyl ammonium sulfate, (6) acrylamidopropyltrimethyl ammonium chloride, (7) methacrylamidopropyl trimethyl ammonium chloride, (8) non-quaternized forms of (2)-(7), (9) vinylformamide (subsequently hydrolyzed to vinylamine), or (10) mixtures thereof.
The nonionic monomer(s) may be: (1) acrylamide, (2) methacrylamide, (3) N-alkylacrylamide, (4) vinylformamide, or (5) mixtures thereof.
Another embodiment of the invention is a heterogeneous polymer blend comprising: (a) one or more anionic polymers formed from monomers selected from the group: (1) acrylic acid, (2) methacrylic acid, (3) styrenesulfonic acid, (4) vinylsulfonic acid, (5) acrylamidomethylpropane sulfonic acid, and (6) mixtures thereof; (b) one or more cationic polymers formed from monomers selected from the group: (1) diallyldimethylammonium chloride, (2) acryloylethyltrimethyl ammonium chloride (3) methacryloylethyl trimethyl ammonium chloride, (4) acryloylethyltrimethylammonium sulfate (5) methacryloylethyl trimethyl ammonium sulfate, (6) aciylamidopropyltrimethyl ammonium chloride, (7) methacrylamidopropyl trimethyl ammonium chloride, (8) non-quaternized forms of (2)-(7), (9) vinylformamide (subsequently hydrolyzed to vinylamine), and (10) mixtures thereof; (c) one or more non-ionic polymers formed from monomers selected from the group: (1) acrylamide, (2) methacrylamide, (3) N-alkylacrylamide, (4) vinylformamide, and (5) mixtures thereof;
The heterogeneous polymer blend may also contain (a) one or more copolymers comprising at least one anionic monomer and at least one non-ionic monomer; (b) one or more copolymers comprising at least one cationic monomer and at least one non-ionic monomer.
The heterogeneous polymer blend may also contain one or more terpolymers comprising at least one anionic monomer, at least one cationic monomer, and at least one non-ionic monomer.
Yet another embodiment of the invention is a method of increasing the filler content of a sheet of paper or paperboard comprising: (a) combining the heterogeneous polymer blend with a precipitated calcium carbonate filler to form a mixture; (b) combining the resulting mixture with a pulp slurry; and (c) processing the resulting pulp slurry mixture to form a sheet of paper or paperboard.
Another embodiment of the invention is a method of increasing the filler content of a sheet of paper or paperboard comprising: (a) combining either the heterogeneous polymer blend or a precipitated calcium carbonate filler with a pulp slurry to form a mixture; (b) combining the remaining component from step (a) with the pulp slurry mixture; and (c) processing the resulting pulp slurry mixture to form a sheet of paper or paperboard.
Another embodiment of the invention is a method of increasing the filler content of a sheet of paper or paperboard comprising: (a) combining a poly-diallyldimethylammonium chloride and acrylamide/acrylate copolymer mixture with a precipitated calcium carbonate filler; (b) combining the resulting mixture with a pulp slurry; and (c) processing the resulting pulp slurry to form a sheet of paper or paperboard.
Yet another embodiment of the invention is a method of increasing the filler content of a sheet of paper or paperboard comprising: (a) combining either a poly-diallyldimethylammonium chloride and acrylamide/acrylate copolymer mixture or a precipitated calcium carbonate filler with a pulp slurry; (b) combining the remaining component from step (a) with the pulp slurry mixture; and (c) processing the resulting pulp slurry mixture to form a sheet of paper or paperboard.
DETAILED DESCRIPTION OF THE INVENTION
As used herein, the singular terms “a” and “the” are synonymous and used interchangeably with “one or more” or “at least one” unless the context clearly indicates a contrary meaning. Accordingly, for example, a reference to “a compound” herein, or in the appended claims, can refer to a single compound or more than one compound. Additionally, all numerical values, unless otherwise specifically noted, are understood to be modified by the word “about.” For all the compositions and processes included herein, it should be understood that there will be at least trace amounts of the unreacted constituent components, including any monomers and polymer reaction initiators used. Unless otherwise indicated “weight %” refers to the weight % of the solids in a particular blend and excludes the weight of the water contained in the aqueous solution.
Compositions and processes in accordance with the various embodiments of the present invention are suitable for use to increase the inorganic filler content of paper and paper board. The present invention also increases the runnability of wet web paper furnish. The present invention includes a novel heterogeneous polymer blend of polymers formed from anionic, cationic, and nonionic monomers. The present invention also includes an in-situ method of making the novel heterogeneous polymer blend. Also included in the present invention is a method of increasing the inorganic filler content of paper or paperboard by treating the pulp slurry with the heterogeneous polymer blend and a precipitated calcium carbonate filler. Finally, included in the present invention is a method of increasing the inorganic filler content of paper by treating a pulp slurry with a poly-diallyldimethylammonium chloride and acrylamide/acrylate copolymer mixture and a precipitated calcium carbonate filler.
Stable, aqueous heterogeneous polymer blend compositions can be prepared in-situ via a stepwise reaction method in a non-neutral solution. Prior to, and during, the reaction, the solution is non-neutral to minimize the reaction between the anionic and cationic monomers. The method comprises the steps of (a) polymerizing one or more anionic monomers using a thermal polymerization initiator in a non-neutral solution; (b) adding one or more nonionic monomers and additional thermal polymerization initiator to the solution; (c) adding one or more cationic monomers and additional thermal polymerization initiator to the solution; (d) reacting any residual monomer with additional thermal polymerization initiator; and (e) neutralizing the resulting aqueous heterogeneous polymer blend. The resulting heterogeneous polymer composition contains, at most, nonionic homopolymer, cationic homopolymer, anionic homopolymer, anionic/nonionic copolymer, cationic/nonionic copolymer, and, optionally, anionic/nonionic/cationic terpolymer. It is understood in the art that the above composition will contain trace amounts of both the thermal polymerization initiator and the constituent monomer components.
As illustrated in the Examples set out below, the addition order of the monomer components may be reversed, so that the cationic monomer is reacted first and the anionic monomer is reacted last. Alternatively, heterogeneous polymer blends may be formed by polymerizing the anionic, cationic, and nonionic monomers separately, and then combining the resulting polymers into a blend. Preferably, the heterogeneous polymer blends are created via in-situ reaction.
The polymerization initiator may be any known polymerization initiation technique, including, but not limited to oxidative reduction and thermal polymerization. Preferably, the polymerization initiator is a thermal polymerization initiator. More preferably, the polymerization initiator is a water-soluble azo initiator. Most preferably, the polymerization initiator is azodiisobutyramidine dihydrochloride (V50), available from Wako, Richmond, Va.
The monomers may be any monomers widely used in the papermaking industry. Preferably, the anionic monomer is acrylic acid, methacrylic acid, styrenesulfonic acid, vinylsulfonic acid, or acrylamidomethylpropane sulfonic acid. More preferably, the anionic monomer is acrylic acid.
Preferably, the cationic monomer is diallyldimethylammonium chloride; acryloylethyltrimethyl ammonium chloride; methacryloylethyl trimethyl ammonium chloride; acryloylethyltrimethylammonium sulfate; methacryloylethyl trimethyl ammonium sulfate; acrylamidopropyltrimethyl ammonium chloride; methacrylamidopropyl trimethyl ammonium chloride; the non-quaternized forms of acryloylethyltrimethyl ammonium chloride, methacryloylethyl trimethyl ammonium chloride, acryloylethyltrimethylammonium sulfate, methacryloylethyl trimethyl ammonium sulfate, acrylamidopropyltrimethyl ammonium chloride, methacrylamidopropyl trimethyl ammonium chloride; and vinylformamide (subsequently hydrolyzed to vinylamine). More preferably, the cationic monomer is diallyldimethylammonium chloride.
Preferably, the nonionic monomer is acrylamide, methacrylamide, N-alkylacrylamide, or vinylformamide. More preferably, the nonionic monomer is acrylamide.
The molar ratio of each component of the heterogeneous polymer blend may range from about 1 mol % to about 50 mol % of each monomer. Preferably, the molar reactant ratio is in the range of from about 10 to about 30 mol % anionic monomer, from about 40 to about 80 mol % nonionic monomer, and from about 10 to about 30 mol % cationic monomer.
Depending on the molar ratio of each monomer component present, the final heterogeneous polymer blend may carry a positive or negative charge, or may be essentially isoelectric. Preferably, the molar ratios of the anionic and cationic components are selected such that the heterogeneous polymer blend is essentially isoelectric at a neutral pH. There may be, however, applications where a net anionic or cationic charge is advantageous.
Monomers polymerize linearly unless in the presence of bi-functional compounds. If branched polymers are necessary for a particular application, small concentrations of bi- or multi-functional compound(s) may be added to one or more steps of the polymerization reaction. Preferably, the reaction does not contain bi- or multi-functional compounds and the resulting polymers are substantially linear.
The heterogeneous polymer blend may be used in any form conventionally used in the papermaking industry, including, but not limited to, aqueous suspensions; inverse emulsions and microemulsions; brine dispersions; and dried or precipitated polymer blends that have been ground or powdered. Preferably, the heterogeneous polymer blend is used in a stable aqueous suspension.
The heterogeneous polymer blends may be used to substantially increase the inorganic filler content of paper or paperboard while maintaining the physical properties—including bulk (weight), runnability, and strength—of the resulting product. The increased filler content is advantageous in papermaking because inorganic filler is inexpensive relative to virgin or recycled wood fiber.
The heterogeneous polymer blends can increase the inorganic filler content of paper or paperboard by 10% (based on dry weight) without lowering other physical properties of the final paper product. The present invention may be used with any inorganic filler, including, but not limited to, precipitated calcium carbonate, ground calcium carbonate, kaolin clay, calcined kaolin clay, talc, calcium sulphate, calcium phosphate, and titanium dioxide. Preferably, the inorganic filler is precipitated calcium carbonate, ground calcium carbonate, or kaolin clay. More preferably, the inorganic filler is precipitated calcium carbonate. Most preferably, the inorganic filler is acicular-aragonite precipitated calcium carbonate or clustered scalenohedral calcite precipitated calcium carbonate. The preferred embodiments of the present invention provided higher finished sheet stiffness levels than other inorganic fillers.
The heterogeneous polymer blends of the present invention may be mixed with the inorganic filler as a filler pre-treatment before final mixture with the pulp slurry or the heterogeneous polymer blends and the inorganic fillers may be added stepwise to the pulp slurry. Preferably, the heterogeneous polymer blend and the inorganic filler are mixed before addition to the pulp slurry. The compounds of the present invention may also be applied in the wet end of the paper machine.
The heterogeneous polymer blend is effective for a wide range of treatment levels. Preferably, the pulp slurry is treated with from about 0.05 to about 1 wt % of the heterogeneous polymer blend relative to the total dry weight of the papermaking furnish (pulp slurry plus additives). More preferably, the pulp slurry is treated with from about 0.1 to about 0.5 wt % of the heterogeneous polymer blend relative to the total dry weight of the papermaking furnish.
The heterogeneous polymer blends may be used in a wide range of final paper products and paper grades, including, but not limited to, uncoated copy paper, coated fine paper, coated mechanical paper, uncoated mechanical paper, and packaging paper.
In addition to maintaining desirable finished paper qualities while increasing the amount of total inorganic filler in the finished paper or paperboard, the present invention has the unexpected benefits of increasing the runnability of pulp slurries with high filler content and providing lubrication for the forming fabrics and stationary dewatering elements of the paper machine. The polymeric blends increase the cohesion of never-dried wet webs containing high filler loadings; this cohesion improves the machine runnability at high filler loadings. Additionally, as the inorganic filler content of pulp slurry increases, the mechanical parts of the paper machine face greater abrasion from the inorganic filler. This abrasion increases maintenance costs and machine downtime, thus reducing productivity. Increased fabric and parts life can reduce the overall cost of paper production and increase machine on-stream time.
Slip agents, such as TEFLON, can be used to decrease the friction experienced by the paper machine, but these agents may have negative impacts on finished paper product quality and are often expensive. The heterogeneous polymer blend of the present invention improved fabric life on paper machines under laboratory tests. Treatment of the pulp slurry with the compound of the present invention will reduce abrasion with treatment levels from about 0.01 to about 10 wt % based on the total dry weight of the filler. A dosage of about 1.5 wt % based on the total dry weight of the filler is preferred. The heterogeneous polymer blend may be applied to reduce abrasion in the same manner as to increase the inorganic filler content of the finished paper or paperboard.
EXAMPLES
The following Examples help to illustrate embodiments of the present invention.
For each of the following examples, weight % refers to the weight % of the active polymer solids and excludes the aqueous solution. For Examples 7-14, which describe methods of using the novel heterogeneous polymer blend to increase the filler content of pulp slurry, all product dosages are expressed as active (solids) material as a percentage of the total dry material being treated (wood fiber plus filler and other additives); water is excluded from the calculation.
Example 1
Synthesis of an In-Situ Heterogeneous Polymer Blend
Samples of the heterogeneous polymer blend were prepared by the following method. Acrylamide, available from SNF, Riceboro, Ga., and DADMAC, available from Kemira, Kennesaw, Ga., were placed in separate flasks and sparged with oxygen-free nitrogen for thirty (30) minutes. 1.10 grams of 10% Copper (II) Sulfate, available from Sigma Aldrich, St. Louis, Mo., was added to the flask containing the sparged acrylamide solution and the flask was monitored to avoid a runaway exothermic reaction.
Separately, a 3,000 mL 4-neck round bottom flask was equipped with a condenser, a mechanical stirrer, a thermocouple attached to a regulator, a nitrogen inlet for sparging, a nitrogen outlet, and a heating mantle. 35.51 g acrylic acid, available from Rohm & Haas, Philadelphia, Pa., was added to the flask. The flask was charged with 1432.53 g of deionized water and sparged with oxygen-free nitrogen for thirty (30) minutes.
In a separate 100 mL round bottom flask, 46.87 g of 10% solution of a,a′-azodiisobutyramidine dihydrochloride (V50), available from Wako, Richmond, Va., was added and stirred at 275 RPM while sparging with oxygen-free nitrogen for thirty (30) minutes. Twenty percent (20%) (9.37 g) of the sparged V50 was added to the acrylic acid. The 3000 mL flask was heated to 55° C. for thirty (30) minutes while stirring at 275 RPM. The temperature was monitored to ensure that there was not a runaway exothermic reaction. An ice bath was kept available to control the temperature.
323.63 g of the sparged acrylamide solution was added to the 3000 mL flask, then an additional 20% (9.37 g) of the sparged V50 was added. The 3000 mL flask was heated to 55° C. for thirty (30) minutes while stirring at 275 RPM. After thirty (30) minutes, the temperature was adjusted to 65° C. and 121.33 g of the sparged DADMAC solution was added. A syringe pump was charged with the remaining V50 solution (28.12 g). Forty percent (40%) of the V50 solution (11.25 g) was added drop-wise over the next 270 minutes while heating and stirring the solution at 275 RPM.
After 270 minutes, the temperature of the 3000 mL flask was increased to 75° C. and the remaining V50 solution (16.87 g) was added drop-wise over the next thirty (30) minutes. After thirty (30) minutes, the temperature of the 3000 mL flask was increased to 80° C. and heated at 80° C. for an additional sixty (60) minutes. The resulting solution was cooled to room temperature. The pH of the solution was measured and adjusted to 7 using sodium hydroxide.
The reaction resulted in a stable, opaque suspension of a heterogeneous polymer blend containing polyacrylamide, sodium polyacrylate, poly-acrylamide/acrylate copolymer, poly-DADMAC, poly-DADMAC/acrylamide copolymer, and a poly-acrylamide/acrylate/DADMAC terpolymer with an active polymer concentration of 10% and a Brookfield viscosity of 3000 cps (measured using a #3 LVT spindle, 30 RPM at 22° C.). The blend fractions were calculated using kinetic sampling and 1H NMR sampling of the in-process composition. The product was also analyzed post-reaction using 13C NMR. The final heterogeneous polymer blend contained the following (as a weight percent of the polymer solids): 13% polyacrylate, 4% poly-acrylamide/acrylate copolymer, 64% polyacrylamide, 6% poly-DADMAC/acrylamide copolymer, 12% poly-DADMAC, and 1% poly-acrylate/acrylamide/DADMAC terpolymer. The heterogeneous polymer blend did not precipitate, gel, or separate when stored at room temperature for thirty (30) days.
Example 2
Synthesis of an In-Situ Heterogeneous Polymer Blend
Samples of the heterogeneous polymer blend were prepared by the following method. Acrylamide, available from Kemira, Kennesaw, Ga., and DADMAC, available from Sigma Aldrich, St. Louis, Mo., were placed in separate flasks and sparged with oxygen-free nitrogen for thirty (30) minutes.
Separately, a 500 mL 4-neck round bottom flask was equipped with a condenser, a mechanical stirrer, a thermocouple attached to a regulator, a nitrogen inlet for sparging, a nitrogen outlet, and a heating mantle. 14.06 g acrylic acid, available from Sigma Aldrich, St. Louis, Mo., was added to the flask. The flask was charged with 205 g of deionized water and sparged with oxygen-free nitrogen for thirty (30) minutes. 0.24 g of isopropanol, available from VWR, West Chester, Pa., was added to the 500 mL flask.
In a separate 50 mL round bottom flask, 11.13 g of 20% solution of a,a′-azodiisobutyramidine dihydrochloride (V50), available from Wako, Richmond, Va., was added and stirred at 275 RPM while sparging with oxygen-free nitrogen for thirty (30) minutes. Twenty percent (20%) (2.23 g) of the sparged V50 was added to the acrylic acid. The 500 mL flask was heated to 45° C. for 45 minutes while stirring at 275 RPM. The temperature was monitored to ensure that there was not a runaway exothermic reaction. An ice bath was available to control the temperature.
54.92 g of the sparged acrylamide solution was added to the 500 mL flask, followed quickly by 40% (4.46 g) of the sparged V50. The 500 mL flask was heated to 45° C. for 45 minutes while stirring at 275 RPM. After 45 minutes, 48.04 g of the sparged DADMAC solution and 20% (2.23 g) of the sparged V50 were added. The 500 mL flask was heated at 45° C. for 45 minutes while stirring at 275 RPM.
After 45 minutes, the temperature of the 500 mL flask was increased to 75° C. and the remaining V50 solution (2.23 g) was added. The mixture was heated at 75° C. for one (1) hour. The resulting solution was cooled to room temperature. The pH of the solution was measured and adjusted to 7 using sodium hydroxide.
The reaction resulted in a stable, opaque suspension of a heterogeneous polymer blend containing polyacrylamide, sodium polyacrylate, poly-acrylamide/acrylate copolymer, poly-DADMAC, poly-DADMAC/acrylamide copolymer, and a poly-acrylamide/acrylate/DADMAC terpolymer with an active polymer concentration of 10.2% and a Brookfield viscosity of 580 cps (measured using a #3 LVT spindle, 30 RPM at 22° C.). The blend fractions were calculated using kinetic sampling and 1H NMR sampling of the in-process composition. The heterogeneous polymer blend did not precipitate, gel, or separate when stored at room temperature for thirty (30) days.
Example 3
Synthesis of an In-Situ Heterogeneous Polymer Blend
Samples of the heterogeneous polymer blend were prepared by the following method. Acrylamide and DADMAC, both available from SNF, Riceboro, Ga., were placed in separate flasks and sparged with oxygen-free nitrogen for thirty (30) minutes.
Separately, a 500 mL 4-neck round bottom flask was equipped with a condenser, a mechanical stirrer, a thermocouple attached to a regulator, a nitrogen inlet for sparging, a nitrogen outlet, and a heating mantle. 14.06 g acrylic acid, available from SNF, Riceboro, Ga., and 205.49 g deionized water were added to the flask and stirred at 275 RPM for 30 minutes while sparging with oxygen-free nitrogen.
In a separate 50 mL round bottom flask, 11.13 g of 20% solution of a,a′-azodiisobutyramidine dihydrochloride (V50), available from Wako, Richmond, Va., was added and stirred at 275 RPM while sparging with oxygen-free nitrogen for thirty (30) minutes. Twenty percent (20%) (2.23 g) of the sparged V50 was added to the acrylic acid. The 500 mL flask was heated to 45° C. for 45 minutes while stirring at 275 RPM. The temperature was monitored to ensure that there was not a runaway exothermic reaction.
54.92 g of the sparged acrylamide solution was added to the 500 mL flask, followed quickly by 40% (4.46 g) of the sparged V50. The 500 mL flask was heated to 45° C. for 45 minutes while stirring at 275 RPM. After 45 minutes, 48.04 g of the sparged DADMAC solution and 20% (2.23 g) of the sparged V50 were added. The 500 mL flask was heated at 45° C. for 45 minutes while stirring at 275 RPM.
After 45 minutes, the temperature of the 500 mL flask was increased to 75° C. and the remaining V50 solution (2.23 g) was added. The mixture was heated at 75° C. for one (1) hour. The resulting solution was cooled to room temperature. The pH of the solution was measured and adjusted to 7 using sodium hydroxide.
The reaction resulted in a stable, opaque suspension of a heterogeneous polymer blend containing polyacrylamide, sodium polyacrylate, poly-acrylamide/acrylate copolymer, poly-DADMAC, poly-DADMAC/acrylamide copolymer, and a poly-acrylamide/acrylate/DADMAC terpolymer with an active polymer concentration of 10.4% and a Brookfield viscosity of 774 cps (measured using a #3 LVT spindle, 30 RPM at 22° C.). The blend fractions were calculated using kinetic sampling and 1H NMR sampling of the in-process composition. The heterogeneous polymer blend did not precipitate, gel, or separate when stored at room temperature for thirty (30) days.
Example 4
Synthesis of a Post-Reaction Polymer Blend
A heterogeneous polymer blend was synthesized using post reaction polymers. First the three polymers were made. To make the polyacrylamide, 219.9 g of acrylamide, available from SNF, Riceboro, Ga., was added to a 2000 mL round bottom flask and diluted with 800 g of deionized water. The mixture was stirred at 275 RPM and sparged with oxygen-free nitrogen for thirty (30) minutes. After thirty (30) minutes, 0.11 g of Copper (H) Sulfate was added. The reactor was heated to 45° C. and 35.6 g of a 10% V50 solution in deionized water was added to the flask. The reaction exothermed to 50° C. and exhibited high viscosity. To reduce viscosity, 400 g of deoxygenated, deionized water was added. After 45 minutes, 17.8 g of 10% V50 solution was added to the flask and the flask was heated to 75° C. for one (1) hour. The polymer's pH was not adjusted. The reaction yielded 1419 g of an 8.0% solids solution of polyacrylamide.
To make the polyacrylic acid, 28.1 g of acrylic acid, available from SNF, Riceboro, Ga., was added to a 1000 mL round bottom flask and diluted with 400 g of deionized water. The mixture was stirred at 275 RPM and sparged with oxygen-free nitrogen for thirty (30) minutes. After thirty (30) minutes, the flask was heated to 45° C. and 17.80 g of a 10% V50 solution in deionized water was added to the flask. The reaction was held at 45° C. (with a slight exotherm to 50° C.) for 45 minutes. The polymer's pH was not adjusted. The reaction yielded 420 g of a clear, 6.9% solids solution of polyacrylic acid.
To make the poly-DADMAC, 121.4 g of DADMAC, available from SNF, Riceboro, Ga., was added to a 1000 mL round bottom flask and diluted with 538 g of deionized water. The mixture was stirred at 275 RPM and sparged with oxygen-free nitrogen for thirty (30) minutes. Next, the reactor was heated to 75° C. and 13.1 g of a 10% V50 solution in deionized water was added to the flask, via syringe pump, over the next 120 minutes. After 120 minutes, an additional 3.3 g aliquot of 10% V50 solution in deionized water was added and the temperature increased to 80° C. and held for 30 minutes. The polymer's pH was not adjusted. The reaction yielded 664 g of a clear, 12.80% solids solution of poly-DADMAC.
After the three polymers were made, the heterogeneous post-reaction polymer blend was made. First, 230 g of polyacrylate (7.0 wt % solids) was slowly mixed into 380 g of the polyacrylamide solution (8.5 wt % solids). The resulting mixture was diluted with 420 g of deionized water and stirred vigorously at 400 RPM. While the mixture was being stirred, 220 g of the poly-DADMAC solution (16.6 wt % solids) was slowly added to the blend. Any precipitated material was redissolved by stepwise addition of a 50% NaOH solution to adjust the pH of the blend to 7.0.
The blend results in a stable, opaque suspension of a heterogeneous blend with an active polymer concentration of 11.7 wt % and a Brookfield viscosity of 1200 cps. The blend is 19 wt % polyacrylate, 38 wt % polyacrylamide, and 43 wt % poly-DADMAC.
Example 5
Synthesis of a Heterogeneous Polymer Blend Containing 4-Styrenesulfonic Acid Sodium Salt Hydrate (SSA), Acrylamide, and Methylacroyl-N-Propyl Trimethyl Ammonium Chloride (MAPTAC)
Samples of a SSA/acrylamide/MAPTAC heterogeneous polymer blend were prepared by the following method. Acrylamide, available from Kemira, Kennesaw, Ga., and MAPTAC, available from Sigma Aldrich, St. Louis, Mo., were placed in separate flasks and sparged with oxygen-free nitrogen for thirty (30) minutes.
Separately, a 500 mL 4-neck round bottom flask was equipped a condenser, a mechanical stirrer, a thermocouple attached to a regulator, a nitrogen inlet for sparging, a nitrogen outlet, and a heating mantle. 133.25 g SSA, available from Sigma Aldrich, St. Louis, Mo., and 23.72 g deionized water were added to the flask and stirred at 275 RPM for 30 minutes. The flask was charged with 242 g of deionized water and stirred at 275 RPM and sparged with oxygen-free nitrogen for thirty (30) minutes.
In a separate 50 mL round bottom flask, 7.45 g of 20% solution of V50, available from Wako, Richmond, Va., was added and stirred at 275 RPM while sparging with oxygen-free nitrogen for thirty (30) minutes, Twenty percent (20%) (1.49 g) of the sparged V50 was added to the SSA. The 500 mL flask was heated to 45° C. for 45 minutes while stirring at 275 RPM.
36.75 g of the sparged acrylamide solution was added to the 500 mL flask, followed quickly by 40% (2.98 g) of the sparged V50 solution. The 500 mL flask was heated to 50° C. for 45 minutes while stirring at 275 RPM. After 45 minutes, 57.06 g of the sparged MAPTAC solution and 20% (1.49 g) of the sparged V50 were added as quickly as possible. The 500 mL flask was heated at 50° C. for 45 minutes while stirring at 275 RPM.
After 45 minutes, the temperature of the 500 mL flask was increased to 75° C. and the remaining V50 solution (1.49 g) was added. The mixture was heated at 75° C. for one (1) hour. The resulting solution was cooled to room temperature. The pH of the solution was measured and adjusted to 7 using sodium hydroxide.
The reaction resulted in a stable, opaque suspension of a heterogeneous polymer blend with an active polymer concentration of 15.3% and a Brookfield viscosity of 46 cps (measured using a #63 spindle, 50 RPM at 22° C.). Residual SSA and acrylamide monomer was measured and found to be less than 2 ppm. This suspension separated on dilution and required vigorous agitation to obtain a uniform suspension suitable for use in papermaking.
Example 6
Synthesis of a Heterogeneous Polymer Blend Using Reverse Addition Order (as Compared to Example 1)
Samples of the heterogeneous polymer blend were prepared by the following method. 161.9 g of acrylamide, available from SNF, Riceboro, Ga., and 17.76 g of acrylic acid, available from Aldrick, St. Louis, Mo., were placed in separate flasks. The acrylamide was mixed with 716.6 g deionized water and 0.11 g solid Copper (II) Sulfate, available from Sigma Aldrich, St. Louis, Mo. Both flasks were sparged with oxygen-free nitrogen for thirty (30) minutes.
Separately, a 500 mL 4-neck round bottom flask was equipped with a Y connector fitted with a 250 mL dropping funnel and a condenser, a mechanical stirrer, a thermocouple attached to a regulator, a nitrogen inlet for sparging, a nitrogen outlet, and a heating mantle. 60.68 g DADMAC, available from SNF, Riceboro, Ga. were added to the flask and stirred at 275 RPM and sparged with oxygen-free nitrogen for thirty (30) minutes.
In a separate 50 mL round bottom flask, a 10% solution of V50, available from Wako, Richmond, Va., was added and stirred at 275 RPM while sparging with oxygen-free nitrogen for thirty (30) minutes. A syringe pump was charged with 9.38 g of the sparged V50 solution and the solution was injected dropwise into the 500 mL flask over 180 minutes. While the solution was being added to the flask, the temperature was kept constant at 65° C. while stirring at 275 RPM.
The sparged acrylamide solution was added to the 500 mL flask, followed quickly by 4.69 g of the sparged 10% V50 solution. The 500 mL flask was cooled to 50° C. and the temperature was maintained for one (1) hour while stirring at 275 RPM. After one (1) hour, 17.76 g of the acrylic acid and 4.69 g of the V50 solution were quickly added to the flask. The temperature was maintained at 50° C. for one (1) hour while stirring at 275 RPM.
After one (1) hour, the temperature of the 500 mL flask was increased to 75° C. and the remaining 4.69 g of V50 solution was added via syringe pump, dropwise, over thirty (30) minutes. After the V50 solution was completely added, the flask was to 80° C. for one (1) hour. The resulting solution was cooled to room temperature. The pH of the solution was measured and adjusted to 7.4 using sodium hydroxide.
The reaction resulted in a light grey, viscous suspension of a heterogeneous polymer blend with an active polymer concentration of 14.5% and a Brookfield viscosity of 20,100 cps (measured using a #63 spindle, 5 RPM at 22° C.). The blend fractions were calculated using kinetic sampling and 1H NMR sampling of the in-process composition. 1H NMR analysis showed 99.9% conversion of DADMAC into poly-DADMAC and less than 1 ppm unreacted acrylic acid and 253 ppm unreacted acrylamide. The heterogeneous polymer blend did not precipitate, gel, or separate when stored at room temperature for thirty (30) days.
Example 7
Papermaking Utility to Increase the Sheet Ash Content of the Final Paper or Paperboard Product
The heterogeneous polymer blend of the present invention as synthesized in Example 2 was used with clustered acicular-aragonite precipitated calcium carbonate filler (ULTRABULK® II PCC), available from Specialty Minerals, Inc., Bethlehem, Pa. The filler had a mean particle diameter of 3.9 microns. Separate runs tested the heterogeneous polymer blend of the present invention as a filler pre-treatment prior to papermaking and as a wet end additive during papermaking with the filler added prior to the heterogeneous polymer blend. For all runs, the polymer was added at a treatment amount equal to 0.45 wt %, based on the total dry paper furnish. Both methods of addition resulted in superior final paper product properties.
The final paper product was made to a sheet ash target of 30 wt % dry weight using a pulp slurry of 70 wt % bleached hardwood and 30 wt % bleached softwood fiber. The fiber stock was refined to a freeness target of 450 mL CSF. Other standard additives (all expressed as wt % of the total dry paper furnish) included 0.75% Stalok 300 starch, available from Tate and Lyle, Decatur, Ill., 0.25% alum, available from General Chemical, Parsippany, N.J., 0.1% Prequel 1000 ASA size, 0.015% PERFORM PC8138 flocculant, and 0.01% PERFORM SP9232 drainage aid, all available from Hercules, Inc., Wilmington, Del. The size press was treated with a surface treatment of 50 lb/T of ETHYLEX 2015 hydroxyethylated corn starch, available from Tate and Lyle, Decatur, Ill., The paper machine was calendered to a top side smoothness target of 150 Sheffield units.
The finished paper product using the present invention was compared to paper made using the same variables and additives, but that used a clustered scalenohedral-calcite filler (SMI ALBACAR® LO PCC), available from Specialty Minerals, Inc., Bethlehem, Pa., with a mean particle diameter of 2.1 microns, a 20 wt % sheet ash target, based on dry weight of the paper furnish, and no heterogeneous polymer blend. The results of the experiment are contained in Table 1. Use of the invention maintained stiffness and strength as filler content increased, when compared to the ALBACAR® LO PCC control at higher filler content, Both filler pretreatment and addition of the copolymer to the pulp furnish helped maintain paper strength at higher filler loading.
TABLE 1
UTILITY OF THE PRESENT INVENTION AS A FILLER TREATMENT
Filler
ALBACAR ®
ULTRABULK ®
ULTRABULK ®
ALBACAR ®
LO PCC
II PCC
II PCC
LO PCC
Chemical Treatment
No
Example 2 - 0.45%
Example 2 - 0.45%
No
Application point
None
Wet End
Filler
None
Ash (525C) (%)
20.9
29.8
29.5
31.0
MD Taber Stiffness (gf-cm)
2.49
2.52
2.32
2.21
CD Taber Stiffness (gf-cm)
1.11
1.06
1.01
0.91
GM Taber Stiffness (gf-cm)
1.66
1.63
1.53
1.42
GM Tensile (lbf/in)
12.61
12.19
10.81
9.87
ZD Tensile (psi)
75.7
71.2
72.6
67.1
Example 8
Comparison of the Heterogeneous Polymer Blend to a Two Component Polymer Blend Addition
The heterogeneous polymer blend of the present invention was synthesized as in Example 3 and compared to a post-reaction cationic/anionic polymer blend. The cationic and anionic polymers were derived from the same cationic and anionic monomers used to synthesize the heterogeneous polymer blend of Example 3, and are available as PERFORM PC8229 and HERCOBOND 2000, both available from Hercules, Inc., Wilmington, Del.
A final paper product was made to a sheet ash target of 30 wt % dry weight using a pulp slurry of 70 wt % bleached hardwood and 30 wt % bleached softwood fiber. The fiber stock was refined to a freeness target of 450 mL CSF. Other standard additives (all expressed as wt % of the total dry paper furnish) included 0.75% Stalok 300 starch, available from Tate and Lyle, Decatur, Ill., 0.25% alum, available from General Chemical, Parsippany, N.J., 0.1% Prequel 1000 ASA size, 0.015% PERFORM PC8138 flocculant, and 0.01% PERFORM SP9232 drainage aid, all available from Hercules, Inc., Wilmington, Del. The size press was treated with a surface treatment of 50 lb/T of ETHYLEX 2015 hydroxyethylated corn starch, available from Tate and Lyle, Decatur, Ill. The paper machine was calendered to a top side smoothness target of 150 Sheffield units. Additionally, the finished paper product made using the present invention was compared to paper made using the same variables and additives, but that used a clustered scalenohedral-calcite filler (SMI ALBACAR® LO PCC), available from Specialty Minerals, Inc., Bethlehem, Pa., with a mean particle diameter of 2.1 microns, a 20 wt % sheet ash target, based on dry weight of the paper furnish, and no heterogeneous polymer blend. The results of the run are contained in Table 2.
At a constant top smoothness of 150 Sheffield units, both polymer treatments improved both the in-plane and z-directional tensile properties over the untreated finished paper. The acicular-aragonite precipitated calcium carbonate exhibits some strength advantages compared to the clustered scalenohedral-calcite precipitated calcium carbonate with no polymer added. However, the heterogeneous polymer compound in conjunction with the acicular-aragonite precipitated calcium carbonate filler provided the highest stiffness values and the overall best finished paper qualities.
TABLE 2
COMPARISION OF BLEND PERFORMANCE V. TWO COMPONENT ADDITION
Filler
ALBACAR ®
ALBACAR ®
ULTRABULK ®
ULTRABULK ®
ULTRABULK ®
LO PCC
LO PCC
II PCC
II PCC
II PCC
Chemical Treatment
No
No
Example 3 - 0.45%
Perform ® PC8229 -
No
0.036% Hercobond ®
2000 - 0.45%
Application
None
None
Wet End
Wet End
None
Ash (525C) (%)
19.0
28.8
28.7
27.7
31.9
MD Taber Stiffness (gf-cm)
2.29
2.09
2.33
2.18
2.05
CD Taber Stiffness (gf-cm)
0.85
0.79
0.96
0.79
0.83
GM Taber Stiffness (gf-cm)
1.39
1.29
1.50
1.32
1.30
GM Tensile (lbf/in)
12.51
9.07
11.06
11.08
9.45
ZD Tensile (lbf/in)
75.9
56.6
64.9
74.9
62.2
Example 9
Comparison of the Present Invention to a Post-Reaction Blend
The heterogeneous polymer blend of the present invention was synthesized as in Example 2 and compared to a post-reaction polymer blend as prepared in Example 4.
A final paper product was made to a sheet ash target of 30 wt % dry weight using a pulp slurry of 70 wt % bleached hardwood and 30 wt % bleached softwood fiber. The fiber stock was refined to a freeness target of 450 mL CSF. Other standard additives (all expressed as wt % of the total thy paper furnish) included 0.75% Stalok 300 starch, available from Tate and Lyle, Decatur, Ill., 0.25% alum, available from General Chemical, Parsippany, N.J., 0.1% Prequel 1000 ASA size, 0.015% PERFORM PC8138 flocculant, and 0.01% PERFORM SP9232 drainage aid, all available from Hercules, Inc., Wilmington, Del. The size press was treated with a surface treatment of 50 lb/T of ETHYLEX 2015 hydroxyethylated corn starch, available from Tate and Lyle, Decatur, Ill. The paper machine was calendered to a top side smoothness target of 150 Sheffield units. Additionally, the finished paper product made using the present invention was compared to paper made using the same variables and additives, but that used a clustered scalenohedral-calcite filler (SMI ALBACAR® LO PCC), available from Specialty Minerals, Inc., Bethlehem, Pa., with a mean particle diameter of 2.1 microns, a 20 wt % sheet ash target, based on dry weight of the paper furnish, and no heterogeneous polymer blend. The results of the run are contained in Table 3.
At a constant top smoothness of 150 Sheffield units, both polymer treatments improved both the in-plane and z-directional tensile properties over the untreated finished paper. However, the heterogeneous polymer compound in conjunction with the acicular-aragonite precipitated calcium carbonate filler provided the highest stiffness values and the overall best finished paper qualities.
TABLE 3
COMPARISON OF IN-SITU HETEROGENEOUS POLYMER
BLEND TO POST-REACTION HOMOPOLYMER BLEND
Filler
ALBACAR ®
ULTRABULK ®
ULTRABULK ®
LO PCC
II PCC
II PCC
Chemical Treatment
No
Example 2 - 0.45%
Example 4 - 0.45%
In-situ blend
Post-reaction blend
Application Point
None
Wet End
Wet End
Ash (525C) (%)
31.0
29.8
30.2
MD Taber Stiffness (gf-cm)
2.21
2.52
2.37
CD Taber Stiffness (gf-cm)
0.91
1.06
1.01
GM Taber Stiffness (gf-cm)
1.42
1.63
1.55
GM Tensile (lbf/in)
9.87
12.19
11.34
ZD Tensile (psi)
67.1
71.2
66.5
Example 10
Ability of the Heterogeneous Polymer Blend to Increase or Maintain Paper Machine Runnability
The heterogeneous polymer blend was synthesized as in Example one and evaluated on a Noble and Wood handsheet study to evaluate the blend's effect on paper machine runnability. The fiber furnish for the runs consisted of 70 wt % of 360 mL CSF bleached hardwood Kraft blended with 30 wt % 500 mL CSF bleached softwood Kraft. An inorganic calcium carbonate filler of ULTRABULK® II PCC, available from Specialty Minerals, Inc., Bethlehem, Pa., was added to the fiber furnish to consist of between 20 and 30 wt %, based on the dry weight of the paper furnish. Additionally, a control sheet using ALBABAR® LO PCC but without the heterogeneous polymer blend was made for comparison purposes. The suspension was diluted with 1 wt % solids, based on the dry weight of the paper furnish. A standard additive package of 0.75% Stalok 300 starch, available from Tate and Lyle, Decatur, Ill., 0.25% alum, available from General Chemical, Parsippany, N.J., 0.02% PERFORM PC8138 flocculant, and 0.02% PERFORM SP7200 drainage aid was added to the furnish (all percentages are based on the dry weight % of the total furnish).
Aliquots of the treated and untreated furnish were used to produce 8×8-inch square handsheets with a target basis weight of 90 lbs/3000 square feet. The sheets were pressed via standard conditions, but were not dried. Each pressed sheet was then sandwiched between two plastic transparency sheets and a paper cutter was used to cut the paper/transparency sheets into 1-inch wide strips. The strips were tested for never-dried wet tensile strength using an Instron-type machine. Separate handsheets from identical test conditions were then dried to evaluate each test condition for solids, basis weight, and retained ash content. These evaluations were done using standard TAPPI methods.
Increasing the retained sheet ash from 17 to 25 wt %, based on the dry weight of the finished paper, in conjunction with the filler type change resulted in a 56% drop in never-dried wet tensile strength with no change in press solids. The addition of 0.2 wt %, based on the dry weight of the paper furnish, of the heterogeneous polymer blend from Example 1, improved performance over the untreated furnish by 38%. When the paper furnish was treated with 0.4 wt %, based on the dry weight of the paper furnish, it improved performance over the untreated furnish by 65%.
Paper machine runnability is closely related to the cohesiveness of the wet web exiting the press section; the higher cohesiveness, the more “runnable” the furnish. The addition of the heterogeneous polymer blend of the present invention increased the web's cohesiveness, which is expected to translate into improved paper machine runnability at elevated sheet ash content. The results of are provided in Table 4.
TABLE 4
IMPROVEMENT IN WET WEB COHESION
Ash
Wet
Condition
(525C)
Filler
Tensile
Solids
Units
(%)
Type
(lbf/in)
(%)
Control
16.7
ALBACAR LO ® PCC
0.92
49.9
Control
25.5
ULTRABULK ® II PCC
0.40
49.7
0.2% Example 1
25.4
ULTRABULK ® II PCC
0.60
47.1
0.4% Example 1
24.7
ULTRABULK ® II PCC
0.74
46.3
Example 11
Utility of the Heterogeneous Polymer Blends to Decrease Slurry Abrasiveness
The heterogeneous polymer blend of the present invention was synthesized as in Example 1 and evaluated against an untreated filler/slurry mixture, and slurry mixture treated with 1.5 wt %, based on the dry weight of the slurry, of a two component poly-DADMAC/acrylate/acrylamide copolymer. Both ALBACAR® SP PCC and ULTRABULK® II PCC, both available from Specialty Minerals, Inc., Bethlehem, Pa., were used as the inorganic filler for evaluation.
Abrasion potential was evaluated using an Einlehner abrasion tester (model AT2000) to determine how the slurries would cause wear on the synthetic wires of paper machines. The amount of wear caused by the fillers or other additives is determined by the weight loss of a test wire. The test wire loses material as a result of the sliding friction generated by a rotary abrader “test body” in an aqueous suspension of the filler or pigment that is being tested. The weight the test wire loses after completion of a specific distance at a defined pressure level is used to compare the amount of wear caused by the filler or pigment tested.
The test wire is fed around a rotary abrader consisting of ceramic ledges. The rotary abrader is attached to the bottom of the vertical drive shaft and is open at the top. The test wire engages a fixed supporting rod and a supporting rod that pivots around this fixed rod and is pressed against the rotary abrader by a loading weight. The test wire and the rotary abrader are immersed completely in a suspension of the filler or pigment that is in a glass test cylinder. The suspension is able to reach the test wire from the inside through the gaps between the ceramic ledges of the rotary abrader, with the help of the suction created between the wire and the rotary abrader. The suspension is kept thoroughly mixed by the rotary movement of the ceramic ledge abrader. The suspension consistency is chosen so that the weight loss is in target with a reference GCC filler sample with both rotary abraders. The outside of the wire is covered with adhesive tape, so that an adequate film of liquid forms between the ceramic ledges and the wire.
The standard setting for the Einlehner AT2000 abrasion test is 1-kg weight for wire tension, and 25,000 meters distance for rotary abrader movement. The rotary abrader moves at a speed of 333 m/min, so one test takes 75-minutes to complete. The filler samples were tested once with two rotary abraders, and the resulting weight loss (in mg) is an average of these two measurements. The sample amount per test was 9.5 g dry for test body #2062, and 8.5 g dry for test body #2137.
Slurry runs were evaluated for both the ALBACAR® SP PCC and the ULTRABULK® II PCC for the following: untreated slurry, 1.5 wt %, based on the dry weight of the slurry, of the heterogeneous polymer blend, 1.5 wt %, based on the dry weight of the slurry, of the two component compound. While use of the two component polymer only resulted in a slight decrease in slurry abrasiveness, the heterogeneous polymer compound of the present invention resulted in a remarkable decrease in slurry abrasion. The results of the various runs are summarized in Table 5.
TABLE 5
SLURRY ABRASIVITY VIA EINLEHNER
ABRASION ANALYSIS
ALBACAR ®
ULTRABULK ®
SP PCC
II PCC
(mg weight loss)
(mg weight loss)
Untreated Control
9.0
7.0
Example 1 treated
3.4
4.1
(1.5% on filler)
Perform ® PC8229,
8.0
6.1
Hercobond ® 2000 treated
(1.5% on filler)
Example 12
Papermaking Utility of a SSA/AM/MAPTAC Heterogeneous Polymer Blend
The SSA/AM/MAPTAC heterogeneous polymer blend was synthesized as in Example 5 and added to a pulp slurry to evaluate the properties of a final paper product made from the slurry. ALBACAR® LO PCC was used as the inorganic filler. The heterogeneous polymer blend was mixed with the ALBACAR® LO PCC and allowed to stir with low shear at room temperature prior to addition to the slurry.
The final paper product was made as in Example 7 to a sheet ash target of 30 wt % dry weight using a pulp slurry of 70 wt % bleached hardwood and 30 wt % bleached softwood fiber. The fiber stock was refined to a freeness target of 450 mL CSF. Other standard additives (all expressed as wt % of the total dry paper furnish) included 0.75% Stalok 300 starch, available from Tate and Lyle, Decatur, Ill., 0.25% alum, available from General Chemical, Parsippany, N.J., 0.1% Prequel 1000 ASA size, 0.015% PERFORM PC8138 flocculant, and 0.01% PERFORM SP9232 drainage aid, all available from Hercules, Inc., Wilmington, Del. The size press was treated with a surface treatment of 50 lb/T of ETHYLEX 2015 hydroxyethylated corn starch, available from Tate and Lyle, Decatur, Ill. The paper machine was calendered to a top side smoothness target of 150 Sheffield units.
Both polymeric products allowed a higher final ash content in the final paper product, without degradation of strength relative to the 20 wt % ash control sheet. The results of the run are contained in Table 6.
TABLE 6
COMPARISON OF SSA/AM/MAPTAC HETEROGENEOUS POLYMER BLEND PERFORMANCE
TO AN AA/AM/DADMAC HETEROGENEOUS POLYMER BLEND PERPORMANCE
Filler
ALBACAR ®
ALBACAR ®
ALBACAR ®
ALBACAR ®
LO PCC
LO PCC
LO PCC
LO PCC
Chemical Treatment
No
No
Example 3 - 2% relative
Example 5 - 2% relative
to PCC solids
to PCC solids
Application Point
None
None
PCC pre-treatment
PCC pre-treatment
Ash (525C) (%)
21.1
30.7
26.6
26.71
MD Taber Stiffness (gf-cm)
2.13
1.79
2.37
2.38
CD Taber Stiffness (gf-cm)
0.79
0.69
0.72
0.76
GM Taber Stiffness (gf-cm)
1.30
1.11
1.31
1.35
GM Tensile (lbf/in)
12.18
10.29
11.43
11.89
ZD Tensile (psi)
99.0
72.4
90.0
92.6
Example 13
Comparison of the Heterogeneous Polymer Blend with a Heterogeneous Polymer Blend Synthesized by Reversing Addition Order
The heterogeneous polymer blend as synthesized in Example 3 was compared against the heterogeneous polymer blend synthesized by reversing the addition or, as in Example 6 and the efficacy of the two polymer blends was compared, ULTRABULK® II PCC was used as the inorganic filler. Additionally, an untreated ALBACAR® LO PCC control sheet was formed.
The final paper product was made as in Example 7 to a sheet ash target of 30 wt % dry weight using a pulp slurry of 70 wt % bleached hardwood and 30 wt % bleached softwood fiber. The fiber stock was refined to a freeness target of 450 mL CSF. Other standard additives (all expressed as wt % of the total dry paper furnish) included 0.75% Stalok 300 starch, available from Tate and Lyle, Decatur, Ill., 0.25% alum, available from General Chemical, Parsippany, N.J., 0.1% Prequel 1000 ASA size, 0.015% PERFORM PC8138 flocculant, and 0.01% PERFORM SP9232 drainage aid, all available from Hercules, Inc., Wilmington, Del. The size press was treated with a surface treatment of 50 lb/T of ETHYLEX 2015 hydroxyethylated corn starch, available from Tate and Lyle, Decatur, Ill. The paper machine was calendered to a top side smoothness target of 150 Sheffield units.
At a constant smoothness of 150 Sheffield units, the heterogeneous polymer blend as synthesized in Example 3 performed better than the heterogeneous polymer blend synthesized using the reverse addition order. Both blends performed better than the untreated control. The results are summarized in Table 7.
TABLE 7
PERFORMANCE COMPARISON OF HETEROGENEOUS POLYMER
BLENDS MADE IN REVERSE REACTION ORDER
Filler
ALBACAR ®
ALBACAR ®
ULTRABULK ®
ULTRABULK ®
LO PCC
LO PCC
II PCC
II PCC
Chemical Treatment
No
No
Example 6 0.45%
Example 3 0.45%
Application Point
None
None
Wet End
Wet End
Ash (525C) (%)
20.0
28.9
29.5
29.1
MD Taber Stiffness (gf-cm)
2.39
1.92
1.94
1.90
CD Taber Stiffness (gf-cm)
1.03
0.81
0.85
0.88
GM Taber Stiffness (gf-cm)
1.56
1.25
1.28
1.29
GM Tensile (lbf/in)
11.64
8.92
9.60
10.39
ZD Tensile (psi)
80.8
67.9
75.7
85.0
Example 14
Papermaking Utility as a Comparison of ALBACAR® SP-3 and ULTRABULK® II Precipitated Calcium Carbonates Used with the Heterogeneous Polymer Blend
The heterogeneous polymer blend of the present invention was synthesized as in Example 6 and the properties of a final paper product were evaluated using two different precipitated calcium carbonate fillers—a acicular-aragonite precipitated calcium carbonate (ULTRABULK® II PCC) and a clustered scalenohedral precipitated calcium carbonate (ALBACAR® SP-3), both available from Specialty Minerals, Inc., Bethlehem, Pa., Wilmington, Del. The two fillers had mean particle diameters of 3.9 and 3.0 microns, respectively. Paper made from pulp slurry containing only the inorganic filler was used as a control.
The final paper product was made as in Example 7 to a sheet ash target of 30 wt % dry weight using a pulp slurry of 70 wt % bleached hardwood and 30 wt % bleached softwood fiber. The fiber stock was refined to a freeness target of 450 mL CSF. Other standard additives (all expressed as wt % of the total dry paper furnish) included 0.75% Stalok 300 starch, available from Tate and Lyle, Decatur, Ill., 0.25% alum, available from General Chemical, Parsippany, N.J., 0.1% Prequel 1000 ASA size, 0.015% PERFORM PC8138 flocculant, and 0.01% PERFORM SP9232 drainage aid, all available from Hercules, Inc., Wilmington, Del. The size press was treated with a surface treatment of 50 lb/T of ETHYLEX 2015 hydroxyethylated corn starch, available from Tate and Lyle, Decatur, Ill. The paper machine was calendered to a top side smoothness target of 150 Sheffield units. The results of the run are contained in Table 8 (ALBACAR®) and Table 9 (ULTRABULK®).
At a constant top smoothness of 150 Sheffield units, final paper made from pulp slurry containing the ULTRABULK® II PCC or ALBACAR SP-3 PCC treated with the heterogeneous polymer mixture performed better than untreated paper.
TABLE 8
PERFORMANCE COMPARISON OF THE HETEROGENEOUS POLYMER BLEND WITH
ALBACAR ® SP-3, AND UNTREATED FINISHED PAPER
Filler
ALBACAR ®
ALBACAR ®
ALBACAR ®
ALBACAR ®
ALBACAR ®
LO PCC
LO PCC
SP-3 PCC
SP-3 PCC
SP-3 PCC
Chemical Treatment
No
No
No
Example 3 0.33%
Example 3 0.50%
Application Point
None
None
None
Wet End
Wet End
Ash (525C) (%)
21.0
29.6
30.4
29.1
30.1
MD Taber Stiffness (gf-cm)
1.99
1.60
1.54
1.65
1.68
CD Taber Stiffness (gf-cm)
0.81
0.58
0.65
0.67
0.71
GM Taber Stiffness (gf-cm)
1.27
0.97
1.00
1.05
1.09
GM Tensile (lbf/in)
9.24
7.26
7.27
7.89
8.02
ZD Tensile (psi)
73.2
61.1
63.0
69.6
69.2
TABLE 9
PERFORMANCE COMPARISON OF THE HETEROGENEOUS
POLYMER BLEND WITH ULTRABULK ® II,
AND UNTREATED FINISHED PAPER
Filler
ULTRABULK ®
ULTRABULK ®
ULTRABULK ®
II PCC
II PCC
II PCC
Chemical Treatment
No
Example 3 0.33%
Example 3 0.50%
Application Point
None
Wet End
Wet End
Ash (525C) (%)
31.0
29.5
28.7
MD Taber Stiffness (gf-cm)
1.69
1.67
1.70
CD Taber Stiffness (gf-cm)
0.61
0.76
0.79
GM Taber Stiffness (gf-cm)
1.02
1.13
1.16
GM Tensile (lbf/in)
8.02
8.50
8.72
ZD Tensile (psi)
69.6
68.6
72.8
It will be appreciated by those skilled in the art that changes could be made to the embodiments and examples described above without departing from the broad inventive concept thereof. It is understood, therefore, that this invention is not limited to the particular embodiments and examples disclosed, but is instead intended to cover modifications within the spirit and scope of the present invention as defined by the appended claims.
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Methods for making a heterogeneous polymer blend comprising one or more anionic polymers, one or more cationic polymers, and one or more non-ionic polymers, which method comprises (a) adding to a non-neutral solution a first amount of polymerization initiator and one or more anionic or cationic monomers, wherein each monomer has the same charge; (b) adding a second amount of the polymerization initiator and one or more non-ionic monomers; (c) adding a third amount of the polymerization initiator and one or more ionic monomers that are oppositely charged from the monomers of (a); adding stepwise, a fourth amount of the polymerization initiator to react any residual monomer, and (e) neutralizing the resulting polymer blend. Also claimed are heterogeneous polymer blends containing polymers formed from one or more anionic, cationic, and non-ionic monomers, either polymerized in situ or separately and then combined. Also claimed are methods for increasing the filler content of paper or paperboard, which methods comprises (a) combining the heterogeneous polymer blend with a precipitated calcium carbonate filler; (b) combining the resulting mixture with a pulp slurry; and (c) processing the resulting slurry mixture to form a sheet of paper or paperboard. Finally, also claimed are methods of increasing the filler content of paper or paperboard, which method comprises (1) combining either the heterogeneous blend or the precipitated calcium carbonate filler with a pulp slurry, (2) combining the remaining component with the pulp slurry; and (c) processing the resulting pulp slurry mixture to form a sheet of paper or paperboard.
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FIELD OF THE INVENTION
[0001] The present application relates generally to low and high molecular weight double stranded RNA (“dsRNA”) and single stranded RNA (“ssRNA”) in their use to induce cell death and cell apoptosis and in particular, in transformed cells.
BACKGROUND OF THE INVENTION
[0002] Several investigators in the 1970s and 1980s have reported the binding of high molecular weight DNA to cell membranes. Various polynucleotide strands have been extensively evaluated as biological response modifiers. One example is polyI:polyC which is a potent inducer of IFN production as well as a macrophage activator and inducer of NK activity (Talmadge et. al., “Immunomodulatory effects in mice of polyinosinic-polycytidylic acid complexed with poly-L:-lysine and carboxymethylcellulose”. Cancer Res. 45:1058, 1985.) Several clinical trials were conducted using polyI:polyC complexed with poly-L-lysine and carboxymethylcellulose to improve stability (Talmadge, J. et al., “Immunomodulatory Effects In Mice of Polyinosinic-polycytidylic Acid Complexed With Poly-L Lysine and Carboxymethylcellulose”, Cancer Res. 45:1058, 1985). However, toxic side effects due to the cytokine TNF-alpha have prevented polyI:polyC from becoming a useful therapeutic agent.
[0003] Short interfering RNA (siRNA) have been shown to induce sequence-specific posttranscriptional gene silencing of homologous RNA using 21 and 22 nucleotide RNA (Elbashir et al “RNA interference is mediated by 21-22 nucleotide RNAs”. Genes Dev. Jan. 15, 2001;15(2):188-200) which is quite different than the non-sequence specific action of the dsRNA noted in this disclosure.
[0004] Certain DNA structures also have been reported to have the potential to activate lymphocytes. For example, nucleosomal protein-DNA complexes in spleen cell supernatants was reported to cause B cell proliferation and immunoglobulin secretion (bell, et al. “Immunogenic DNA-related factors”. J. Clin. Invest. 85:1487, 1990). Naked DNA has also been reported to have immune effects. For example, it was reported that 260 to 800 bp fragments of poly (dG):(dC) were mitogenic for B cells (Messina, et al. “The influence of DNA structure on the in vitro stimulation of murine lymphocytes by natural and synthetic polynucleotide antigens”. Cell. Immunol. 147:148, 1993). Pisetsky et al. reported that pure mammalian DNA has no detectable immune effects, but that DNA from certain bacteria induces B cell activation and immunoglobulin secretion (Pisetsky et al. “Stimulation of in vitro murine lymphocyte proliferation by bacterial DNA”. J. Immunol. 147:1759; 1991). There were also certain oligodeoxynucleotides containing unmethylated cytosine-guanine (CpG) dinucleotides activate lymphocytes as evidenced by in vitro and in vivo data.
[0005] Non-coding RNA motifs are produced by cells infected with negative stranded RNA or certain DNA viruses. Certain dsRNAs are recognized by innate immune cells and known to bind to Toll-like receptor 3 (Alexopoulou et al. “Recognition of double-stranded RNA and activation of NF-kappaB by Toll-like receptor 3”. Nature 413:732-738; 2001). In addition, these dsRNAs have been found to influence both the innate and adaptive immune response (Wang et al. “Noncoding RNA danger motifs bridge innate and adaptive immunity and are potent adjuvants for vaccination”. J. Clin. Invest. 110: 1175-84; 2002).
SUMMARY OF THE INVENTION
[0006] The present application is directed to the use of dsRNA and ssRNA for the purpose of inducing apoptosis and/or cell death in living cells. Specifically, low molecular weight and high molecular weight dsRNA and ssRNA are shown to induce apoptosis and/or cell death in proliferating cells, to arrest proliferation of transformed cells or tumor cells, to cause rapid induction of the pro-inflammatory cytokine TNF-alpha and also induce production of IL-12 (high molecular weight RNA), a modulator in the induction of IFN-gamma T cells and the Th1 immune response.
[0007] The present invention has practical application in anti-tumor therapy or anti-leukemia therapy in the arrest of proliferation of transformed tumor cells or leukemia cells, respectively, and to rapidly induce the cytokine TNF-alpha and/or IL-12. The present invention also has practical application in anti-microbial therapy. This technology circumvents the need for a cellular transfection reagent which makes it compatible with in vivo applications and lacks the need for epitope or gene specificity, as with antisense or siRNAs, in therapy for solid cancers and leukemias. Antisense compounds need transfection reagents for both in vitro and in vivo uses and in general antisense compounds access few cells. In contrast, low molecular weight RNAs (single stranded and double stranded) transport easily across cell membranes and do not require transfection reagents.
[0008] Certain of the disclosed dsRNAs induce in innate cells either, or both, pro-inflammatory (TNF-alpha) responses or pro-apoptotic responses which may enhance the cross presentation of antigen and enhance specific immune effectors specifically toward a Th-1 response. Apoptotic cells are an excellent source of antigenic material and important for induction of effector cells (Th1 or Tc1) in cancer and infectious disease.
[0009] It is not entirely understood how low molecular weight and high molecular weight RNA strands are inducing apoptosis and/or cell death in cells. The RNA motifs may be being recognized by either Toll-like receptors on the cell membrane or following cell internalization by cells, function by mediating negative regulation of gene expression causing non-specific gene silencing. Regarding the low molecular weight RNA (ssRNA and dsRNA), it is believed that they enter the cell directly without utilizing a cell receptor. Regarding high molecular weight RNA strands (ssRNA and dsRNA), it is believed that they enter into the cell via a cell receptor and that secondary structure is therefore important or possibly critical to their function.
[0010] This invention teaches that small or low molecular weight ssRNA or dsRNA induce rapid cell death with induction of TNF-alpha in a fast growing transformed cell. In addition, this invention teaches that in fast growing transformed cells, large or high molecular weight ssRNA or dsRNA induce apoptosis with induction of IL-12, a known modulator in the induction of IFN-gamma T cells and of a Th-1 immune response, and TNF-alpha to a lesser extent, than found when induced by the low molecular weight ssRNA or dsRNA. Further, high molecular weight ssRNA or dsRNA can also be used an adjuvant and administered with an antigen to increase T 1 immunity and is important in use against infectious disease and cancers as taught in WO 03/078595 and PCT/US2003/030188, both of which are incorporated by reference in their entireties. In contrast, low molecular weight RNAs (single or double stranded), can be used as adjuvants only in some cases.
[0011] It is believed the pro-apoptotic and/or cell necrotic cellular effects of the disclosed RNA compounds to be, to a great extent, more specific to cells of high or fast proliferation capacity (as is the case with many cancer and tumor cells) in contrast to primary cells. Regarding amounts or dosage to be therapeutically effective in humans, the RNA compositions of the present invention may be administered to human patients topically, systematically, or by direct injection into a tumor, in solutions or in emulsions, and in amounts in the ranges of 1 ng/kg-999 mg/kg. Therapeutically effective dosages in humans range from 1 ng/kg-10 ng/kg, to 10 ng/kg-500 ng/kg, to 500 ng/kg-999 ng/kg, 1 μg/kg-10 μg/kg, to 10 μg/kg-100 μg/kg, 100 μg/kg-200 μg/kg, 200 μg/mg-500 μg/mg, 500 μg/kg-999 μg/kg, to 1 mg/kg-10 mg/kg, to 10 mg/kg-100 mg/kg, to 100 mg/kg-200 mg/kg and 200 mg/kg-500 mg/kg. Most preferable human dosages, depending on the application, are in the range of 1-999 μg/kg and most preferably 1-500 μg/kg or 1-100 μg/kg. If injected directly into a tumor mass, it is expected that the dosages would be in the 1 mg/kg-500 mg/kg and in the 1 mg/kg-100 mg/kg range.
[0012] Various embodiments of the invention include:
1) A method of inducing apoptosis or cell death in transformed or non-transformed cells in a patient by administering to the cells RNA strands. 2) The method of paragraph 1 wherein the RNA strands are on average between 1 kDa and 50 kDa in size. 3) The method of paragraph 1 wherein the RNA strands are dsRNA. 4) The method of paragraph 1 wherein the RNA strands are ssRNA. 5) The method of paragraph 3 wherein the dsRNA is pA:pU. 6) The method of paragraph 5 wherein the dsRNA is administered in dosages ranging from the group consisting of 1-999 μg/kg, 1-500 μg/kg, 1-100 μg/kg, 1-50 μg/kg, 1-25 μg/kg, 1-10 μg/kg and 1-5 μg/kg. 7) The method of paragraph 6 wherein the dsRNA is administered intravenously and is administrated in dosages selected from the group consisting of 1-999 μg/kg, 1-500 μg/kg, 1-100 μg/kg, 1-50 μg/kg, 1-25 μg/kg, 1-10 μg/kg and 1-5 μg/kg. 8) The method of paragraph 1 wherein the patient is human and the cells are transformed cells and dsRNA is pA:pU and the dsRNA is injected directly into the cancer cells. 9) The method of paragraph 4 wherein the ssRNA is pA. 10) The method of paragraph 1 wherein the patient is human and the transformed cells are selected from the group consisting of T cell leukemia cells, human monocytic leukemia cells, human adenocarcinoma cells and human lung fibroblasts. 11) A method of inducing cell death or apoptosis in cells by in vivo administration of ssRNA or dsRNA to cells, wherein the ssRNA or dsRNA is smaller on average than 20 kDa in size. 12) The method of paragraph 11 wherein the ssRNA or dsRNA is smaller on average than 10 kDa in size. 13) The method of paragraph 12 wherein the cells are transformed cells. 14) The method of paragraph 12 wherein the ssRNA is pA. 15) The method of paragraph 11 wherein the dsRNA is pA:pU. 16) The method of paragraph 12 wherein the cells are cancer cells. 17) The method of paragraph 1 wherein the RNA strand induces an enhanced cytokine production of TNF-alpha. 18) The method of paragraph 12 wherein the RNA strand induces an enhanced cytokine production of TNF-alpha. 19) The method of paragraph 1 wherein the use of RNA to induce cell death induces an enhanced immune response against the cells. 20) The method of paragraph 1 wherein the RNA is administered in vivo to cells and the modes of administration are selected from the group consisting of topically, systemically or by direct injection. 21) A method of inducing apoptosis in cells by administering ssRNA or dsRNA to cells, wherein the ssRNA or dsRNA is smaller than 10 KDa in size. 22) The method of paragraph 21 wherein the RNA is ssRNA and is pA. 23) The method of paragraph 21 wherein the RNA is dsRNA and is pA:pU. 24) The method of paragraph 21 wherein the cells are transformed cells. 25) The method of paragraph 21 wherein the induced apoptotic cells induce an enhanced IL-12 cytokine production against similar live cells. 26) The method of paragraph 21 wherein a Th-1 response is directed. 27) The method of paragraph 1 wherein the RNA is dsRNA and is greater than 50 kDa in weight and induces an enhanced IL-12 response. 28) A composition for inducing cell death or apoptosis in transformed cells wherein the composition is comprised of RNA with an average weight between 1-50 kDa. 29) The composition of paragraph 28 wherein the average weight of the dsRNA or ssRNA is less than 20 kDa. 30) The composition of paragraph 28 wherein the average weight of the dsRNA or ssRNA is less than 10 kDa. 31) The composition of paragraph 28 wherein the dsRNA is pA:pU. 32) The composition of paragraph 28 wherein the dsRNA induces an enhanced cytokine production of TNF-alpha thereby inducing a T 1 immune response against the transformed cells. 33) A composition for inducing cell death or apoptosis in transformed cells in a patient wherein the composition is comprised of an oligonucleotide wherein the oligonucleotide is comprised of at least two base pairs selected from the group consisting of adenine, uracil, cytosine, guanine and inosine and wherein the oligonucleotide is between 1 kDa-50 kDa in weight. 34) The composition of paragraph 33 wherein the oligonucleotide is ssRNA. 35) The composition of paragraph 33 wherein the oligonucleotide is dsRNA. 36) The composition of paragraph 33 wherein the ssRNA is pA. 37) The composition of paragraph 35 wherein the oligonucleotide is pA:pU. 38) The composition of paragraph 33 wherein the oligonucleotide is between 1 kDa-10 kDa in weight. 39) The composition of paragraph 33 wherein the oligonucleotide is between 1 kDa-5 kDa in weight. 40) Use of a composition in the manufacture of a medicament for inducing cell death or apoptosis in transformed cells wherein the composition is comprised of an oligonucleotide wherein the oligonucleotide is comprised of at least two base pairs selected from the group consisting of adenine, uracil, cytosine, guanine and inosine and wherein the oligonucleotide is between 1 kDa-50 kDa in weight. 41) The use of paragraph 40 wherein the oligonucleotide is ssRNA. 42) The use of paragraph 40 wherein the oligonucleotide is dsRNA. 43) The use of paragraph 40 wherein the ssRNA is pA. 44) The use of paragraph 40 wherein the oligonucleotide is pA:pU. 45) The use of paragraph 40 wherein the oligonucleotide is between 1 KDa-10 kDa in weight. 46) The use of paragraph 40 wherein the oligonucleotide is between 1 kDa-5 kDa in weight. 47) Use of a composition in the manufacture of a medicament for inducing cell death or apoptosis in transformed cells wherein the composition is comprised of RNA with an average weight between 1-50 kDa. 48) The use of paragraph 47 wherein the average weight of the dsRNA or ssRNA is less than 20 kDa. 49) The use of paragraph 47 wherein the average weight of the dsRNA or ssRNA is less than 10 kDa. 50) The use of paragraph 47 wherein the dsRNA is pA:pU. 51) The use of paragraph 47 wherein the dsRNA induces an enhanced cytokine production of TNF-alpha. 52. The use of paragraph 51 wherein the enhanced production of TNF-alpha and induces T 1 immunity against the transformed cells.
BRIEF DESCRIPTION OF THE DRAWINGS
[0065] FIG. 1 shows the effects of high molecular weight synthetic RNAs on inducing apoptosis in antigen presenting cells (APCs),
[0066] FIG. 2 shows the effects of low and high molecular weight RNAs on inducing cell death on transformed human monocytic cells;
[0067] FIG. 3 shows the cytokine profile of TNF-α and IL-12 expression based on human antigen presenting cells;
[0068] FIG. 4 is a table showing the differential effects of fractionated low molecular and high molecular weight RNA;
[0069] FIG. 5 shows that various concentrations of low molecular weight pA:pU was significantly better at inducing substantial apoptosis and cell death among human T cell leukemia cell lines than the high molecular weight pA:pU, whole pA:pU or the controls;
[0070] FIG. 6 demonstrates that low molecular weight pA:pU was significantly able to induce apoptosis and cell death among the human T lymphocyte cell lines than either the high molecular weight pA:pU and whole pA:pU and the controls;
[0071] FIG. 7 demonstrates that low molecular weight pA:pU, particularly at the higher concentration of 100 μg/ml, was able to induce significant levels of cell death and apoptosis among human T cell lymphoblastic leukemia cells;
[0072] FIG. 8 demonstrates that low molecular weight pA:pU, particularly at concentrations of 100 μg/ml, was significantly better at inducing substantial apoptosis and cell death among human monocytic leukemia cells lines than either the controls or high molecular weight pA:pU;
[0073] FIG. 9 demonstrates that low molecular weight pA:pU was successful at inducing apoptosis and cell death among human cervical adenocarcinoma cells;
[0074] FIG. 10 demonstrates that low molecular weight pA:pU was significantly better at inducing substantial apoptosis and cell death among human lung fibroblasts than either the high molecular weight pA:pU, whole pA:pU or the controls;
[0075] FIG. 11 shows that neither low or high molecular weight pA:pU was able to induce cell death in breast cancer cells;
[0076] FIGS. 12A-12B shows that neither low nor high molecular weight dsRNA was able to induce cell death or apoptosis in human PBMCs; and,
[0077] FIG. 13 shows low molecular weight dsRNA fraction and pA:pU of known oligomer length to display cell death inducing effects on monocytic leukemia cells.
DETAILED DESCRIPTION OF THE INVENTION
[0000] Definitions:
[0078] As used herein, the following terms and phrases shall have the meanings set forth below:
[0079] A “dsRNA” shall mean a double stranded RNA segment which may be comprised of the bases adenine, cytosine, uracil, guanine and inosine and which may be entirely complimentary, partially -complementary or a mixed nucleotide strand;
[0080] A “ssRNA” shall mean a single stranded RNA segment which may be comprised of the bases adenine, cytosine, uracil, and guanine either uniformly of one nucleotide or of mixed nucleotides;
[0081] “Low molecular weight dsRNA or ssRNA” means RNA strands of approximately 10 kDa or less (<10 k MW). Preferably, the low molecular weight ssRNA and dsRNA strands of the present invention range between 2 to 40 base pairs;
[0082] “High molecular weight dsRNA or ssRNA” means RNA strands of approximately 10 kDa or more and between 10 kDa and 50 kDa but also greater than 50 kDa (>50 k MW);
[0083] “Whole dsRNA” refers to the dsRNA of any or all molecular weight or oligomer length;
[0084] “APC” means antigen presenting cell;
[0085] “Cell death” refers to death of a cell from other than apoptosis;
[0086] “Apoptosis” refers to programmed cell death;
[0087] “Th-1 response” refers to a T-helper 1 response;
[0088] “pA:pU”—refers to dsRNA where the RNA strand or segment is comprised of adenine and uracil where the RNA strand or segment is complementary and encompasses RNA strands or segments that are not uniformly complementary;
[0089] “-mer”—shorthand term for oligomer;
[0090] “HL-1 media”—HL-1 medium (BioWhittaker, Walkersville Md., cat#344017) with 2 mM L-glutamine (Invitrogen, Carlsbad, Calif., cat#11875-085), 50 units/ml penicillin-streptomycin (Invitrogen, cat#15070-063), 1.0 mM sodium pyruvate (Invitrogen, cat#11360-070) and supplemented with 0.05 mM 2-mercaptoethanol (Invitrogen, cat#21985-023);
[0091] “<” means less than; and
[0092] “>”—means greater than.
EX. 1
High Molecular Weight Synthetic RNA was Able to Induce Substantial Apoptosis of Human Antigen Presenting Cells (APC)
[0093] Human APCs (THP-1 cells, American Type Culture Collection [ATCC], Manassas, Va.) were maintained under conditions as suggested by the ATCC: (a) Media: RPMI 1640 medium with 2 mM L-glutamine (Invitrogen, Carlsbad, Calif., cat#11875-085) adjusted to contain 10 mM HEPES (Invitrogen, cat#15630-080), 50 units/ml penicillin-streptomycin (Invitrogen, cat#15070-063) and 1.0 mM sodium pyruvate (Invitrogen, cat#11360-070) and supplemented with 0.05 mM 2-mercaptoethanol (Invitrogen, cat#21985-023), fetal bovine serum (FBS) 10% (Invitrogen, cat#26170-019); (b) continuous culture: in cell culture flasks (Corning, Corning N.Y., cat#430641) fresh media substituted every 3 days for up to 4 months when a new culture was started; and (c) temperature: 37° C., 5% CO 2 .
[0094] THP-1 cells were suspended in the above described media and differentiated upon addition of 0.05 μM vitamin D3 (CalBiochem, San Diego, Calif.). Cells were immediately added to sterile 48 well tissue culture plates (BD Falcon, cat#353078) at a concentration of 0.4×10 6 cells per well (0.5 ml of 0.8×10 6 cells per ml) and allowed to mature for 3 days. At this time, 0.2 mls fresh non-FBS containing HL-1 media replaced the 0.5 mls of media covering the now adherent cells in the microtiter plate wells. The endotoxin tested and fractionated (described separately) high molecular weight (>50 kDa) polyadenylic acid-polyuridylic acid (pA:pU, Sigma, cat#P1537, lot#022K4068) or polyadenylic acid (pA, Sigma, cat#P9403, lot#022K4022) was added to cells in media at 50 μg/ml. Cells were allowed to incubate in sterile conditions at 37° C./5% CO 2 for 2, 6 or 24 hrs. At these same time points, supernatants were collected and frozen (−70° C.) for further analysis at a later time. Sterile, cold phosphate buffered saline (PBS, Sigma, cat#D8537) was added gently over the cells followed by staining with Yo-Pro (Molecular Probes, Eugene, Oreg., cat#Y-3603, 0.15 μM final concentration) an indicator of apoptosis. After 10 minutes of incubation, cells were washed once and suspended in buffer containing 2% FBS and stored on ice. Cells were then analyzed for apoptosis with a FACS Calibur flow cytometer (BD Bioscience, San Jose, Calif.) using appropriate filters to analyze cellular uptake of Yo-Pro in comparison to appropriate control cells.
[0095] The results demonstrate that higher molecular weight dsRNA fractions, pA:pU (>50 KDa), were able to induce substantial apoptosis of human antigen presenting cells. In the control at time intervals of 2, 6 and 24 hours, only minimal apoptosis was observed. However, a significantly higher level of apoptosis was observed for pA (>50 kDa) at intervals of 2, 6 and 24 hours and a dramatically higher induction of apoptosis was observed in cells incubated with pA:pU (>50 kDa).
EX. 2
Low dsRNA Molecular Weight Fractions Display Apoptosis and Cell Death Inducing Effects on Transformed Human Monocytic Cells
[0096] Human APCs (THP-1 cells, American Type Culture Collection [ATCC], Manassas, Va.) were maintained under conditions as suggested by the ATCC: Media: RPMI 1640 medium with 2 mM L-glutamine (Invitrogen, Carlsbad, Calif., cat#11875-085) adjusted to contain 10 mM HEPES (Invitrogen, cat#15630-080), 50 units/ml penicillin-streptomycin (Invitrogen, cat#15070-063) and 1.0 mM sodium pyruvate (Invitrogen, cat#11360-070) and supplemented with 0.05 mM 2-mercaptoethanol (Invitrogen, cat#21985-023), fetal bovine serum (FBS) 10% (Invitrogen, cat#26170-019); temperature: 37° C., 5% CO 2 . Continuous culture: in cell culture flasks (Corning, Corning, N.Y.; cat#430641) fresh media substituted every 3 days for up to 4 months when a new culture was started.
[0097] THP-1 cells were suspended and differentiated in above media to which 0.05 μM vitamin D3 (CalBiochem, San Diego, Calif.) was added. Cells were immediately added to sterile 48 well tissue culture plates (BD Falcon, cat#353078) at a concentration of 0.4×10 6 cells per well and allowed to mature for 3 days. At this time, 0.2 mls fresh non-FBS containing HL-1 media replaced the 0.5 mls of media covering the now adherent cells in the microtiter plate wells. The endotoxin tested and fractionated (described separately) high molecular weight (>50 kDa) polyadenylic acid-polyuridylic acid (pA:pU, Sigma, cat#P1537, lot#022K4068) or polyadenylic acid (pA, Sigma, cat#P9403, lot#022K4022) was added to cells in media at 50 mg/ml. Cells were allowed to incubate in sterile conditions at 37° C./5% CO 2 for 2, 6 or 24 hrs. At these same time points, supernatants were collected and frozen (−70° C.) for further analysis at a later time. Sterile, cold phosphate buffered saline (PBS, Sigma, cat#D8537) was added gently over the cells followed by staining with ethidium bromide (Sigma, cat#46067, 1.5 μg/ml final concentration) an indicator of cell death and/or Yo-Pro (Molecular Probes, Eugene, Oreg., cat#Y-3603, 0.15 μM final concentration) an indicator of apoptosis. After 10 minutes of incubation, cells were analyzed by fluorescent microscopy using appropriate filters to differentiate between apoptotic and dead cells from live cells and images taken (as shown in FIG. 2 ) using a fluorescent microscope with appropriate filters and image analysis system using Image Pro software (Media Cybernetics, Carlsbad, Calif.).
[0098] The results demonstrate that low molecular weight RNA strands (pA and pA:pU <10 kDa) induce cell death significantly more effectively than higher molecular weight RNA strands (pA and pA:pU>50 kDa) and both induced cell death more extensively than the control (nil). The results also indicate that low molecular weight ssRNA and dsRNA (<10 kDa) are more successful than high molecular weight ssRNA and dsRNA (>50 kDa) at inducing apoptosis in cells and are dramatically more successful in inducing apoptosis than the control.
[0099] It is theorized that low molecular weight RNAs (<10 kDa) enter into the cell without a receptor while high molecular weight RNAs (>50 kDa) enter into a cell by engaging a cellular receptor. It is also theorized that the uptake by cellular receptors of high molecular weight RNAs depend on the secondary structure of the RNA strand.
EXAMPLE 3
Cytokine Profile of Human APC Following Exposure to RNA Motif Fractions
[0100] Human APCs (THP-1 cells, American Type Culture Collection [ATCC], Manassas, Va.) were maintained under conditions as suggested by the ATCC: Media: RPMI 1640 medium with 2 mM L-glutamine (Invitrogen, Carlsbad, Calif., cat#11875-085) adjusted to contain 10 mM HEPES (Invitrogen, cat#15630-080), 50 units/ml penicillin-streptomycin (Invitrogen, cat#15070-063) and 1.0 mM sodium pyruvate (Invitrogen, cat#11360-070) and supplemented with 0.05 mM 2-mercaptoethanol (Invitrogen, cat#21985-023), fetal bovine serum (FBS) 10% (Invitrogen, cat#26170-019) Temperature: 37° C., 5% CO 2 . Continuous culture: in cell culture flasks (Corning, Corning, N.Y., cat#430641) fresh media substituted every 3 days for up to 4 months when a new culture was started.
[0101] THP-1 cells were suspended and differentiated in above media to which 0.05 μM vitamin D3 (CalBiochem, San Diego, Calif.) was added. Cells were immediately added to sterile 48 well tissue culture plates (BD Falcon, cat#353078) at a concentration of 0.4×10 6 cells per well and allowed to mature for 3 days. At this time, 0.2 mls fresh non-FBS containing HL-1 media replaced the 0.5 mls of media covering the now adherent cells in the microtiter plate wells. The endotoxin tested whole and fractionated (described separately) high molecular weight (>50 kDa) polyadenylic acid-polyuridylic acid (pA:pU, Sigma, cat#P1537, lot#022K4068) or polyadenylic acid (pA, Sigma, cat#P9403, lot#022K4022) was added to cells in media at 50 mg/ml. Cells were allowed to incubate in sterile conditions at 37° C./5% CO 2 for 2, 6 or 24 hrs. At these same time points, supernatants were collected and frozen (−70° C.) prior to cytokine analysis. ELISA assays for human EL-12 (Biosourse International, Camarillo, Calif., cat #KHC0121) or human TNF-alpha (Biosourse International, cat#KHC3011) were used to determine cytokine concentrations in cell supernatants ( FIG. 3 ). ELISA assays were carried out per instructions provided by manufacturer.
[0102] The results demonstrate (see FIG. 3 ) that low molecular weight ssRNA and dsRNA (<10 kDa pA:pU and pA) motifs are able to induce the pro-inflammatory cytokine TNF-alpha. Of low molecular weight RNA motifs, dsRNAs (<10 kDa pA:pU) were somewhat more successful in inducing TNF-alpha than ssRNAs (<10 kDa pA). Higher molecular weight RNA motifs (>50 kDa pA:pU and >50 kDa pA) were also able to significantly induce TNF-alpha significantly better than the control. Thus not only do low and higher molecular weight RNAs induce cell death and apoptosis but they are able to induce pro-inflammatory cytokine TNF-alpha thereby facilitating an immune response against cells thereby resulting in both a cytotoxic effect against the cells followed by directing a subsequent or enhanced immune response against the cells. In contrast to the pro-inflammatory cytokine TNF-alpha production following treatment with low molecular weight single or double stranded RNA, the results demonstrate that higher molecular weight (>50 kDa pA:pU) was able to induce a significant IL-12 production, when compared to any other treatment or control (nil), which is indicative of Th1 response modulation.
EXAMPLE 4
Demonstrates how Synthetic RNA is Fractionated, Purified and the Concentration Ascertained Prior to Use
[0103] The bulk synthetic RNA material is obtained by standard methods of organic synthesis and can be obtained commercially. For example, RNA motif polyadenylic acid -polyuridylic acid (pA:pU, Sigma, cat#P1537, lot #22K4068) or polyadenylic acid (pA, Sigma, cat#p9403, lot#22K4022) can be obtained from Sigma. The fractions used in many of these Examples comprise synthetic RNA of less than 20 bp to approximately 100 bp in size. However, use of all sizes of RNA can be used and are within the scope of the invention.
[0104] The synthetic RNA material is fractionated by a series of centrifugation steps through filters of defined porosity. Per the manufacturer's instructions, approximately 20 mgs of the pA:pU was placed into a Centriprep YM-50, 50K MWCO (Amicon, cat #4323) for centrifugal filtration and centrifuged at 1500×g for 15 minutes. The filtrate, of less than 50K MW, was collected and the YM-50 was spun two additional times, as above, with both the filtrate (<50K MW) and retentate (>50K MW) saved. The filtrate (<50K MW) was then placed into a Centriprep YM-10, 10K MWCO (Amicon, cat #4304) and centrifuged at 3000×g, two times, for 20 minutes and both the filtrate (<10K MW) and retentate (>10K MW) was saved.
[0105] After fractionating the bulk synthetic RNA material, the material is dissolved in sterile endotoxin-free saline (e.g., Dulbecco's Phosphate Buffered Saline [PBS], sterile, endotoxin tested, [Sigma, cat#D8537]) and passed through separate endotoxin removal columns such as AffinitiPak Detoxi-Gel Endotoxin Removing Gel Column (Pierce Chemical, cat #20344) and effluent was collected. The effluent is passed through the endotoxin removal columns until endotoxin levels were below 10 EU/mg as measured by the concentration of lipopolysaccharide (LPS). The measurement of LPS is carried out by Limulus assay (e.g., Limulus Amebocyte Lysate [“LAL”] chromogenic assay [BioWhitakker, Kinetic-QCL, cat #50-650 U]).
[0106] Following endotoxin removal, the motifs were diluted 1:100 in PBS and absorbance at 260 nm with a Beckman DU-640 Spectrophotometer was obtained on a known concentration of motif in PBS (Dulbecco's Phosphate Buffered Saline, Sigma, cat #D8537). This yielded the following extinction coefficients (“ec”):
[0107] a) pA:pU, (Sigma, Lot #22K4068): ec=0.0601;
[0108] b) pA, (Sigma, Lot#22K4022): ec=0.0575.
[0000] Bioactivity of the motifs was then determined as shown in the Examples.
[0000] A. Leukemia Cell Lines
EXAMPLE 5
Low Molecular Weight dsRNA Fractions Display Apoptosis and Cell Death Inducing Effects on T Cell Leukemia Cell Lines
[0109] Human acute T cell leukemia cell lines (Jurkat) were obtained from American Type Culture Collection (ATCC, Manassas, Va.) and maintained under conditions as suggested by the ATCC: (a) Media: RPMI 1640 medium with 2 mM L-glutamine (Invitrogen, Carlsbad, Calif., cat#11875-085) adjusted to contain 10 mM HEPES (Invitrogen, cat#15630-080), 50 units/ml penicillin-streptomycin (Invitrogen, cat#15070-063), 1.0 mM sodium pyruvate (Invitrogen, cat#11360-070) and supplemented with 0.05 mM 2-mercaptoethanol (Invitrogen, cat#21985-023), fetal bovine serum (FBS) 10% (Invitrogen, cat#26170-019); (b) continuous culture: in cell culture flasks (Corning, Corning N.Y., cat#430641) fresh media substituted every 3 days for up to 4 months when a new culture was started; and (c) temperature: 37° C., 5% CO 2 . Jurkat cells are a non-transfected human acute T cell leukemia cell line which mimic human T cell leukemias in vivo. Selective killing of this and other leukemias would be of clinical benefit.
[0110] The T cell leukemia lines were then placed in 48 well plates at a concentration of 0.4×10 6 cells per well, approximately 80% confluence, in FBS containing media at and allowed to mature for 3-4 days. The following day, the media was changed to 0.2 mls fresh non-FBS containing HL-1 media The cells were then pulsed with the endotoxin tested and fractionated dsRNA (pA:pU) (as taught in Example 4) at concentrations ranging from 10, 30 to 100 μg/ml for 6 hours followed by the media being replaced with fresh HL-1 media and incubated overnight in sterile conditions at 37° C./5% CO 2 . Cells were then resuspended in cold, phosphate buffer saline (PBS, Sigma, cat#D 8537 ) which was added gently over the cells followed by staining with Yo-Pro (Molecular Probes, Eugene, Oreg., cat #Y-3603, 0.15 μM final concentration) an indicator of apoptosis and ethidium bromide (Sigma, cat#46067, 1.5 μg/ml final concentration) an indicator of cell death. After 10 minutes of incubation, cells were washed once and suspended in buffer containing 2% FBS and stored on ice. Cells were then analyzed for apoptosis and cell death with a FACS Calibur flow cytometer (BD Bioscience, San Jose, Calif.) using appropriate filters to analyze cellular uptake of Yo-Pro and ethidium bromide in comparison to appropriate control cells.
[0111] The results, as shown in FIG. 5 , demonstrate that low molecular weight pA:pU, which is indicated as mixtures under pA:pU of 10 kD or approximately 40 basepairs or less, was significantly better at inducing substantial apoptosis and cell death among human T cell leukemia cell lines than the high molecular weight pA:pU, whole pA:pU containing oligonucleotides over a wide range of base pair lengths (from a few through a few thousand) and the controls. In particular, the higher concentrations of LMW, 30 μg/ml and 100 μg/ml, were more successful at inducing cell death and apoptosis than the lower concentration LMW pA:pU (10 μg/ml).
EXAMPLE 6
Low Molecular Weight dsRNA Fractions Display Apoptotic and Cell Death Inducing Effects on Human T Lymphocytes
[0112] Human T lymphocyte cell lines (ATL-2) were obtained from American Type Culture Collection [ATCC], Manassas, Va.) and maintained under conditions as suggested by the ATCC: (a) Media: RPMI 1640 medium with 2 mM L-glutamine (Invitrogen, Carlsbad, Calif., cat#11875-085) adjusted to contain 10 mM HEPES (Invitrogen, cat#15630-080), 50 units/ml penicillin-streptomycin (Invitrogen, cat#15070-063), 1.0 mM sodium pyruvate (Invitrogen, cat#11360-070) and supplemented with 0.05 mM 2-mercaptoethanol (Invitrogen, cat#21985-023), fetal bovine serum (FBS) 10% (Invitrogen, cat#26170-019); (b) continuous culture: in cell culture flasks (Corning, Corning N.Y., cat#430641) fresh media substituted every 3 days for up to 4 months when a new culture was started; and (c) temperature: 37° C., 5% CO 2 . ATL-2 cells are a non-transfected human T cell leukemia cell line which mimics human T cell leukemias in vivo. Selective killing of these and other leukemias would be of significant clinical benefit. The T lymphocyte cell lines were then placed in 48 well plates at a concentration of approximately 0.4×10 6 cells per well in FBS containing media at approximately 80% confluence and allowed to mature for 3-4 days. The following day, the media was changed to non-FCS containing HL-1 media of approximately 0.2 mls per well as outlined above but without FBS.
[0113] The cells were then pulsed with the purified and fractionated dsRNA (pA:pU) (see Example 4) at concentrations of 10, 30 and 100 μg/ml for 6 hours followed by the media being replaced with fresh HL-1 media and incubated overnight in sterile conditions at 37° C./5% CO 2 Cells were then resuspended in cold, phosphate buffer saline (PBS, Sigma, cat#D8537) which was added gently over the cells followed by staining with Yo-Pro (Molecular Probes, Eugene, Oreg., cat #Y-3603, 0.15 μM final concentration) an indicator of apoptosis and ethidium bromide (Sigma, cat#46067, 1.5 μg/ml final concentration) an indicator of cell death. After 10 minutes of incubation, cells were washed once and resuspended in buffer containing 2% FBS and stored on ice. Cells were then analyzed for apoptosis with a FACS Calibur flow cytometer (BD Bioscience. San Jose, Calif.) using appropriate filters to analyze cellular uptake of Yo-Pro and ethidium bromide in comparison to appropriate control cells.
[0114] The results, as shown in FIG. 6 , demonstrate that low molecular weight pA:pU, which is indicated as mixtures under pA:pU of 10 kD or less, was significantly able to induce apoptosis and cell death among the human T lymphocyte cell lines than either the high molecular weight pA:pU and whole pA:pU and the controls. The higher concentration of 100 μg/ml of LMW pA:pU was significantly more successful in inducing cell death and apoptosis in T lymphocyte cell lines than lower concentrations of pA:pU.
EX. 7
Low Molecular Weight dsRNA Fractions Demonstrate Apoptotic and Cell Death Inducing Effects on Human T Cell Lymphoblasts
[0115] Human T cell lymphoblastic leukemia cells (CEM) were obtained from American Type Culture Collection [ATCC], Manassas, Va.) and maintained under conditions as suggested by the ATCC: (a) Media: RPMI 1640 medium with 2 mM L-glutamine (Invitrogen, Carlsbad, Calif., cat#11875-085) adjusted to contain 10 mM HEPES (Invitrogen, cat#15630-080), 50 units/ml penicillin-streptomycin (Invitrogen, cat#15070-063), 1.0 nM sodium pyruvate (Invitrogen, cat#11360-070) and supplemented with 0.05 mM 2-mercaptoethanol (Invitrogen, cat#21985-023), fetal bovine serum (FBS) 10% (Invitrogen, cat#26170-019); (b) continuous culture: in cell culture flasks (Corning, Corning N.Y., cat#430641) fresh media substituted every 3 days for up to 4 months when a new culture was started; and (c) temperature: 37° C., 5% CO 2 . CEM cells are a non-transfected human T cell lymphoblastic leukemia cell line which mimics human T cell leukemias in vivo. Selective killing of this and other leukemias would be of clinical benefit.
[0116] The human T cell lymphoblastic leukemia cells were then placed in 48 well plates at a concentration of 0.4×10 6 cells per well, approximately 80% confluence, in FBS containing media and allowed to mature for 3-4 days. The following day, the media was changed to non-FCS containing HL-1 media, 0.2 mls per well. The cells were then pulsed with endotoxin tested and fractionated dsRNA (pA:pU) (see Example 4) at concentrations of 10 μg/ml, 30 μg/ml and 100 μg/ml for 6 hours followed by the media being replaced with fresh HL-1 media and incubated overnight in sterile conditions at 37° C./5% CO 2 . Cells were then resuspended in cold, phosphate buffer saline (PBS, Sigma, cat#D8537) which was added gently over the cells followed by staining with Yo-Pro (Molecular Probes, Eugene, Oreg., cat #Y-3603, 0.15 μM final concentration) an indicator of apoptosis and ethidium bromide (Sigma, cat#46067, 1.5 μg/ml final concentration) an indicator of cell death. After 10 minutes of incubation, cells were washed once and resuspended in buffer containing 2% FBS and stored on ice. Cells were then analyzed for apoptosis and cell death with a FACS Calibur flow cytometer (BD Bioscience, San Jose, Calif.) using appropriate filters to analyze cellular uptake of Yo-Pro and ethidium bromide in comparison to appropriate control cells.
[0117] The results, as shown in FIG. 7 , demonstrate that low molecular weight pA:pU, particularly at the higher concentration of 100 μg/ml, was able to induce significant levels of cell death and apoptosis among human T cell lymphoblastic leukemia cells lines than the controls or the high molecular weight pA:pU and whole pA:pU.
EXAMPLE 8
Low Molecular Weight dsRNA Fractions Demonstrate Apoptotic and Cell Death Inducing Effects on Human Monocytic Leukemia Cells
[0118] Human monocytic leukemia cells (THP-1) were obtained from American Type Culture Collection [ATCC], Manassas, Va.) and maintained under conditions as suggested by the ATCC: (a) Media: RPMI 1640 medium with 2 mM L-glutamine (Invitrogen, Carlsbad, Calif. , cat#11875-085) adjusted to contain 10 mM HEPES (Invitrogen, cat#15630-080), 50 units/ml penicillin-streptomycin (Invitrogen, cat#15070-063), 1.0 mM sodium pyruvate (Invitrogen, cat#11360-070) and supplemented with 0.05 mM 2-mercaptoethanol (Invitrogen, cat#21985-023), fetal bovine serum (FBS) 10% (Invitrogen, cat#26170-019); (b) continuous culture: in cell culture flasks (Corning, Corning N.Y., cat#430641) fresh media substituted every 3 days for up to 4 months when a new culture was started; and (c) temperature: 37° C., 5% CO 2 . THP-1 cells are a non-transfected human monocytic leukemia cell line which mimics human monocytic leukemias in vivo. Selective killing of this and other leukemias would be of clinical benefit
[0119] The human monocytic leukemia cells were then placed in 48 well plates at a concentration of 0.4×10 6 cells per well, approximately 80% confluence in FBS containing media and allowed to mature for 3-4 days. The following day, the media was changed to non-FBS containing HL-1 media, 0.2 mls per well.
[0120] The cells were then pulsed with the endotoxin tested and fractionated dsRNA (pA:pU) (see Example 4) at concentrations of 10, 30 and 100 μg/ml for 6 hours followed by the media being replaced with fresh HL-1 media and incubated overnight in sterile conditions at 37° C./5% CO 2 Cells were then resuspended in cold, phosphate buffer saline (PBS, Sigma, cat#D8537) which was added gently over the cells followed by staining with Yo-Pro (Molecular Probes, Eugene, Oreg., cat #Y-3603, 0.15 μM final concentration) an indicator of apoptosis and ethidium bromide (Sigma, cat#46067, 1.5 μg/ml final concentration) an indicator of cell death. After 10 minutes of incubation, cells were washed once and resuspended in buffer containing 2% FBS and stored on ice. Cells were then analyzed for apoptosis with a FACS Calibur flow cytometer (BD Bioscience. San Jose, Calif.) using appropriate filters to analyze cellular uptake of Yo-Pro and ethidium bromide in comparison to appropriate control cells.
[0121] The results, as shown in FIG. 8 , demonstrate that low molecular weight pA:pU, particularly at concentrations of 100 μg/ml, was significantly better at inducing substantial apoptosis and cell death among human monocytic leukemia cells lines than either the controls or high molecular weight pA:pU and whole pA:pU.
[0000] B. Non-Leukemia Cell Lines
EXAMPLE 9
Low and High Molecular Weight dsRNA Fractions were Unsuccessful at Inducing Either Cell Death or Apoptosis in Human Adenocarcinoma Cell Lines at a Rate Greater than the Control
[0122] Human cervical adenocarcinoma cell lines (HeLa) were obtained from American Type Culture Collection [ATCC], Manassas, Va.) and maintained under conditions as suggested by the ATCC: (a) Media: RPMI 1640 medium with 2 mM L-glutamine (Invitrogen, Carlsbad, Calif., cat#11875-085) adjusted to contain 10 mM HEPES (Invitrogen, cat#15630-080), 50 units/ml penicillin-streptomycin (Invitrogen, cat#15070-063), 1.0 mM sodium pyruvate (Invitrogen, cat#11360-070) and supplemented with 0.05 mM 2-mercaptoethanol (Invitrogen, cat#21985-023), fetal bovine serum (PBS) 10% (Invitrogen, cat#26170-019); (b) continuous culture: in cell culture flasks (Corning, Corning N.Y., cat#430641) fresh media substituted every 3 days for up to 4 months when a new culture was started; and (c) temperature: 37° C., 5% CO 2 . HeLa cells are a non-transfected cervical adenocarcinoma human cell line which mimics adenocarcinoma in vivo. Selective killing of this and other carcinomas would be of clinical benefit.
[0123] The human cervical adenocarcinoma cell lines were then placed in 48 well plates at a concentration of 0.4×10 6 cells per well, approximately 80% confluence, in FBS containing media and allowed to mature for 3-4 days. The following day, the media was changed to non-FBS containing EL-1 media, 0.2 mls per well. The cells were then pulsed with the endotoxin tested and fractionated dsRNA (pA:pU) (see Ex. 4) at concentrations ranging from 10-100 μg/ml for 6 hours followed by the media being replaced with fresh HL-1 media and incubated overnight in sterile conditions at 37° C./5% CO 2 . Cells were then resuspended in cold, phosphate buffer saline (PBS, Sigma, cat#D8537) which was added gently over the cells followed by staining with Yo-Pro (Molecular Probes, Eugene, Oreg., cat #Y-3603, 0.15 μM final concentration) an indicator of apoptosis and ethidium bromide (Sigma, cat#46067, 1.5 μg/ml final concentration) an indicator of cell death. After 10 minutes of incubation, cells were washed once and resuspended in buffer containing 2% FBS and stored on ice. Cells were then analyzed for apoptosis and cell death with a FACS Calibur flow cytometer (BD Bioscience, San Jose, Calif.) using appropriate filters to analyze cellular uptake of Yo-Pro and ethidium bromide in comparison to appropriate control cells.
[0124] The results, as shown in FIG. 9 , demonstrate that low molecular weight pA:pU was no more successful at inducing apoptosis and cell death among human cervical adenocarcinoma cells than either the high molecular weight pA:pU or controls.
EXAMPLE 10
Low Molecular Weight pA:pU, at a Concentration of 100 μg/ml, was Significantly Better at Inducing Substantial Apoptosis and Cell Death Among Human Lung Fibroblasts than either the High Molecular Weight pA:pU and Whole pA:pU and the Controls
[0125] Human Lung Fibroblasts (“WI 38”) were obtained from American Type Culture Collection [ATCC], Manassas, Va.) and maintained under conditions as suggested by the ATCC: (a) Media: RPMI 1640 medium with 2 mM L-glutamine (Invitrogen, Carlsbad, Calif., cat#11875-085) adjusted to contain 10 mM HEPES (Invitrogen, cat#15630-080), 50 units/ml penicillin-streptomycin (Invitrogen, cat#15070-063) and 1.0 mM sodium pyruvate (Invitrogen, cat#11360-070) and supplemented with 0.05 mM 2-mercaptoethanol (Invitrogen, cat#21985-023), fetal bovine serum (FBS) 10% (Invitrogen, cat#26170-019); (b) continuous culture: in cell culture flasks (Corning, Corning N.Y., cat#430641) fresh media substituted every 2-3 days for up to 50 days when a new culture was started; and (c) temperature: 37° C., 5% CO 2 . WI-38 is a human lung fibroblast cell line which mimics a lung carcinoma.
[0126] The human lung fibroblasts were then placed in 48 well plates at a concentration of 0.4×10 6 cells per well, approximately 80% confluence, in FBS containing media and allowed to mature for 3-4 days. The following day, the media was changed to non-FCS containing HL-1 media, 0.2 mls per well. The cells were then pulsed with the endotoxin tested and fractionated dsRNA (pA:pU) (see Example 4) at concentrations ranging from 10-100 μg/ml for 6 hours followed by the media being replaced with fresh HL-1 media and incubated overnight in sterile conditions at 37° C./5% CO 2 . Cells were then resuspended in cold, phosphate buffer saline (PBS, Sigma, cat#D8537) which was added gently over the cells followed by staining with Yo-Pro (Molecular Probes, Eugene, Oreg., cat #Y-3603, 0.15 μM final concentration) an indicator of apoptosis and ethidium bromide (Sigma, cat#46067, 1.5 μg/ml final concentration) an indicator of cell death. After 10 minutes of incubation, cells were washed once and resuspended in buffer containing 2% FBS and stored on ice. Cells were then analyzed for apoptosis and cell death with a FACS Calibur flow cytometer (BD Bioscience. San Jose, Calif.) using appropriate filters to analyze cellular uptake of Yo-Pro and ethidium bromide in comparison to appropriate control cells.
[0127] The results, as shown in FIG. 10 , demonstrate that low molecular weight pA:pU, at a concentration of 100 μg/ml, was significantly better at inducing substantial apoptosis and cell death among human lung fibroblasts than either the high molecular weight pA:pU and whole pA:pU and the controls.
EXAMPLE 11
Neither High nor Low Molecular Weight dsRNA or ssRNA was More Successful at Inducing Cell Death or Apoptosis in Human Breast Cancer Cells than the Control
[0128] Human breast cancer cell lines (SKBR-3) were obtained from American Type Culture Collection [ATCC], Manassas, Va.) and maintained under conditions as suggested by the ATCC: (a) Media: RPMI 1640 medium with 2 mM L-glutamine (Invitrogen, Carlsbad, Calif., cat#11875-085) adjusted to contain 10 mM HEPES (Invitrogen, cat#15630-080), 50 units/ml penicillin-streptomycin (Invitrogen, cat#15070-063), 1.0 mM sodium pyruvate (Invitrogen, cat#11360-070) and supplemented with 0.05 mM 2-mercaptoethanol (Invitrogen, cat#21985-023), fetal bovine serum (FBS) 10% (Invitrogen, cat#26170-019); (b) continuous culture: in cell culture flasks (Corning, Corning N.Y., cat#430641) fresh media substituted every 3 days for up to 4 months when a new culture was started; and (c) temperature: 37° C., 5% CO 2 .
[0129] The human breast cancer cell lines were then placed in 48 well plates at a concentration of 0.4×10 6 cells per well, approximately 80% confluence, in FBS containing media and allowed to mature for 3-4 days. The following day, the media was changed to non-FCS containing HL-1 media, 0.2 mls per well. The cells were then pulsed with the endotoxin tested and fractionated dsRNA (pA:pU) (see Example 4) at concentrations ranging from 10-100 μg/ml for 6 hours followed by the media being replaced with fresh HL-1 media and incubated overnight in sterile conditions at 37° C./5% CO 2 . Cells were then resuspended in cold, phosphate buffer saline (PBS, Sigma, cat#D8537) which was added gently over the cells followed by staining with Yo-Pro (Molecular Probes, Eugene, Oreg., cat #Y-3603, 0.15 μM final concentration) an indicator of apoptosis and ethidium bromide (Sigma, cat#46067, 1.5 μg/ml final concentration)an indicator of cell death). After 10 minutes of incubation, cells were washed once and resuspended in buffer containing 2% FBS and stored on ice. Cells were then analyzed for apoptosis and cell death with a FACS Calibur flow cytometer (BD Bioscience. San Jose, Calif.) using appropriate filters to analyze cellular uptake of Yo-Pro and ethidium bromide in comparison to appropriate control cells.
[0130] The results, as shown in FIG. 11 , demonstrate that neither low molecular weight pA:pU, high molecular weight pA:pU or whole pA:pU was able to induce cell death in breast cancer cells any more successfully than the controls.
EX. 12
Low or High Molecular Weight dsRNA was Unable to Induce Cell Death or Apoptosis in Human PBMCs any Greater than Either High Molecular Weight dsRNA or the Control
[0131] The Histopaque density gradient medium (Sigma, cat#1077-1) was brought to room temperature and inverted several times to ensure thorough mixing. 3 mL of Histopaque was added to a 15 ml centrifuge tube. 5-6 mL of a human blood sample obtained from a human donor (Donors 1 and 2) was carefully layered on the Histopaque and then centrifuged at 400×g for 30 min at 20° C. Using a sterile pipette, the white lymphocyte layer was removed with as little Histopaque and plasma contamination as possible.
[0132] The lymphocyte layer was then transferred to a new 15 mL centrifuge tube and 3 volumes of PBS was added to the lymphocytes. The lymphocytes were then resuspended and the tube centrifuged at 1500 RPM for 10 min at 20° C. The supernatant was then decanted and the lymphocytes gently resuspended using a pipette. The tube was then centrifuged again at 1200 RPM for 10 min at 20° C. The supernatant was decanted and the lymphocytes were gently resuspended in HL-1 media. Once again, the tube was centrifuged at 1000 RPM for 10 min at 20° C. and resuspend in HL-1 media.
[0133] The lymphocytes were then counted and plated in a 48 well plate at 4×10 5 /well in HL-1 media. The fractionated and purified RNA motifs (pA:pU) (see Example 4) were added at 10, 30 and 100 μg/ml final concentration or LPS ( E.coli 055:B5) at 10 ng/ml to the cells and allowed to incubate at 37° C., 5% CO 2 overnight.
[0134] The cells were then resuspended and stained with ethidium bromide and/or Yo-Pro as follows: 100 μl of sterile, cold phosphate buffered saline (PBS, Sigma, cat#D8537) was added to the cells followed by staining with ethidium bromide (Sigma, cat#46067, 1.5 μg/ml final concentration) an indicator of cell death and/or Yo-Pro (Molecular Probes, Eugene Oreg., cat#Y-3603, 0.15 μM final concentration) an indicator of apoptosis. The cells were incubated for 10 minutes on ice followed by resuspension in PBS with 2% PBS with subsequent analysis for apoptosis/cell death with a FACS Calibur flow cytometer (BD Bioscience, San Jose Calif.) using appropriate filters to analyze cellular uptake of Yo-Pro and ethidium bromide in comparison to appropriate controls (LPS, 100 ng/ml or Nil, HL-1 media alone.) Cells were also analyzed by fluorescent microscopy using appropriate filters to differentiate between apoptotic and dead cells and images taken using an image analysis system running Image Pro software (Media Cybernetics, Carlsbad Calif.).
[0135] The results in FIGS. 12A-12B show that low or high molecular weight dsRNA was not any more capable of inducing cell death or apoptosis in human PBMCs than either high molecular weight dsRNA or the control.
EXAMPLE 13
Low Molecular Weight dsRNA Fraction and dsRNA of Known Oligomer Length Display Cell Death Inducing Effects on Monocytic Leukemia Cells
[0136] Human monocytic leukemia cells (THP-1) were obtained from American Type Culture Collection [ATCC], Manassas, Va.) and maintained under conditions as suggested by the ATCC: (a) Media: RPMI 1640 medium with 2 mM L-glutamine (Invitrogen, Carlsbad, Calif., cat#11875-085) adjusted to contain 10 mM HEPES (Invitrogen, cat#15630-080), 50 units/ml penicillin-streptomycin (Invitrogen, cat#15070-063), 1.0 mM sodium pyruvate (Invitrogen, cat#11360-070) and supplemented with 0.05 mM 2-mercaptoethanol (Invitrogen, cat#21985-023), fetal bovine serum (FBS) 10% (Invitrogen, cat#26170-019); (b) continuous culture: in cell culture flasks (Corning, Corning N.Y., cat#430641) fresh media substituted every 3 days for up to 4 months when a new culture was started; and (c) temperature: 37° C., 5% CO 2 . THP-1 cells are a non-transfected human monocytic leukemia cell line that mimics human monocytic leukemias in vivo. Selective killing of this and other leukemias would be of significant clinical benefit
[0137] The human monocytic leukemia cells were then placed in 48 well plates at a concentration of 0.4×10 6 cells per well, approximately 80% confluence in FBS containing media and allowed to mature for 3-4 days. The following day, the media was changed to non-FBS containing HL-1 media, 0.2 mls per well.
[0138] The cells were then pulsed with the endotoxin tested whole and fractionated low molecular weight (<10 k MW) dsRNA (pA:pU) (see Example 4) at a concentration of 100 μg/ml, with adenylic acid (Sigma, cat #A-1752), or uridylic acid (Sigma, cat#U-1752) at 50, 100, 200 and 400 μg/ml in sterile PBS, or polyA:polyU of 5-mer, 10-mer or 20-mer annealed nucleotide (oligomer) lengths (Ambion, Austin Tex.) at 50, 100, 200 and 400 μg/ml in sterile PBS. In addition LPS (200 ng/ml) or HL-1 media alone were used as controls. Samples were incubated overnight in sterile conditions at 37° C./5% CO 2 . Cells were then resuspended in cold, phosphate buffer saline (PBS, Sigma, cat#D8537) which was added gently over the cells followed by staining with Yo-Pro (Molecular Probes, Eugene, Oreg., cat #Y-3603, 0.15 μM final concentration) an indicator of apoptosis and ethidium bromide (Sigma, cat#46067, 1.5 μg/ml final concentration) an indicator of cell death. After 10 minutes of incubation, cells were washed once and resuspended in buffer containing 2% FBS and stored on ice. Cells were then analyzed for apoptosis with a FACS Calibur flow cytometer (BD Bioscience. San Jose, Calif.) using appropriate filters to analyze cellular uptake of Yo-Pro and ethidium bromide in comparison to appropriate control cells.
[0139] The results, as shown in FIG. 13 , demonstrate that while low molecular weight (<10 k) pA:pU at a concentration of 100 μg/ml was able to induce substantial necrotic cell death as previously shown, the pA:pU 5-mer at concentrations of 200 μg or 400 μg was able to induce necrotic cell death in slightly higher amounts and in sharp contrast to the cell death induced by the 10-mer or 20-mer pA:pU, the adenylic acid or uridylic acid or controls. This also demonstrates that, as the monomeric adenylic acid or uridylic acid showed only background necrotic activity, the initial pA:pU oligomeric format is important. In addition the low molecular weight (<10 k MW) pA:pU fraction may have oligomers of less than 10-mer length from which it's necrotic activity is due.
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The present application is directed to the use of dsRNA and/or ssRNA for the purpose of inducing apoptosis or cell death in proliferating cells. Specifically, low molecular weight and high molecular weight dsRNA and ssRNA are shown to induce apoptosis and/or cell death in proliferating cells, to arrest proliferation of transformed cells or tumor cells and to cause rapid induction of the cytokine TNF-alpha and/or also induce production of IL-12 which directs a Th-1 response.
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CROSS REFERENCE TO RELATED APPLICATION
This application claims priority to International Patent Application No. PCT/US2012/69761, filed Dec. 14, 2012, which claims priority to U.S. Provisional Application No. 61/578,986, filed Dec. 22, 2011, all of which are hereby incorporated herein by reference in their entireties.
FIELD
This invention relates to processes and apparatuses for forced circulation evaporative crystallization. In particular, this invention relates to processes and apparatuses for prolonging the operational time of an evaporative crystallizer by reducing build up due to fouling deposits.
BACKGROUND
Evaporative crystallizers are used to produce valuable crystalline products, such as tetrasodium ethylenediaminetetraacetic acid (“Na4EDTA”) and disodium EDTA. However, the operation of evaporative crystallizers is often limited in length of reliable operation due to the build-up of fouling deposits inside the evaporative crystallizer vessel. These deposits can interfere with the evaporative crystallizer equipment by partially or fully plugging pumps, transfer lines, and/or heat exchangers, thus requiring that the system frequently be shut down for cleaning
A typical design for a forced circulation evaporative crystallizer includes an outlet flow leaving the evaporative crystallizer at the bottom of the vessel and an inlet on the side of the vessel. Because fouling deposits accumulate at the bottom of the vessel, these deposits exit through the outlet and enter a circulation loop, thus partially or fully plugging the pumps, transfer lines, and/or heat exchangers in that loop. Thus, a need exists for a forced circulation evaporative crystallization system which allows for the accumulation of fouling deposits in order to avoid clogging of the circulation loop.
BRIEF SUMMARY
In one aspect, an illustrative embodiment provides an apparatus comprising an evaporative crystallizer, wherein the evaporative crystallizer includes a deposit accumulation volume located at the bottom of the evaporative crystallizer. The apparatus further comprises a first inlet for supplying a first flow to the evaporative crystallizer; and an outlet, wherein the outlet is located above the deposit accumulation volume and wherein the first inlet comprises a particle exit positioned above the outlet.
In another aspect, an illustrative embodiment provides a process comprises providing a feedstock of a solvent and a solute to a recirculation loop and heating the feedstock with a heat exchanger to provide a heated feedstock. The process further comprises supplying the heated feedstock to an evaporative crystallizer through a first inlet to produce a slurry, wherein the evaporative crystallizer includes a deposit accumulation volume; and returning the slurry to the recirculation loop through an outlet.
In another aspect, an illustrative embodiment provides a process comprises providing a feedstock of a solvent and a solute to a recirculation loop; heating the feedstock with a heat exchanger to provide a heated feedstock; and supplying the heated feedstock to an evaporative crystallizer through a first inlet to produce a slurry, wherein the evaporative crystallizer includes a deposit accumulation volume, and wherein fouling deposits accumulate in the deposit accumulation volume. The process further comprises returning the slurry to the recirculation loop through an outlet; extracting a portion of the slurry from the recirculation loop; supplying a first portion of the extracted slurry to the evaporative crystallizer through a second inlet, wherein the first portion of the extracted slurry sweeps crystalline product away from the deposit accumulation volume; and recovering crystalline product in a recovery system.
The foregoing summary is illustrative only and is not intended to be in any way limiting. In addition to the illustrative aspects, embodiments, and features described above, further aspects, embodiments, and features will become apparent by reference to the drawings and the following detailed description.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic diagram of an apparatus for evaporative crystallization.
FIG. 2 is a top view of an apparatus for evaporative crystallization.
FIG. 3 is a schematic diagram of an apparatus for producing a crystalline product.
FIG. 4 is a graph showing the outlet flow over time for an apparatus for evaporative crystallization with a deposit accumulation volume.
FIG. 5 is a graph showing the outlet flow over time for an apparatus for evaporative crystallization without a deposit accumulation volume.
FIG. 6 is a graph showing the number of particles at various sizes for an apparatus for evaporative crystallization with a deposit accumulation volume and for an apparatus for evaporative crystallization without a deposit accumulation volume.
FIG. 7 is a graph showing analysis of run time by system product.
DETAILED DESCRIPTION
In one aspect, an apparatus for producing a crystalline product through evaporative crystallization is provided. The apparatus may be structured to reduce the build-up of fouling deposits and may prolong the operational time of an evaporative crystallizer between cleanings.
FIG. 1 illustrates an apparatus 100 for evaporative crystallization. The apparatus 100 may include a lower evaporative crystallizer section 101 , a first inlet 102 , an outlet 103 , a second inlet 104 , and a cone portion 105 allowing for the formation of a liquid-vapor interface. The first inlet 102 may enter the lower evaporative crystallizer section 101 at a position offset from the center or lowest point of the lower evaporative crystallizer section 101 , which may allow for complete drainage from the lower evaporative crystallizer section 101 . The first inlet 102 may comprise a particle exit positioned above the outlet 103 . The outlet 103 may be positioned above the lowest point of the lower evaporative crystallizer section 101 , thus forming a deposit accumulation volume 106 . Fouling deposits from the crystallization process may accumulate in the deposit accumulation volume 106 . For example, fouling deposits may form at the liquid-vapor interface and may fall to the deposit accumulation volume 106 . Collecting these deposits may prevent such deposits from clogging a recirculation line. The deposit accumulation volume 106 may have a volume of between about 1 and about 50 percent of the volume of the lower evaporative crystallizer section 101 , more preferably between 2 percent and 10 percent of the volume of the lower evaporative crystallizer section 101 . For example, the lower evaporative crystallizer section 101 may have a volume of about 11 cubic meters (about 3000 gallons) and the deposit accumulation volume 106 may have a volume of about 1.9 cubic meters (about 500 gallons).
The lower evaporative crystallizer section 101 may have a substantially vertical sidewall 107 . The second inlet 104 may be located at an angle of between about 45 degrees and about 90 degrees from the substantially vertical sidewall 107 . FIG. 2 shows a top view of apparatus 100 . The second inlet 104 may enter tangentially to or perpendicular to the substantially vertical sidewall 107 , preferably in the lower quartile range of the vessel or more preferably from about 10 degrees to about 50 degrees from a tangent line 108 . The second inlet 104 may provide a secondary flow that may sweep crystalline product particles away from the deposit accumulation volume 106 without sweeping the large fouling deposits out of the deposit accumulation volume 106 . The secondary flow may also be used for providing solvent to clean the evaporative crystallizer at the end of a product run. The secondary flow may be between about 0.1 percent and about 20 percent of the flow through the first inlet 102 , more preferably between about 0.5 percent and about 5 percent of the flow through the first inlet 102 . For example, the flow through the first inlet 102 may be about 15 cubic meters per minute (about 4000 gallons per minute) and the secondary flow may be about 0.15 cubic meters per minutes (about 40 gallons per minute).
FIG. 3 illustrates an apparatus 200 for producing a crystalline product. A feedstock 201 is provided to a recirculation system 202 . The feedstock 201 may comprise a solvent and a solute. The solvent may be, for example, water. The solute may be, for example, tetrasodium EDTA or disodium EDTA. Other commonly known solvents and solutes may also be used. The recirculation system 202 may include a first inlet 203 , an outlet 204 , a heat exchanger 205 , and a recirculation pump 206 . Shell and tube, plate, finned, and other types of well-known heat exchangers may be used; such as, for example, the shell and tube type of heat exchanger with the process fluid residing within the tubes of the heat exchanger. The feedstock 201 may enter the recirculation system 202 , where the recirculation pump 206 may pump the feedstock 201 , plus recirculating fluid entering the circulation loop at crystallizer outlet 204 , to the heat exchanger 205 . The heat exchanger 205 may heat the recirculating fluid 201 above the solvent boiling point. Generally the recirculating fluid is heated to achieve a temperature rise of between 0.1° C. to 10° C. above the solvent boiling point, more preferably between 1° C. to 2° C. above the solvent boiling point at the vapor liquid interface. The heated feedstock 201 may then enter an evaporative crystallizer 207 through the first inlet 203 . The first inlet 203 may be offset from the center of the evaporative crystallizer 207 in order to allow for complete drainage from the evaporative crystallizer 207 . The feedstock 201 may form a slurry in the evaporative crystallizer 207 as a portion of the feedstock 201 plus recirculating fluid evaporates to form vapor, causing a portion of the solute content to precipitate out of solution in the form of solid particles. The slurry may exit the evaporative crystallizer 207 into the recirculation system 202 through the outlet 204 .
A portion of the slurry may be extracted from the recirculation system 202 as extracted slurry 208 . This extraction may occur before the feedstock 201 . Alternatively, this extraction may occur at another point of the recirculation system 202 , or, alternatively, a nozzle may be added to the crystallizer 207 in such a location as to allow the removal of a portion of the slurry contents. The non-extracted portion of the slurry may flow back to the recirculation pump 206 , the heat exchanger 205 , and return to the evaporative crystallizer 207 . The extracted slurry 208 may enter a first pump 209 . After the first pump 209 , the extracted slurry 208 may be divided into a first portion 210 and a second portion 211 . The first portion 210 may be supplied to the evaporative crystallizer 207 through a second inlet 212 . The first portion 210 may be introduced into the crystallizer at a direction sufficient to sweep crystalline product away from the deposit accumulation volume. The second portion 211 may be supplied to a recovery system 213 in order to recover a crystalline product. The second portion 211 may be about 10 percent of the flow of the first portion 210 . For example, the first portion 210 may have a flow rate of 0.15 cubic meters per minute (40 gallons per minute) and the second portion 210 may have a flow rate of 0.015 cubic meters per minute (4 gallons per minute). The recovery system 213 may comprise a cooling crystallizer 214 , a centrifuge 215 , a drier 216 , and a packaging apparatus 217 . The second portion 211 may be supplied to the cooling crystallizer 214 to produce cooled crystalline slurry 218 . The cooling crystallizer 214 may include a stirrer 219 . The cooling crystallizer 214 may cool the second portion 211 to decrease the solubility of the crystalline product in the solvent. The cooled crystalline slurry 218 may be supplied to a second pump 220 , then to the centrifuge 215 , and then to the drier 216 in order to produce a crystalline product 221 . The crystalline product 221 may then be sent to a packaging apparatus 217 . A portion of stream 218 can be returned to the cooling crystallizer 214 via stream 222 .
EXAMPLES
An evaporative crystallizer with an about 11 cubic meter operating volume (about 3000 gallons) that has a deposit inventory volume of approximately 0.28 cubic meters, or about 2.5 percent of the total working inventory is used. Steam is used to evaporate water from an approximate 40 percent solution of Na4EDTA to form Na4EDTA tetrahydrate crystals. The evaporative crystallizer includes a primary recycle with heating flowing at approximately 12.5 cubic meters per minute (about 3300 gallons per minute) and secondary tangential entry recycle that operates at approximately 0.28 cubic meters per minute (about 75 gallons per minute). The process is fed at a rate of approximately 2700 kg per hour (about 6000 pounds per hour) with an estimated 30 percent boil off rate.
The evaporative crystallizer operates continuously for nine days without plugging of the evaporative crystallizer primary or secondary recycle flows or the evaporator heat exchanger located in the primary flow recycle loop (as shown in FIG. 4 ). This compares to 4-5 days operation for comparable systems using agitation for mixing, internal coils for heat transfer, no equivalent primary flow, and a secondary recycle flow of approximately 0.21 cubic meters per minute (about 55 gallons per minute) (as shown in FIG. 5 ). The operational run time between required system washes for the system using the primary flow recycle loop is 338 hours. This compares to 150 hours of operational run time between required system washes for the system using agitation for mixing (as shown in FIG. 7 ). Table 1 below shows the calculations used in FIG. 7 .
TABLE 1
Calculations used for analysis of run time (as shown in FIG. 7)
Means and Std Deviations
Std Err
Level
Number
Mean
Std Dev
Mean
Lower 95%
Upper 95%
New
5
338.000
55.5608
24.848
269.01
406.99
Old
15
150.133
65.0482
16.795
114.11
186.16
Means Comparisons
Comparisons for each pair using Student's t
t
Alpha
2.10092
0.05
Abs(Dif)-LSD
New
Old
New
−83.79
119.45
Old
119.45
−48.38
Positive values show pairs of means that are significantly different.
Impact on particle size distribution is also improved by decreasing the amount of small particles being generated. Particles sizes that are too small may create a particle dust, whereas particle sizes that are too large will not easily dissolve. A comparison of the number of particles at various sizes for a forced circulation system with a deposit accumulation volume (inventory) and for an agitated evaporative crystallizer utilizing internal heating coils is shown in FIG. 6 .
While the invention has been described above according to its preferred embodiments, it can be modified within the spirit and scope of this disclosure. This application is therefore intended to cover any variations, uses, or adaptations of the invention using the general principles disclosed herein. Further, the application is intended to cover such departures from the present disclosure as come within the known or customary practice in the art to which this invention pertains and which fall within the limits of the following claims.
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Disclosed are processes and apparatuses for producing a crystalline product. The processes and apparatuses may extend the operational time of an evaporative crystallizer by providing an internal volume or large deposit inventory for fouling deposits to reside without impacting the unit operation.
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BACKGROUND
The present invention relates generally to the field of semiconductor structure fabrication methods, and specifically to determining the thermal profiles of semiconductor structures.
Reflow soldering is a process in which a plated metallurgy may be used to temporarily attach one or several electrical components to their contact pads, after which, the entire assembly is subjected to controlled heat, which melts the solder, permanently connecting the joint. Heating may be accomplished by passing the assembly through a reflow oven, or under an infrared lamp, or by soldering individual joints with a hot air pencil. The goal of the reflow process is to melt the solder and heat the adjoining surfaces without overheating and damaging the electrical components that are included therein.
SUMMARY
According to embodiments of the present invention, a semiconductor substrate is formed on at least a portion of a surface of a semiconductor substrate. The emitting layer is excited for a first predetermined time period. A first luminescent intensity value of the emitting layer is determined. In response to exposing the semiconductor substrate and the emitting layer to a condition for a second predetermined time period, a second luminescent intensity value of the emitting layer is determined. A thermal profile of at least the portion of the surface of the semiconductor substrate is determined utilizing the first luminescent intensity value and the second luminescent intensity value of the emitting layer. The thermal profile at least reflects information about one or more of the condition and the semiconductor substrate subsequent to exposure to the condition.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
FIG. 1 is a functional block diagram illustrating an environment, in accordance with an embodiment of the present invention.
FIG. 2 is a reflow profile of a semiconductor structure, in accordance with an embodiment of the present invention.
FIG. 3 is a flowchart depicting the operational steps of a program function, in accordance with an embodiment of the present invention.
FIG. 4 depicts a block diagram of components of the computing device executing the program function, in accordance with an embodiment of the present invention.
DETAILED DESCRIPTION
With reference now to FIGS. 1-4 , the descriptions of the various embodiments of the present invention have been presented for purposes of illustration, but are not intended to be exhaustive or limited to the embodiments disclosed. Many modifications and variations will be apparent to those of ordinary skill in the art without departing from the scope and spirit of the described embodiments. The terminology used herein was chosen to best explain the principles of the embodiments, the practical application or technical improvement over technologies found in the marketplace, or to enable others of ordinary skill in the art to understand the embodiments disclosed herein
The present invention may be a system, a method, and/or a computer program product. The computer program product may include a computer readable storage medium (or media) having computer readable program instructions thereon for causing a processor to carry out aspects of the present invention.
The computer readable storage medium can be a tangible device that can retain and store instructions for use by an instruction execution device. The computer readable storage medium may be, for example, but is not limited to, an electronic storage device, a magnetic storage device, an optical storage device, an electromagnetic storage device, a semiconductor storage device, or any suitable combination of the foregoing. A non-exhaustive list of more specific examples of the computer readable storage medium includes the following: a portable computer diskette, a hard disk, a random access memory (RAM), a read-only memory (ROM), an erasable programmable read-only memory (EPROM or Flash memory), a static random access memory (SRAM), a portable compact disc read-only memory (CD-ROM), a digital versatile disk (DVD), a memory stick, a floppy disk, a mechanically encoded device, such as punch-cards or raised structures in a groove having instructions recorded thereon, and any suitable combination of the foregoing. A computer readable storage medium, as used herein, is not to be construed as being transitory signals per se, such as radio waves or other freely propagating electromagnetic waves, electromagnetic waves propagating through a waveguide or other transmission media (e.g., light pulses passing through a fiber-optic cable), or electrical signals transmitted through a wire.
Computer readable program instructions described herein can be downloaded to respective computing/processing devices from a computer readable storage medium or to an external computer or external storage device via a network, for example, the Internet, a local area network (LAN), a wide area network (WAN), and/or a wireless network. The network may comprise copper transmission cables, optical transmission fibers, wireless transmission, routers, firewalls, switches, gateway computers and/or edge servers. A network adapter card or network interface in each computing/processing device receives computer readable program instructions from the network and forwards the computer readable program instructions for storage in a computer readable storage medium within the respective computing/processing device.
Computer readable program instructions for carrying out operations of the present invention may be assembler instructions, instruction-set-architecture (ISA) instructions, machine instructions, machine dependent instructions, microcode, firmware instructions, state-setting data, or either source code or object code written in any combination of one or more programming languages, including an object-oriented programming language such as Java™ Smalltalk, C++ or the like, and conventional procedural programming languages, such as the “C” programming language or similar programming languages. The computer readable program instructions may execute entirely on the user's computer, partly on the user's computer, as a stand-alone software package, partly on the user's computer and partly on a remote computer, or entirely on the remote computer or server. In the latter scenario, the remote computer may be connected to the user's computer through any type of network, including a local area network (LAN) or a wide area network (WAN), or the connection may be made to an external computer (for example, through the Internet using an Internet Service Provider). In some embodiments, electronic circuitry including, for example, programmable logic circuitry, field-programmable gate arrays (FPGA), or programmable logic arrays (PLA) may execute the computer readable program instructions by utilizing state information of the computer readable program instructions to personalize the electronic circuitry, in order to perform aspects of the present invention.
Aspects of the present invention are described herein with reference to flowchart illustrations and/or block diagrams of methods, apparatus (systems), and computer program products according to embodiments of the invention. It will be understood that each block of the flowchart illustrations and/or block diagrams, and combinations of blocks in the flowchart illustrations and/or block diagrams, can be implemented by computer readable program instructions.
These computer readable program instructions may be provided to a processor of a general purpose computer, a special purpose computer, or other programmable data processing apparatus to produce a machine, such that the instructions, which execute via the processor of the computer or other programmable data processing apparatus, create means for implementing the functions/acts specified in the flowchart and/or block diagram block or blocks. These computer readable program instructions may also be stored in a computer readable storage medium that can direct a computer, a programmable data processing apparatus, and/or other devices to function in a particular manner, such that the computer readable storage medium having instructions stored therein comprises an article of manufacture, including instructions which implement aspects of the function/act specified in the flowchart and/or block diagram block or blocks.
The computer readable program instructions may also be loaded onto a computer, other programmable data processing apparatus, or other device to cause a series of operational steps to be performed on the computer, other programmable apparatus, or other device to produce a computer implemented process, such that the instructions which execute on the computer, other programmable apparatus, or other device implement the functions/acts specified in the flowchart and/or block diagram block or blocks.
The flowchart and block diagrams in the Figures illustrate the architecture, functionality, and operation of possible implementations of systems, methods, and computer program products according to various embodiments of the present invention. In this regard, each block in the flowchart or block diagrams may represent a module, segment, or portion of instructions, which comprises one or more executable instructions for implementing the specified logical function(s). In some alternative implementations, the functions noted in the block may occur out of the order noted in the Figures. For example, two blocks shown in succession may, in fact, be executed substantially concurrently, or the blocks may sometimes be executed in the reverse order, depending upon the functionality involved. It will also be noted that each block of the block diagrams and/or flowchart illustration, and combinations of blocks in the block diagrams and/or flowchart illustration, can be implemented by special purpose hardware-based systems that perform the specified functions or acts or carry out combinations of special purpose hardware and computer instructions.
Reflow soldering is a process in which a plated metallurgy can be used to temporarily attach one or more electrical components to their contact pads, after which the entire assembly is subjected to controlled heat, which melts the solder, permanently connecting the joint. Heating may be accomplished by passing the assembly through a reflow oven, or under an infrared lamp, or by soldering individual joints with a hot air pencil. The goal of the reflow process is to melt the solder and heat the adjoining surfaces without overheating and damaging the electrical components. During reflow, controlled collapse chip connections (C4) packages can exhibit non-uniform thermal profiles, which can result in, for example, thermal stress or a difference in microstructures.
Embodiments of the present invention seek to provide a method, product, and system to determine the thermal profile of semiconductors. Sequential steps of an exemplary embodiment of a method, product, and system for determining thermal profiles of a semiconductor structures are described below with respect to the schematic illustrations of FIGS. 1-4 . Similar reference numerals denote similar features.
FIG. 1 is a functional block diagram illustrating an environment, generally designated 100 , in accordance with an embodiment of the present invention. Environment 100 includes equipment 120 , emitter 130 , sensor 140 , and computing device 110 . In an embodiment, equipment 120 , emitter 130 , sensor 140 , computing device 110 , or any combination thereof may be depicted as a single entity. Although not shown, environment 100 may include additional connections than depicted. In certain embodiments, environment 100 does not include emitter 130 . Equipment 120 is in communication with computing device 110 via communications link 116 . Equipment 120 deposits emitting material on the surface of semiconductor structures, in accordance with an embodiment of the present invention. In an embodiment, equipment 120 deposits one or layers of emitting material utilizing a slurry painting method or a conventional deposition process, such as chemical vapor deposition.
Applicable emitting material includes material capable of luminescent decay, material diffusion, ionizing radiation, temperature-based spectral shift, and temperature-dependent luminescence (discussed further below). In an embodiment, the emitting layer emits one or more of a luminescence, visible light, infrared light, and ions. In other embodiments, the emitting layer is capable of chemiluminescence, bioluminescence, and/or photoluminescence. In other embodiments, the emitting layer is comprises quantum dots capable of temperature-based spectral shifts.
In certain embodiments, the emitting layer includes a first and second diffusion layer, wherein the first diffusion layer diffuses into the second diffusion layer at a diffusion rate that is a function of time and/or temperature. Emitter 130 is in communication with computing device 110 via communications link 117 . Emitter 130 is not utilized in embodiments wherein the emitting material is capable of material diffusion (discussed below). In an embodiment, photoluminescent material, such as material that includes erbium or ytterbium, is the emitting material.
In an embodiment, applicable photoluminescent material includes phosphors. For example, phosphors, such as SrAlO 4 :Eu 2+ , Dy 3+ , are alkaline earth aluminates that are co-doped with divalent europium (Eu 2+ ) and trivalent dysprosium (Dy 3+ ) ions. Alkaline earth aluminates typically have a general formula, MAl 2 O 4 , wherein M may be barium (Ba), calcium (Ca), or strontium (Sr). Emitter 130 is a device that exudes a type of signal, such as photons or ionizing particles, and exposes emitting material to the signal. In an embodiment, emitter 130 emits photons in the 510 nm to 530 nm wavelength range.
Sensor 140 is in communication with computing device 110 via communications link 118 , accordance with an embodiment of the present invention. Sensor 140 detects signals that are, for example, associated with luminescent decay, material diffusion, ionizing radiation, temperature-based spectral shift, and/or temperature-dependent luminescence. In an embodiment, sensor 140 is a photometer. Sensor 140 can measure light by counting photons or incoming flux. Photon measurements may be defined in units, such as photons/cm 2 or photons*cm −2 . Computing device 110 is used to determine thermal profiles of semiconductor structures, in accordance with an embodiment of the present invention. Computing device 110 includes test data 114 and program function 112 . Test data 114 are emission readings generated by sensor 140 and received via communications link 118 .
Program function 112 is software that determines the thermal profile of semiconductor structures, in accordance with an embodiment of the present invention. Program function 112 can send instructions to equipment 120 and emitter 130 via communications links 116 and 117 , respectively. Program function 112 can, via communications link 118 , receive emission readings generated by sensor 140 . Program function 112 can determine the thermal profile of semiconductor structures.
FIG. 2 is a reflow profile of a semiconductor structure, in accordance with an embodiment of the present invention. Specifically, FIG. 2 illustrates a reflow profile of a semiconductor structure (not shown), for example, a semiconductor package comprising a first and second semiconductor structure joined by C4, wherein the first semiconductor structure comprises an emitting layer that includes, for example, an alkaline earth aluminate is formed on the backside thereof using equipment 120 . The emitting material that comprises the emitting layer undergoes photoexcitation using emitter 130 . In this particular example, T P is the peak temperature of the package and should not exceed the maximum operating temperature of the C4.
T L is the liquidus temperature and denotes the temperature above which the C4 is in a liquid state, and t L is the time maintained above T L . In certain embodiments, program function 112 determines emission readings while the C4 is in a solid state, wherein the initial read is taken at to and the final read is taken at t k . In other embodiments, program function 112 determines emission readings while the C4 is in a liquid state, wherein the initial read is taken at t i and the final read is taken at t f . In certain embodiments, the reflow profile comprises a maximum ramp up rate of 3° C./s and a maximum ramp down rate of 6° C./s. Program function 112 determines the thermal profile of the semiconductor package by determining the difference between the initial and final reads.
In an embodiment, program function 112 determines a thermal profile that reflects regions of high and low temperature. In other embodiments, sensor 140 comprises a 2-dimensional array of sensors, such as photodiodes, that can detect ultraviolet and/or infrared wavelengths, such as wavelengths in the 300 nm to 1700 nm range. Program function 112 can generate a 2-dimensional or 3-dimensional graphic representation of the determined thermal profile. FIG. 3 is a flowchart depicting the operational steps of program function 112 , in accordance with an embodiment of the present invention.
Program function 112 instructs equipment 120 to deposit one or more layers of emitting material on the backside of a semiconductor structure (step 300 ). For example, equipment 120 deposits a layer of an emitting material that includes an alkaline earth aluminate, for example, SrAlO 4 : Eu, Dy. Program function 112 takes an initial emissions reading using sensor 140 (step 310 ). For example, program function 112 instructs emitter 130 to excite the emitting material for a predetermined time period. Subsequently, program function 112 takes an initial emissions reading of two adjacent regions of the emitting material, regions A and B, for example, 75 photons/cm 2 and 75 photons/cm 2 , respectively.
At the end of the reflow process, program function 112 takes a final emissions reading using sensor 140 (step 320 ). At the end of the reflow process, program function 112 takes a final emissions reading for regions A and B using sensor 140 , 52 photons/cm 2 and 35 photons/cm 2 , respectively. Program function 112 determines the thermal profile of the semiconductor package using the initial and final readings (step 330 ). For example, region B has a lower photon count compared to region A, which is reflective that region B retained more heat, which may be reflective of reflow issues. Such regional photon count comparisons can assist one in, for example, determining whether the chip was sufficiently heated to form proper interconnects, quantitating thermal load, and/or ascertaining the thermal uniformity across a substrate.
Additional reflow issues may be addressed using photon count comparisons. For example, during reflow of C4s, a difference in the thermal profiles of modules can result in thermal stress or a difference in the microstructures included therein. Regional comparisons of photon counts can assist one in ascertaining the uniformity of the local thermal budget across each module. Multiple reflows of wafers and dies may affect EM performance. Here, regional photon count comparisons can assist one in ascertaining a die's thermal history through manufacturing.
FIG. 4 shows a block diagram of an exemplary design flow 400 used, for example, in semiconductor IC logic design, simulation, test, layout, and manufacture. Design flow 400 includes processes, machines, and/or mechanisms for processing design structures or devices to generate logically or otherwise functionally equivalent representations of the design structures and/or devices described above and shown in FIGS. 1-3 . The design structures processed and/or generated by design flow 400 may be encoded on machine-readable transmission or storage media to include data and/or instructions that, when executed or otherwise processed on a data processing system, generate a logically, structurally, mechanically, or otherwise functionally equivalent representation of hardware components, circuits, devices, or systems.
Machines include, but are not limited to, any machine used in an IC design process, such as designing, manufacturing, or simulating a circuit, component, device, or system. For example, machines may include: lithography machines, machines and/or equipment for generating masks (e.g., e-beam writers), computers or equipment for simulating design structures, any apparatus used in the manufacturing or test process, or any machines for programming functionally equivalent representations of the design structures into any medium (e.g., a machine for programming a programmable gate array). Design flow 400 may vary depending on the type of representation being designed. For example, a design flow 400 for building an application specific IC (ASIC) may differ from a design flow 400 for designing a standard component, or from a design flow 400 for instantiating the design into a programmable array, for example, a programmable gate array (PGA) or a field programmable gate array (FPGA) offered by Altera® Inc. or Xilinx® Inc.
FIG. 4 depicts a block diagram of components of server computing device 110 in accordance with an illustrative embodiment of the present invention. It should be appreciated that FIG. 4 provides only an illustration of one implementation and does not imply any limitations with regard to the environments in which different embodiments may be implemented. Many modifications to the depicted environment may be made.
A non-transitory computer readable storage medium embodiment herein is readable by a computerized device. The non-transitory computer readable storage medium stores instructions executable by the computerized device to perform a method that tests integrated circuit devices to measure a voltage overshoot condition.
Server 110 includes communications fabric 402 , which provides communications between computer processor(s) 404 , memory 406 , persistent storage 408 , communications unit 410 , and input/output (I/O) interface(s) 412 . Communications fabric 402 can be implemented with any architecture designed for passing data and/or control information between processors (such as microprocessors, communications and network processors, etc.), system memory, peripheral devices, and any other hardware components within a system. For example, communications fabric 402 can be implemented with one or more buses.
Memory 406 and persistent storage 408 are computer readable storage media. In this embodiment, memory 406 includes random access memory (RAM) 414 and cache memory 416 . In general, memory 406 can include any suitable volatile or non-volatile computer readable storage media.
Program function 112 and test data 114 are stored in persistent storage 408 for execution and/or access by one or more of the respective computer processor(s) 404 via one or more memories of memory 406 . In this embodiment, persistent storage 408 includes a magnetic hard disk drive. Alternatively, or in addition to a magnetic hard disk drive, persistent storage 408 can include a solid-state hard drive, a semiconductor storage device, a read-only memory (ROM), an erasable programmable read-only memory (EPROM), a flash memory, or any other computer readable storage media that is capable of storing program instructions or digital information.
The media used by persistent storage 408 may also be removable. For example, a removable hard drive may be used for persistent storage 408 . Other examples include optical and magnetic disks, thumb drives, and smart cards that are inserted into a drive for transfer onto another computer readable storage medium that is also part of persistent storage 408 .
Communications unit 410 , in these examples, provides for communications with other data processing systems or devices. In these examples, communications unit 410 includes one or more network interface cards. Communications unit 410 may provide communications through the use of either or both physical and wireless communications links. Program function 112 may be downloaded to persistent storage 408 through communications unit 410 .
I/O interface(s) 412 allows for input and output of data with other devices that may be connected to server 110 . For example, I/O interface(s) 412 may provide a connection to external device(s) 418 such as a keyboard, a keypad, a touch screen, and/or some other suitable input device. External device(s) 418 can also include portable computer readable storage media such as, for example, thumb drives, portable optical or magnetic disks, and memory cards. Software and data used to practice embodiments of the present invention, e.g., program function 112 and test data 114 , can be stored on such portable computer readable storage media and can be loaded onto persistent storage 408 via I/O interface(s) 412 . I/O interface(s) 412 also connects to a display 420 . Display 420 provides a mechanism to display data to a user and may be, for example, a computer monitor.
The programs described herein are identified based upon the application for which they are implemented in a specific embodiment of the invention. However, it should be appreciated that any particular program nomenclature herein is used merely for convenience and, thus, the invention should not be limited to use solely in any specific application identified and/or implied by such nomenclature.
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According to embodiments of the present invention, a semiconductor substrate is formed on at least a portion of a surface of a semiconductor substrate. The emitting layer is excited for a first predetermined time period. A first luminescent intensity value of the emitting layer is determined. In response to exposing the semiconductor substrate and the emitting layer to a condition for a second predetermined time period, a second luminescent intensity value of the emitting layer is determined. A thermal profile of at least the portion of the surface of the semiconductor substrate is determined utilizing the first luminescent intensity value and the second luminescent intensity value of the emitting layer. The thermal profile at least reflects information about one or more of the condition and the semiconductor substrate subsequent to exposure to the condition.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation-in-part of U.S. patent application Ser. No. 14/095,298, entitled Elongate Pipe-Base Structure For Supporting Heavy Loads, and filed Dec. 3, 2013 by the same inventors. That application is incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] This invention relates, generally, to temporary structures for supporting heavy loads over bodies of water or wetlands. More particularly, it relates to a modular heavy load-supporting structure having cylindrical sections that are laid end to end quickly to save time and materials.
[0004] 2. Description of the Prior Art
[0005] It was a common practice before wetlands conservation was a concern to dredge out large sections of wetlands as needed when building roadways or bridges over such wetlands. Such dredging enabled barges to carry heavy equipment to the jobsite as the job site progressed across the landscape.
[0006] Over time, it became apparent that dredged wetlands were not recovering as expected, and laws now ban such dredging.
[0007] Stone causeways built in wetlands areas avoid such dredging, but they too are environmentally unacceptable.
[0008] The industry has adopted the practice of building a temporary bridge into the wetlands for the purpose of enabling heavy equipment to reach the job site. Although such bridges require pile driving, the small footprint of a pile causes no permanent damage to the wetlands, i.e., the wetlands recover quickly when the temporary piles are removed.
[0009] The primary drawback to the temporary bridge solution to the wetlands conservation problem is that such temporary bridges, since they must carry very heavy loads, can be quite expensive and time-consuming to build even though they are temporary structures that are removed when the main roadway or bridge is completed.
[0010] Thus there is a need for a temporary bridge structure that is assembled quickly from low cost materials but which can support extremely heavy loads.
[0011] There is also a need for a temporary bridge structure that is quickly disassembled as well when no longer needed.
[0012] However, in view of the art considered as a whole at the time of making the present invention, it was not obvious to those of ordinary skill in the art how the needed structure could be provided.
SUMMARY OF THE INVENTION
[0013] The long-standing but heretofore unfulfilled need for an improved structure for a temporary structure that supports heavy loads is met by a new, useful, and non-obvious invention.
[0014] The inventive structure includes at least one hollow cylinder having a longitudinal axis of symmetry and an elongate extent. In a preferred embodiment, a hollow cylinder has a thirty six inch outside diameter and a wall thickness of three-eighths of an inch. Such dimensions are preferred but are not critical because pipes of many different outside diameter and wall thicknesses can be used when building temporary bridges as disclosed herein.
[0015] A plurality of stress-distributing strengthening members is circumferentially positioned about and secured to the hollow cylinder in parallel relation to the longitudinal axis of symmetry.
[0016] The strengthening members have an extent substantially equal to the elongate extent of the elongate hollow cylinder and in the preferred embodiment each strengthening member has a generally “L” shape where the legs of the “L” are disposed in angular relation to one another. Another embodiment saves materials by providing one leg per strengthening member.
[0017] A first flat plate of rigid construction is disposed in a horizontal plane in overlying and secured relation to the hollow cylinder. A second flat plate of rigid construction is disposed in a horizontal plane in underlying and secured relation to the hollow cylinder in parallel and diametrically opposed relation to the first flat plate. The width of each flat plate may exceed but is substantially equal to the diameter of the hollow cylinder to which it is secured and the length of each flat plate is substantially equal to the length of its hollow cylinder.
[0018] In the preferred embodiment, a first pair of two-leg strengthening members is secured to a hollow cylinder on opposite sides of a vertical plane that bisects the hollow cylinder and above a horizontal plane that bisects the hollow cylinder. A second pair of two-leg strengthening members is secured to the hollow cylinder on opposite sides of the vertical plane and below the horizontal plane.
[0019] Each leg of each strengthening member of the first pair has a free end disposed in abutting and secured relation to the first rigid flat plate along the elongate extent of the first rigid flat plate. Each leg of each strengthening member of the second pair has a free end disposed in abutting and secured relation to the second rigid flat plate along the elongate extent of the second rigid flat plate.
[0020] As in the parent disclosure, an imperforate circular disc is positioned within the lumen of the hollow cylinder in perpendicular relation to the longitudinal axis of symmetry of the hollow cylinder and in longitudinally spaced relation to a preselected end of the hollow cylinder.
[0021] A first circular disc has a central opening formed therein is secured to a first end of the hollow cylinder. A second circular disc having a central opening formed therein is secured to a second, opposite end of the hollow cylinder. The central opening of the second circular disc having said central opening forms a socket that mates with a key when first and second hollow cylinder members are disposed in end-to-end abutting relation to one another along a common longitudinal axis of symmetry.
[0022] A first end of a truncate cylindrical member is secured to the imperforate cylindrical disc in concentric relation thereto and a second end protrudes through the central opening formed in the first circular disc having a central opening. The protrusion forms the key.
[0023] In a second embodiment of the invention, longitudinally disposed timbers form a timber mat.
[0024] At least one pedestrian walkway is provided in a third embodiment.
[0025] A fourth embodiment enables a non-linear connection between elongate hollow cylinders so that a temporary bridge may include at least two straight sections that are disposed at a predetermined angle relative to one another.
[0026] A fifth embodiment discloses strengthening members having only one leg.
[0027] An important object of the invention is to provide a temporary bridge structure capable of supporting extremely heavy equipment.
[0028] Another important object is to provide such a structure that can be made of any length.
[0029] Another object is to provide a structure that assembles quickly, without tight tolerances, and which is made from readily available materials.
[0030] Still further objects are to disclose a better method for building timber mats, pedestrian walkways, paths of travel having at least one angular turn, and strengthening members that save materials.
[0031] These and other important objects, advantages, and features of the invention will become clear as this disclosure proceeds.
[0032] The invention accordingly comprises the features of construction, combination of elements, and arrangement of parts exemplified in the disclosure set forth hereinafter and the claims indicate the scope of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0033] For a fuller understanding of the nature and objects of the invention, reference should be made to the following detailed disclosure, taken in connection with the accompanying drawings, in which:
[0034] FIG. 1 is an end view of a hollow cylinder, strengthening members, and rigid flat plates used in the novel structure;
[0035] FIG. 2 is a top plan view depicting two hollow cylinders in transversely disposed relation to one another;
[0036] FIG. 3 is a top plan view of the FIG. 2 embodiment after longitudinally and transversely disposed timbers have been added thereto;
[0037] FIG. 4A is an end view of a first variation of a third embodiment;
[0038] FIG. 4B is an end view of a second variation of the third embodiment;
[0039] FIG. 5 is a top plan view of a fourth embodiment including a predetermined angle between two straight sections of a bridge;
[0040] FIG. 6A is a top plan view of a truncate hollow cylinder that creates a predetermined angle between end-to-end elongate hollow cylinders;
[0041] FIG. 6B is a first side elevation view of said truncate hollow cylinder, taken along line 6 B- 6 B in FIG. 6A ;
[0042] FIG. 6C is a second side elevation view of said truncate hollow cylinder, taken along line 6 C- 6 C in FIG. 6A ;
[0043] FIG. 6D is an end elevation view of said truncate hollow cylinder, taken along line 6 D- 6 D in FIG. 6A ; and
[0044] FIG. 7 is an end elevation view of a fifth embodiment.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0045] FIG. 1 depicts an illustrative embodiment of a novel structural flexural element which is denoted as a whole by the reference numeral 10 .
[0046] Novel structure 10 includes elongate hollow pipe or cylinder 12 having a longitudinal axis of symmetry. Four (4) elongate, generally L-shaped stress-distributing strengthening members, denoted 14 a, 14 a, 14 b, and 14 b are circumferentially positioned about elongate hollow cylinder 12 in parallel relation to said longitudinal axis of symmetry and are secured to said elongate hollow cylinder by suitable means such as welding. The legs of each L-shaped strengthening member are disposed in angular relation to one another.
[0047] A first flat plate 16 of rectangular configuration and rigid construction overlies cylinder member 12 and the first or upper pair 14 a, 14 a of the strengthening members is positioned to orient said first flat plate 16 in a horizontal plane. More particularly, the free end of each leg of strengthening members 14 a, 14 a is welded or otherwise secured to an underside of said first flat plate. Strengthening members 14 a, 14 a are secured to said hollow cylinder on opposite sides of a vertical plane that longitudinally bisects hollow cylinder 12 .
[0048] A second flat plate 18 of rectangular configuration and rigid construction underlies cylinder member 12 and the second or lower pair 14 b, 14 b of stress-distributing strengthening members 14 b, 14 b is positioned to orient said second flat plate 18 in a horizontal plane. More particularly, the free end of each leg of strengthening members 14 b, 14 b is welded or otherwise secured to a top side of said second flat plate. Strengthening members 14 b, 14 b are secured to hollow cylinder 12 on opposite sides of the vertical plane. Upper strengthening members 14 a, 14 a and lower strengthening members 14 b, 14 b are positioned on opposite sides of a horizontal plane that bisects hollow cylinder 12 .
[0049] First and second flat plates 16 and 18 are parallel to one another in their respective horizontal planes.
[0050] Defining the end view of hollow cylinder 12 as the face of an analog clock where twelve o'clock is the highest point of said hollow cylinder as drawn in FIG. 1 , upper strengthening members 14 a, 14 a are positioned roughly at the one and eleven o'clock positions and lower strengthening members 14 b, 14 b are positioned roughly at the five and seven o'clock positions.
[0051] FIG. 2 depicts a pair of said hollow cylinders 12 disposed in transversely spaced apart, parallel relation to one another. Said cylinders are interconnected to one another along their respective extents by a plurality of transversely disposed, longitudinally spaced apart diaphragm members, collectively denoted 19 .
[0052] As in the parent application, an imperforate circular disc 20 is positioned within the lumen of each hollow cylinder 12 in perpendicular relation to the longitudinal axis of symmetry of said hollow cylinder. A first circular disc 22 having a central opening 23 formed therein is secured to a first end of hollow cylinder 12 . A second circular disc 22 a having a central opening 23 a that forms a key-receiving socket is secured to a second, opposite end of hollow cylinder 12 in closing relation thereto. No reference numeral is provided for central openings 23 and 23 a in FIG. 2 to avoid cluttering of the drawings.
[0053] Truncate hollow cylinder member 24 has a first end 24 a secured to imperforate circular disc 20 in concentric relation thereto, i.e., truncate cylindrical member 24 has the same longitudinal axis of symmetry as does elongate hollow cylinder 12 . Second end 24 b of truncate cylindrical member 24 extends through the central opening formed in first circular disc 22 . The protrusion of second end 24 b forms a key or pin that mates with the key-receiving socket formed in second cylindrical disc 22 a when two (2) cylindrical members 12 are disposed in end-to-end abutting relation to one another along a common longitudinal axis of symmetry.
[0054] Thus a first or leading end of each elongate hollow cylinder 12 is provided with key or pin 24 b as depicted in FIG. 2 and the second or trailing end of each elongate hollow cylinder is provided with a key-receiving socket in the form of said central opening formed in second circular disc 22 a. The first and second centrally apertured circular discs 22 and 22 a, respectively, have the same structure. The difference in reference numerals merely points out their difference in positions at opposite ends of each elongate hollow cylinder.
[0055] FIG. 3 depicts a plurality of longitudinally-disposed timbers, collectively denoted 26 , supported by said transversely disposed diaphragms 19 . Timbers 26 collectively form a timber mat that provides a roadway for heavy equipment. As mentioned above, all prior art timber mats are formed by a plurality of transversely disposed timbers which are supported by longitudinally disposed diaphragms which are in turn supported by transversely disposed diaphragms. The novel arrangement of FIG. 3 thus eliminates the longitudinally disposed diaphragms of the prior art.
[0056] As best understood in connection with FIGS. 4A and 4B , each diaphragm 19 is connected at its opposite ends to a flat brace 21 that is welded to its associated hollow cylinder 12 in a vertical plane. The cylinder-abutting side of each brace 21 is arcuate to conform to the surface of its associated hollow cylinder. A plurality of openings, collectively denoted 28 , is formed in each brace 21 along its outboard edges and each diaphragm 19 has a plurality of openings formed in each of its ends which can be aligned with preselected openings 28 . Suitable nuts and bolts are used to secure the opposite ends of each diaphragm 19 to its associated brace 21 .
[0057] Such structure allows height adjustment of each diaphragm 19 along the vertical extent of its associated brace 21 and thus height adjustment of the timber mat supported by said diaphragms. The timber mat in FIG. 4B is elevated with respect to the timber mat depicted in FIG. 4A . The FIG. 4B timber mat is a prior art timber mat having transversely disposed timbers.
[0058] In the embodiment of FIGS. 3 and 4A , a pedestrian walkway is supported by a plurality of transversely disposed, longitudinally spaced apart boards, collectively denoted 30 , that are mounted atop and secured to rigid flat top plate 16 in cantilever relation thereto and which extend in an outboard direction relative to each hollow cylinder 12 . Elongate strips of plywood 32 or other suitable material overlie boards 30 and provide support for a pedestrian. As depicted in said FIGS. 3 and 4A , such a pedestrian walkway is provided on the outboard side of each hollow cylinder. An upstanding safety hand rail 34 is provided on the outboard side of each walkway and a longitudinally disposed timber 26 a that is smaller than a timber mat timber 26 may be used to provide a guiding curb for the equipment as depicted in said FIG. 4A . Still smaller timbers 26 b are used to support plywood 32 .
[0059] FIGS. 3 and 4A also disclose transversely disposed shorter boards 30 a directly overlying upper rigid flat plate 16 of their associated hollow cylinder 12 and filling in the spaces between the longer, cantilevered boards 30 .
[0060] As indicated in FIG. 4A , the transverse spacing of piles 13 that support hollow cylinders 12 may be selected to directly support treads 11 of a crane 15 or other item of heavy equipment.
[0061] A pedestrian walkway may also be provided as disclosed in FIG. 4B . In this embodiment, transversely disposed, cantilevered boards 30 and the shorter boards 30 a therebetween are not used. A plurality of transversely disposed, longitudinally spaced apart elongate timber mats 27 , only one of which is depicted in the end view of FIG. 4B , is mounted and secured to the rigid flat mounting plate 16 that surmounts each hollow cylinder 12 . Each of said timber mats 27 has a transverse extent that exceeds the distance between the transversely spaced apart hollow cylinders 12 . The distance by which each transverse timber mat 27 extends outboard of the hollow cylinders defines the width of each pedestrian walkway. Although not depicted in FIG. 4B , a longitudinally extending strip of plywood 32 fills in the gap between timbers 27 to provide a pedestrian walkway and a suitable safety handrail may be provided as well.
[0062] The structure that enables the novel temporary bridge to turn relative to a straight line is depicted in FIGS. 5 and FIGS. 6A-D .
[0063] FIG. 5 depicts novel turn-creating member 40 and its position between two end-to-end elongate hollow cylinders 12 . Note that no such turn or curve-creating member 40 is provided between the transversely spaced associated elongate hollow cylinders 12 that are disposed end-to-end because such elongate hollow cylinders follow the interior curvature of the turn or curve and thus are not as widely spaced apart as are the elongate hollow cylinders on the outboard side of the curve.
[0064] Turn-creating member 40 is hereinafter referred to as the first or outer truncate hollow cylinder. It has a diameter equal to the diameter of each elongate hollow cylinder 12 and a structure that is much the same as the structure as each elongate hollow cylinder.
[0065] FIGS. 6A-D respectively provide top plan, first side, second side, and end views of turn or curve-creating outer truncate hollow cylinder 40 .
[0066] FIG. 5 may be interpreted as depicting a turn to the left in the novel temporary bridge structure. Accordingly, the upwardly inclined (as drawn) second or inner truncate hollow cylinder 24 depicted in the top plan view of FIG. 5 and in enlarged view in FIG. 6A indicates such left turn. Similarly, first centrally-apertured circular disc 22 is disposed at an obtuse angle in FIG. 6A relative to a horizontal plane, and the left side 40 a of member 40 has a shorter extent than right side 40 b thereof. Moreover, said left and right sides 40 a, 40 b are inclined upwardly from a horizontal plane as depicted in said FIG. 6A . A member 40 for creating a right turn would include a downwardly tilted inner truncate hollow cylinder 24 in FIG. 6A and the respective lengths and inclinations of sides 40 a and 40 b would be reversed.
[0067] The rate of curvature is increased by employing more than one member 40 at the desired turn location. This cumulative structure is possible because each member 40 has a socket opening 23 a formed in each centrally-apertured circular disc 22 and 22 a and a key 24 b that protrudes through the central opening formed in each first centrally-apertured circular disc 22 .
[0068] More particularly, first or outer truncate hollow cylinder 40 is truncate relative to said elongate hollow cylinders 12 , and said first truncate hollow cylinder 40 has a diameter substantially equal to a diameter of each elongate hollow cylinder 12 .
[0069] A second or inner truncate hollow cylinder 24 is disposed concentrically within said first truncate hollow cylinder 40 and has a longitudinal axis of symmetry disposed at a predetermined angle relative to a longitudinal axis of symmetry of said first truncate hollow cylinder 40 . Said second truncate hollow cylinder 24 therefore has a leading end disposed in oblique relation to a trailing end of said second truncate hollow cylinder.
[0070] First truncate hollow cylinder 40 is positioned between two elongate hollow cylinders 12 disposed in end-to-end relation to one another, one of which is a leading elongate hollow cylinder and one of which is a trailing elongate hollow cylinder.
[0071] As best understood in connection with FIG. 5 , the trailing elongate hollow cylinder is in axial alignment with a trailing end of said first or outer truncate hollow cylinder 40 and said leading elongate hollow cylinder is in axial alignment with a leading end of said second or inner truncate hollow cylinder 24 .
[0072] The predetermined angle of said second truncate hollow cylinder 24 enables construction of a temporary bridge having at least two straight sections that form an angle with one another equal to the predetermined angle of said second truncate hollow cylinder 24 with respect to the longitudinal axis of symmetry of said first truncate hollow cylinder 40 .
[0073] In all other respects the structure of first or outer truncate hollow cylinder 40 is the same as each elongate hollow cylinder 12 . An imperforate circular disc 20 is positioned within a lumen of first truncate hollow cylinder 40 in parallel relation to a trailing end of said first truncate hollow cylinder and in spaced apart relation to the leading end of said first truncate hollow cylinder.
[0074] A first circular disc 22 having a central opening formed therein is secured to the leading end of first truncate hollow cylinder 40 and a second circular disc 22 a having a central opening that forms a key-receiving socket is secured to the trailing end of said first truncate hollow cylinder 40 in closing relation thereto.
[0075] Second or inner truncate hollow cylinder member 24 has a trailing end secured to said imperforate circular disc 20 in concentric relation thereto and a leading end protruding through the central opening formed in first centrally-apertured circular disc 22 . The leading forms a key that engages said key-receiving socket.
[0076] FIG. 7 depicts an elongate hollow cylinder 12 having flat top plate 16 secured thereto in a horizontal plane and flat bottom plate 18 secured thereto in a horizontal plane. Top flat plate 16 makes tangential contact as at 16 a with hollow cylinder 12 at the twelve o'clock position of the circle defined by said hollow cylinder 12 in end view and bottom flat plate 18 makes tangential contact as at 18 a with hollow cylinder 12 at the six o'clock position of the circle.
[0077] Upper strengthening members 14 a, 14 a are formed integrally with or welded to flat top plate 16 and depend therefrom in normal relation thereto. Lower strengthening members 14 b, 14 b are formed integrally with or welded to flat bottom plate 18 and project upwardly therefrom in normal relation thereto.
[0078] Upper strengthening members 14 a, 14 a are positioned on opposite sides of the twelve o'clock point of tangential contact 16 a in equidistantly spaced relation to said twelve o'clock point of tangential contact. Lower strengthening members 14 b, 14 b are positioned on opposite sides of the sic o'clock point of tangential contact 18 a in equidistantly spaced relation to said six o'clock point of tangential contact.
[0079] This embodiment has the advantage of providing substantially as much strengthening as the above-disclosed embodiments with less materials in that each strengthening member has one leg instead of two. It has the disadvantage of requiring a more precise placement of legs 14 a, 14 a, 14 b, 14 b relative to the placement of the two leg embodiments because there are only four points of strengthening contact instead of eight.
[0080] It will thus be seen that the objects set forth above, and those made apparent from the foregoing disclosure, are efficiently attained and since certain changes may be made in the above construction without departing from the scope of the invention, it is intended that all matters contained in the foregoing disclosure or shown in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense.
[0081] It is also understood that the following claims are intended to cover all of the generic and specific features of the invention herein described, and all statements of the scope of the invention that, as a matter of language, might be said to fall therebetween.
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A temporary bridge for supporting heavy loads includes elongate hollow cylinders. A first rigid flat plate is horizontally disposed in overlying relation to each hollow cylinder and a second rigid flat plate is horizontally disposed in underlying relation to each hollow cylinder. Stress-distributing strengthening members formed by a pair of legs that are angularly disposed with respect to one another are circumferentially positioned about each hollow cylinder and the respective free ends of the legs are secured to their associated rigid flat plates. A key extends from a first end of each hollow cylinder and a mating socket is formed in a second end of each hollow cylinder to facilitate end-to-end interconnection of a plurality of hollow cylinders. Further embodiments include longitudinally-disposed timber mats, pedestrian walkways and curvature-creating members so that the bridge may follow a non-linear path of travel.
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REFERENCE TO RELATED APPLICATIONS
[0001] This patent application claims the benefit of U.S. Provisional Application No. 61/255,961 filed on Oct. 29, 2009, the disclosure of which is incorporated herein by reference in its entirety.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to a light assembly that can be attached to virtually any welding helmet to create a well lit working area. The light emitting diode (LED) provides a bright white colored light, which is ideal while doing repair welds, fabrication, and the like. The adjustable light enables the welder to position the light as needed. The product substantially eliminates the need to work in poorly lit conditions by providing welders with the lighting means for starting their welds and inspecting their work, without the need to raise and lower their helmet.
[0004] 2. Description of Related Art
[0005] Typically, in most welding situations there is a lack of available light. Many times welders have to position themselves under a vehicle, in a passageway of a ship, and other such dimly lit areas to perform the weld. Even seemingly well-lit shops can provide insufficient direct lighting in certain locations. In order to see what they are doing, welders have to continuously raise and lower their helmets during welding to start their welds and inspect their work. This is inconvenient and unnecessary.
[0006] To resolve this inconvenience, mounting illumination equipment on or inside the welder helmet for providing lighting is known in the prior art. More specifically, by way of example, U.S. Pat. No. 4,332,004 to Slaughter discloses a lighting system for a welder's helmet which includes a high intensity, high Kelvin temperature electric light source attached to the face shield for directing a higher energy light beam forwardly of the viewing port.
[0007] U.S. Pat. No. 6,340,234 B1 to Brown, Jr. discloses a means to illuminate the lens of a face shield to be worn by a welder. The lens is illuminated to enable the welder to see through the lens prior to the welding are being lighted.
[0008] U.S. Pat. No. 7,161,116 B2 to Steinemann discloses a welding protective mask, which includes illumination equipment for illuminating a work area. The illumination equipment includes an illumination device, a detection device for detecting an ambient light intensity, energy storage for electrically supplying the illumination equipment and controller for controlling an intensity of light radiated by the illumination means according to the ambient light intensity. In this prior art, the intensity of the radiant light is in dependence of a detected ambient light intensity. The direction of the light source is not adjustable.
[0009] Although these illumination equipment in prior art fulfill their respective, particular objective and requirements, the aforementioned patents do not provide adjustable light source. A more efficient method of providing an adjustable light source is needed for illuminating a working area. In this respect, the adjustable light assembly for the welder helmet and the welder helmet with an adjustable light assembly according to the present invention substantially departs from the conventional concepts and design of the prior art.
SUMMARY OF THE INVENTION
[0010] The present invention discloses a light assembly that can be attached to virtually any welding helmet to create a well lit working area. The light emitting diode (LED) provides a bright white colored light, which is ideal while doing repair welds, fabrication, and the like. The adjustable light enables the welder to position the light as needed. The product substantially eliminates the need to work in poorly lit conditions by providing welders with the lighting means for starting their welds and inspecting their work, without the need to raise and lower their helmet.
[0011] A primary object of the present invention is to provide a light assembly for welder to mount on the welder helmets. The light assembly can be retrofitted onto existing helmets or manufactured as an integral part of new welder's helmets.
[0012] Another object of the invention is to provide a light assembly which can be easily controlled (switched on or off and adjusted intensity) by the person performing the welding task.
[0013] A further object of the present invention is to provide an adjustable light assembly to enable the welder to position the light beams in the desired direction as needed.
[0014] Still yet another object of the present invention is to provide a light assembly with an adjustment knob on the helmet so that the users have easy access to position the light beam in the desired direction as needed.
[0015] More particularly, the present invention is a welder's helmet light that can be attached to virtually any welding helmet to create a well lit working area. The present invention comprises a small LED light substantially contained within a plastic housing. The light itself may be covered with a clear plate. A battery pack may also be included to power the light. The unit may contain an accessible power switch and intensity adjustment knobs. The light may be mounted onto the top and/or face of a welding helmet. It may be mounted in such a way that it adjustably illuminates the area in front of the helmet's viewing window. Adjustment knobs may be included on the housing, which allow the user to position the light beam in the desired direction. The LED lamp may be approximately 2″ in height, 3″ in length, and 2″ in width. The LED lamp is designed to provide a bright white light source. It may be incorporated into the helmet during manufacture. The exact specifications may vary. The present invention can be retrofitted onto existing helmets or manufactured as an integral part of new welder's helmet.
[0016] The more important features of the invention have thus been outlined in order that the more detailed description that follows may be better understood and in order that the present contribution to the art may better be appreciated. Additional features of the invention will be described hereinafter and will form the subject matter of the claims that follow.
[0017] Before explaining at least one embodiment of the invention 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 the components set forth in the following description or 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.
[0018] As such, those skilled in the art will appreciate that the conception, upon which this disclosure is based, may readily be utilized as a basis for the designing of other structures, methods and systems for carrying out the several purposes of the present invention. It is important, therefore, that the claims be regarded as including such equivalent constructions insofar as they do not depart from the spirit and scope of the present invention.
[0019] The foregoing has outlined, rather broadly, the preferred feature of the present invention so that those skilled in the art may better understand the detailed description of the invention that follows. Additional features of the invention will be described hereinafter that form the subject of the claims of the invention. Those skilled in the art should appreciate that they can readily use the disclosed conception and specific embodiment as a basis for designing or modifying other structures for carrying out the same purposes of the present invention and that such other structures do not depart from the spirit and scope of the invention in its broadest form.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] Other aspects, features, and advantages of the present invention will become more fully apparent from the following detailed description, the appended claim, and the accompanying drawings in which similar elements are given similar reference numerals.
[0021] FIG. 1 is a cross sectional view from the side of the light assembly 1
[0022] FIG. 2 is a cross sectional view from the top of the light assembly 1
[0023] FIG. 3 is a cross sectional view from the front of the light assembly 1
[0024] FIG. 4 is a perspective view showing the light assembly 1 mounted onto the top of a welder helmet 6 .
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0025] Referring to FIG. 1-3 , there is disclosed a preferred embodiment of a light assembly 1 contained within a plastic housing.
[0026] FIG. 1 is a cross sectional view from the side of the light assembly 1 wherein a LED lamp 2 is contained in the front chamber of a plastic housing, a light beam adjust knob 3 is connected to the LED lamp 2 , and the on/off switch 4 is connected to the LED lamp 2 by electronic circuit.
[0027] FIG. 2 is a cross sectional view from the top of the light assembly 1 wherein light beam adjustment knobs 3 are located on the side walls of the housing. The LED lamp 2 is attached to a rod 5 that transverses through the light assembly 1 , reaches to both side walls of the housing and connects with light beam adjustment knob 3 .
[0028] FIG. 3 is a cross sectional view from the front of the light assembly 1 wherein the LED lamp 2 is connected with the battery pack 6 through electronic circuits and on/off switch (not shown). The battery pack is mounted under welding hood.
[0029] FIG. 4 is a perspective view showing the light assembly 1 mounted onto the top of a welder helmet 6 .
[0030] The housing has a generally right angled trapezium configuration. The housing is defined by a top wall, a bottom wall, a front wall, a back wall, opposed side walls, and a hollow chamber. The light source, high efficiency LED lamp 2 includes a plurality of LED disposed within the front part of the chamber. The LED lamp 2 may be covered with a clear plate. The adjustment knobs 3 may be included on the housing, which allow the user to position the light beam in the desired direction. In one of embodiments, the LED lamp 2 may be mounted to a rod 5 that traverses through the housing, reaches to both side walls of the housing and connects with rotatable knobs 3 . Consequently, rotating the knobs 3 , rotate the connected LED lamp 2 . After each rotation, the LED lamp 2 will stay in place through a ratcheting mechanism thus the light beam can be positioned in the desired direction. FIG. 2 illustrates a cross sectional view from the top of the light assembly 1 . This figure shows the position of light beam adjustment knobs 3 relative to LED lamp 2 and shows how the control knobs allow for adjustment of the lighting direction.
[0031] An on/off power switch 4 is disposed within the rear chamber of the housing. The on/off power switch is in communication with the LED lamp 2 and the power source 5 to control the flow of electrical energy from the power source 5 to the LED lamp 2 . The on/off switch 4 extends outwardly to the back wall of the housing in FIG. 1 . The on/off switch 4 may extends outwardly to the side wall of the housing in another embodiment. The power source 6 may be battery pack. The battery pack can be mounted for example through a clip-on- or snap-in connection, or with the help of slideable locking elements, that can be engaged and disengaged again by hand.
[0032] In general, LEDs vary in size, color output, and manufacturer. The LED selected for the preferred embodiment provides a broad spectrum so as to appear white to human eyes. The LED lamp 2 may further include a means to focus the light such as a lens to focus and change the light beam size. The high efficiency LED lamp 2 used in the embodiment is approximately 2″ in height, 3″ in length, and 2″ in width. It may be incorporated into the helmet during manufacture. The exact specifications may vary.
[0033] The advantage of using LED lamp for lighting is well known and does not need detail explanation here. White-light light emitting diode lamps have the characteristics of long life expectancy and relatively low energy consumption. The LED sources are compact, which gives flexibility in designing lighting fixtures and good control over the distribution of light with small reflectors or lenses. Due to the small size of LEDs, control of the spatial distribution of illumination is extremely flexible, and the light output and spatial distribution of a LED array can be controlled without efficiency loss.
[0034] The light assembly 1 may be mounted onto the top and/or face of a welding helmet 6 . It may be mounted in such a way that it adjustably illuminates the area in front of the helmet's viewing window. FIG. 4 disclosed an embodiment of a welder helmet 6 wherein the light assembly 1 is incorporated onto the top of the welder helmet 6 during manufacture. The on/off power switch button 4 is located on the side of the helmet of this embodiment. The light direction adjustment knobs 3 are located on the side wall of the welder's helmet 6 , which allow the user to easily access the knobs. By turning the knobs 3 , the users can position the light beams in the desired direction. The light assembly 1 may also include a light intensity tuning function and include a tuning knob on the side of the welder helmet.
[0035] The light assembly 1 created as an independent unit is preferably mounted on the top or face of the welder helmet 6 . It can be mounted for example through a clip-on- or snap-in connection, or with the help of slideable locking elements, that can be engaged and disengaged again by hand.
[0036] The foregoing description of specific embodiment of the present invention has been presented for purposes of illustration and description. They are not intended to be exhaustive or to limit the present invention to the precise forms disclosed, and obviously many modifications and variations are possible in light of the above teaching. The exemplary embodiment was chosen and described in order to best explain the principles of the present invention and its practical application, to thereby enable others skilled in the art to best utilize the present invention and various embodiments with various modifications as are suited to the particular use contemplated.
[0037] While there have been shown and described and pointed out the fundamental novel features of the invention as applied to the preferred embodiments, it will be understood that the foregoing is considered as illustrative only of the principles of the invention and not intended to be exhaustive or to limit the invention to the precise forms disclosed. Obvious modifications or variations are possible in light of the above teachings. The embodiments discussed were chosen and described to provide the best illustration of the principles of the invention and its practical application to enable one of ordinary skill in the art to utilize the invention in various embodiments and with various modifications as are suited to the particular use contemplated All such modifications and variations are within the scope of the invention as determined by the appended claims when interpreted in accordance with the breadth to which they are entitled.
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A light assembly that can be attached to virtually any welding helmet to create a well lit working area. The light emitting diode (LED) provides a bright white colored light, which is ideal while doing repair welds, fabrication, and the like. The adjustable light enables the welder to position the light as needed. The product substantially eliminates the need to work in poorly lit conditions by providing welders with the lighting means for starting their welds and inspecting their work, without the need to raise and lower their helmet.
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BACKGROUND OF THE INVENTION
In the manufacturing process of semiconductor integrated circuits said rotary coating apparatus is used to drop diffusion agent or photo resist on semiconductor wafers and form their uniform coatings thereon utilizing a centrifugal force.
In said rotary coating apparatus liquid to be applied is dropped around the center of the surface of a semiconductor wafer (hereinafter called a substrate) held by attraction on top of the disc of a spindle, with said spindle stopped, then said spindle is rotated to spread the liquid all over the substrate and at same time scatter unnecessary liquid out thereof due to the centrifugal force, thereby providing uniform diffusion agent or photo resist film over the surface of said substrate.
By the way, during the time required from just after forming a film over a substrate by spindle rotation to just before making dropping on the succeeding substrate, or between the dropping operations e.g. because of changes in applying conditions some solvent contained by liquid in contact with air will diffuse at the lower surface of said nozzle, causing a change in liquid viscosity.
The slightest change in said viscosity will exert a great influence on film thickness in the formation of coatings by means of spindle rotation; in the case of diffusion agent it will result in the dispersion of diffusion density; for photo resist, uneven film thickness will cause the internal distortion of exposure to photo resist, thus leading to inaccurate exposure and therefore it will become extremely difficult to obtain high-accuracy micropatterns.
Hitherto, any countermeasures have not been proposed to solve said problems.
OBJECTS OF THE PRESENT INVENTION
An object of the present invention is to prevent solvent contained by liquid from volatilizing at a nozzle tip by fitting a cap on the lower surface of said nozzle when not in use to fill the internal space with solvent vapor.
A further object of the invention is to provide uniform coatings all over substrates by eliminating viscosity change of liquid to be applied, thereby contributing to quality improvements.
A still further object of the invention is to permit smooth and efficient operations for the automatic and continuous formation of coatings.
These and other objects of the present invention may become clearer with reference to the following detailed descriptions.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates the dropping operation of liquid on a semiconductor wafer.
FIG. 2 illustrates the prevention of solvent from volatilizing with said nozzle capped at the bottom.
FIG. 3 illustrates the sectional details of said capped nozzle.
FIG. 4 illustrates another example of preventing solvent from volatilizing with said nozzle capped.
DESCRIPTION OF THE PREFERRED EMBODIMENT
A saucer designated as numeral 1 is secured to the body frame of said apparatus not illustrated herein and can accommodate scattered liquid during the coating formation to be described later. A spindle 2 driven and rotated by a motor mounted on the frame of said apparatus runs through the center of the saucer 1 and has an integrated seat 3 for a substrate at the upper end and a through hole 4 for vacuum attraction along the core.
At the bottom of one end of a horizontal support bar 5 which corresponds to the center of the substrate seat 3 of the spindle 2 is a nozzle 6 which is so arranged that liquid is supplied through a pipe 7 led from the side of the support bar 5. The operation of a cylinder 10 attached to the other end of the support 5 enables it to go up and down through a given distance, correspondingly causing the nozzle 6 to rise and lower the same distance just above the seat 3.
A cap 11 comprising a cylindrical container with the open end upward and the wall top inclined as much as the inclined wall S of the nozzle 6 (See FIG. 3) fits on the lower surface thereof. A support bar 12 holding the cap 11 is activated by a cylinder 13 to travel in and out horizontally between said nozzle 6 and said seat 3 in the saucer 1.
In operation, a substrate 14 is vacuum-attracted on the seat 3 through the hole 4, and the contraction of a cylinder 10 causes the nozzle 6 via the support 5 to lower near the substrate 14 and start dropping; at the termination of dropping the nozzle 6 rises to the upper limit as the cylinder 10 extends. Simultaneously a cylinder 13 extend until the cap 11 shifts up to the bottom of the nozzle 6 and with the opening of an air supply port at each end of the air cylinder 10 the nozzle 6 goes down by weight of the support 5, thereby covering its lower surface with a cap.
For the next dropping procedure, the cylinder 10 first extends and at the same time the nozzle 6 moves to the upper limit before the retraction of the cylinder 13 to remove the cap 11 from the nozzle 6, then said cylinder 10 contracts to make the nozzle 6 go down to the lower limit and start dropping.
The repetition of the above procedures permits the dropping of liquid of constant viscosity regardless of varying dropping intervals and hence provides uniform coatings. In the present invention the nozzle 6 which can shift vertically has permitted droppings made just above and near a substrate 14, thereby reducing solvent volatilization at the time of dropping and enabling the formation of uniform coatings of diffusion agent containing a solvent of large volatility such as alcohol.
It is advisable to put solvent 16 in the cap 11 beforehand so that, when the cap 11 fits on the lower surface of said nozzle, the internal space is kept in effective solvent vapor atmosphere. This is shown in FIG. 3: when the nozzle tip is covered with the cap 11, the space enclosed with said nozzle and said cap gets gradually filled with solvent volatilizing from the liquid until the saturation is reached, thereby preventing viscosity change.
It may be also a good example to lead solvent vapor 18 into the space via a hose 16 from a separate solvent container 17 with the nozzle 6 capped as shown in FIG. 4.
The inventor made experiments on semiconductor wafers by following the procedures as illustrated in FIGS. 1 and 2 to apply diffusion agent containing alcoholic solvent and using the cap 11 of volatilization prevention construction as shown in FIGS. 3 and 4. As a result, no viscosity change was found at the nozzle tip even after twelve hours had passed between the two succeeding dropping operations and uniform coatings were always provided, while in the conventional method using no cap, viscosity change was produced around the nozzle in two minutes between droppings.
As described above, the present invention can reduce solvent volatilization and hence eliminate sectional change in viscosity and lend itself to forming even coatings regardless of varying dropping intervals; for diffusion agent the apparatus disclosed by the invention can always provide its even film, thus eliminating the dispersion of diffusion density and enabling the manufacturing of semiconductors of uniform characters; in the case of photo resist it can provide uniform photo resist coatings and has proven to be prominently effective particularly when micropatterns are desired.
Furthermore, the present invention has proved to be effective not only with semiconductor wafers but also with other substrates such as glass masks and other metal plates.
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The present invention relates to a rotary coating apparatus wherein liquid to be applied (diffusion agent, photo resist, and others) is dropped through a nozzle on a rotating glass plate or semiconductor wafer seated on top of a spindle to form coatings over their surfaces and a cap is fitted on the lower surface of the nozzle when not in use to provide sealing so that the space enclosed with said nozzle and said cap is filled with solvent vapor.
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FIELD OF THE INVENTION
This invention relates to a pump means and coupling means for moving water from a reservoir in the bottom of an evaporative cooler to a water manifold at the top of said cooler for dripping water down the sides of the cooler.
BACKGROUND OF THE INVENTION
Evaporative or "swamp" coolers are generally rectangular box like structures mountable on the roof of a building. The cooler usually includes corners, top and bottom frame members with porous water absorbing material such as excelsior forming the vertical walls thereof. A centrifugal or "squirrel" cage fan is usually provided to draw air in through the wet porous material and channel the same through the cage to a duct conveying the air into the building.
In order to cool the air, water is provided to drip from the top of the cooler by a manifold through the porous material ending at the bottom of the cooler in a dish or reservoir for reuse.
Various types of pumps and couplings have been employed to move the water upward from the reservoir to the manifold for distribution into the porous material. Some of such water pumps were powered by small motors separate from larger motors used to drive the centrifugal fan. These smaller motors often malfunctioned and required repair. Further, some of the water pumps in the past did not include filtration means and became clogged and would not function.
OBJECTS OF THE INVENTION
An object of the invention is to provide a water pump of the impeller type which can be activated and move water from a base reservoir vertically to a water manifold at the top of the cooler for distribution over porous material forming the four sides of the cooler.
Another object of the invention is to provide a coupling means between the water pump and a single electric motor for driving the squirrel cage blower of the cooler.
A further object is to provide a water pump of the impeller type that includes a filtration or strainer cover to strain any relatively large foreign matter out of the water which might cause injury to the pump.
Another object of the invention is to provide an impeller pump which may have a single or double exit configuration.
A still further object of the invention is to provide a flexible shaft means extending from the single motor to the pump to rotate the same.
Further objects and advantages of the invention may be brought out in the following part of the specification wherein small details have been described for the competence of disclosure, without intending to limit the scope of the invention which is set forth in the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
Referring to the accompanying drawings, which are for illustration purposes:
FIG. 1 is a top elevational view partly in section of an evaporative cooler illustrating the present invention;
FIG. 2 is a side elevational view partly in section taken on line 2--2 of FIG. 1;
FIG. 3 is an exploded perspective view of the water pump and coupling means;
FIG. 4 is a top plan view of the preferred water pump;
FIG. 5 is a cross-sectional view of the pump taken on line 5--5 of FIG. 3;
FIG. 6 is a plan view of the bottom of the pump taken on line 6--6 of FIG. 5;
FIG. 7 is a top plan view partially in section of a modified water pump with only a single outlet or exit means; and
FIG. 8 is a cross-sectional view of the modified pump taken on line 8--8 of FIG. 7.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIGS. 1 and 2 show a conventional evaporation cooler 10 sometimes referred to as a "swamp cooler" which is generally square in dimension. The cooler 10 includes four corner vertical posts 12, 14, 16 and 18. Extending between the respective posts 12 and 14, 14 and 16, 16 and 18 and 18 and 12 are sheets of porous material such as excelsior forming sides 20, 22, 24 and 26. In order to reinforce the sides 20, 22, 24 and 26 vertical stiffing members 28 may be provided.
In FIG. 2 there is illustrated a top member 30 which fits over the side walls. The member 30 is usually metal so that the interior machinery is protected from the elements. Also best seen in FIG. 2 is a bottom pan 32 which forms a water reservoir 34 on the inside of the pan 32.
Mounted within the cooler 10 is a conventional centrifugal type fan or squirrel case fan generally designated 36. The housing 38 is fitted with a duct 40 that extends downward through an opening (not seen in the drawing) to communicate with the interior of a building. The fan 36 includes a plurality of fan blades 42 mounted in the round housing 38 extending from a central shaft 44.
The shaft 44 extends outward from the side panel 46 of the housing 38. Journalled on the shaft 44 is a large belt pulley 48. At the top of the housing 38 is a motor mount 50, best seen in FIG. 2. Secured on the mount 50 is an electric motor 52 having a shaft 54 projected therefrom. Journalled on the shaft 54 is a relatively small belt pulley 56 which is aligned with the pulley 48. An endless drive belt 58 extends around the pulleys 48 and 56 so that when the motor is activated the pulleys rotate and the fan blade 42 will suck air into the side of the housing 38 opposite side 46 in view of the fact that the opposite side is open. The air will be drawn through the porous side walls 20, 22, 24 and 26 and forced down the duct 40.
The object of the evaporative cooler 10 is to cause water to flow downward in the porous walls 20, 22, 24 and 26 so that the air drawn in is cooled as it passes over the water when being pulled into the cooler by the fan 36.
In order to accomplish the distribution of water a water manifold 60 in the form of an endless pipe is suspended above the porous sides 20, 22, 24 and 26 within the top member 30, as best seen in FIGS. 1 and 2. In the bottom of the manifold 60 are a plurality of holes (not seen) whereby water in a spray form 62 may pass to the porous material some of which will drip down the material by gravity and return to the water 64 in the reservoir 34. A source of new water may be added to the reservoir by any conventional means.
To move the water 64 to the manifold 60 a new and unique pump generally designated 66 is provided. In addition, the pump is uniquely activated through the single electric motor 52 by means of a flexible connection to be described.
The preferred embodiment of the pump 66 is best seen in FIGS. 3 through 6. The pump 66 is an impeller type pump and sits in the reservoir 34 so that when it is activated water will be drawn from the reservoir through the pump 66 to appropriate conduits to the manifold 60.
The pump 66 is round and includes a housing 70 formed of an annular side wall 72, a bottom 74 and parallel top 76. The side wall 72, bottom 74 and top 76 form a water chamber 78. Extending downward from the bottom 74 are a pair of legs 80 that sit on the bottom of the pan 32. In this way the bottom 74 is elevated, whereby the vacuum will be broken by the ports 82, best seen in FIGS. 2 and 6. In addition to the bottom ports 82 the top 76 includes a pair of elongated water inlets 84 and 86 so that water 64 may be pulled into the inlets as shown by the upper arrows in FIG. 5. In addition, mounted on the top 76 are a pair of hinged plates 88 and 90 of the same contour as inlets 84 and 86. These plates 88 and 90 can be pivoted over the inlets and restrict the same to control the amount of water passing into the pump 66.
As best seen in FIGS. 3 and 4 there are a pair of water outlet nipples 92 and 94 which extend from the side wall 72 and communicate with the chamber 78.
Extending upward from the top 76 in the center thereof is bearing collar 96 which is fitted with a bearing 98. Extending through the bearing is an impeller shaft 100 which is joined to a two bladed impeller 102, FIG. 5, rotatable in the chamber 78. In order to facilitate the rotation of the impeller 102 the shaft 100 is seated in a thrust bearing 104 projecting from the bottom 74. The top 76 of the shaft 100 is formed with a recess 108 of a square cross-section, see FIG. 3.
Fitted over the pump 66 is a strainer or filter element 110 which is preferably frusto-conical as best seen in FIG. 3. However, it should be realized that the sides of the strainer 110 may be vertical without departing from the spirit of the invention. The strainer element 110 is preferrably formed of plastic and is adapted to fit over the pump 66 and filter or strain large foreign elements that might be in the water 64 as it is drawn into pump 66.
The strainer element 110 includes circular bottom 112 which will rest on the pan 32 over the pump 66, see FIG. 5. The annular side wall 114 extends upwardly and tapers inwardly to an annular top rim 116 of lesser diameter than the bottom 112. There is also an annular top wall 118. Centrally located in the annual top wall 118 is an opening 120 through which will extend the impeller shaft 100, see FIG. 5. In addition these are two semi-circular openings 122 (only one observable in FIG. 3) in the annular side wall 114 which fit the nipples 92 and 94 so the strainer element 110 will encase the pump 66.
In addition the strainer element 110 is formed with a plurality of slots 124 in the wall 114 to allow water 64 to pass through but yet they are small enough to prevent large pieces of foreign matter from passing therethrough. While slots are shown and preferred a number of small circular openings will accomplish the intended strainer purpose.
As has become evident there is only a single electric motor to activate the fan 36 and the pump 66. In order to accomplish the roration of the pump 66 a coupling means 126 is associated with the motor shaft 54. The coupling means 126 includes a motor shaft connector means 130 and a flexible shaft means 132.
The motor shaft connector means 130 includes on the conventional pulley 56 a shank 134 with a set screw 136 to mount the pulley to the stub 138 of the shaft 54. Secured to the shank 134 is a coupling adaptor 140 which includes an annular wall 142 and an outwardly inwardly tapered wall 144 terminating in a flat end wall 146. There is a recess 148 which is square in cross-section which extends into the adaptor 140. At the end remote from the end wall 146 there is an annular opening (not seen) adapted to fit over the shank 134 A set screw 150 in the wall 142 will retain the adaptor 140 to the shank 134.
Uniting the adaptor 140 and pump 66 there is the flexible shaft means 132 which includes a rotatable rod shaft 152 which is flexible and includes ends 153 which are square in cross-section to interfit within recess 148 at one end and in recess 108 at the other end. The shaft 132 is preferably covered with insulation 154. In the case of the illustration in FIG. 1, the flexible shaft 152 is bent to fit within a bracket 156 on the side of the wall 22.
Thus with rotation of motor shaft 54 through the coupling means 126 the pump 66 will be rotated and draw the water 64 into the pump 66 passing it out the outlet nipples 92 and 94 into hoses 158 and 160 respectively connected thereto. The hoses 158 and 160 extend upward, see FIG. 1 to the manifold 60 to assure a continuous flow of water down the panels of porous material so that the air pulled in through the panels or walls will be cool as it enters the building.
With regard to FIGS. 7 and 8 there is illustrated a modified pump 66'. The pump 66' includes side wall 72', top 76' and bottom 74'. In addition mounted on the top 76' is a bearing 98' which is surrounded by an inlet collar 162. The difference over the pump 66 resides in the fact pump 66' has the water inlets 164 in the collar 162, best seen in FIG. 8 and there is a single water outlet nipple 92'.
The impeller shaft 100' and impeller 102' remain the same as with the preferred embodiment.
While the above embodiments have been disclosed as the best mode presently contemplated by the inventor, it should be realized that these examples should not be interpreted as limiting, because artisans skilled in this field, once given the present teachings can vary from these specific embodiments. Accordingly, the scope of the present invention should be determined solely from the claims.
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This invention relates to an evaporative cooler with improved water pump means wherein a single motor will operate the cooler fan and the pump. The water pump is of the impeller type that draws water therein and it will exit by one or more outlets. In addition there are new and unique coupling means which extend from the single motor to the pump whereby activation of the motor will rotate both the pump and a fan forming a part of the evaporative cooler.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit under 35 U.S.C. §119(e) of U.S. Provisional Application Nos. 61/040,112 filed Mar. 27, 2008 and 61/143,370 filed Jan. 8, 2009; the contents of each of these applications are incorporated by reference herein in their entirety.
TECHNICAL FIELD
[0002] A pulmonary drug delivery system is disclosed. The system includes a dry powder inhaler; and a unit dose cartridge for using with the inhaler. The cartridge can contain a drug delivery formulation for pulmonary delivery, for example, a formulation comprising a diketopiperazine and an active ingredient including peptides and proteins such as insulin and glucagon-like peptide 1. The dry powder inhaler is compact and comprises a housing, and a mouthpiece having a chamber to install the unit dose cartridge containing medicament and can be separated from its housing for ease of cleaning.
[0003] All references cited in this specification, and their references, are incorporated by reference herein in their entirety where appropriate for teachings of additional or alternative details, features, and/or technical background.
BACKGROUND
[0004] Drug delivery systems for the treatment of disease which introduce active ingredients into the circulation are numerous and include oral, transdermal, inhalation, subcutaneous and intravenous administration. Drugs delivered by inhalation are typically delivered using positive pressure relative to atmospheric pressure in air with propellants. Such drug delivery systems deliver drugs as aerosols, nebulized or vaporized. More recently, drug delivery to lung tissue has been achieved with dry powder inhalers. Dry powder inhalers can be breath-activated to deliver drugs by converting drug particles in a carrier into a fine dry powder which is entrained into an airflow and inhaled by the patient. Drugs delivered with the use of a dry powder inhaler can no longer be intended to treat pulmonary disease only, but also specific drugs can be used to treat many conditions, including diabetes and obesity.
[0005] Dry powder inhalers, used to deliver medicaments to the lungs, contain a dose system of a powder formulation usually either in bulk supply or quantified into individual doses stored in unit dose compartments, like hard gelatin capsules or blister packs. Bulk containers are equipped with a measuring system operated by the patient in order to isolate a single dose from the powder immediately before inhalation. Dosing reproducibility requires that the drug formulation is uniform and that the dose can be delivered to the patient with consistent and reproducible results. Therefore, the dosing system must operate to completely discharge all of the formulation effectively during an inspiratory maneuver when the patient is taking his/her dose. Flow properties of the powder formulation, and long term physical and mechanical stability in this respect, are more critical for bulk containers than they are for single unit dose compartments. Good moisture protection can be achieved more easily for unit dose compartments such as blisters, however. foils used to seal the blisters and subsequent drug formulation lose viability with long storage.
[0006] Dry powder inhalers such as those describe in U.S. Pat. No. 7,305,986 and U.S. patent application Ser. No. 10/655,153 (US 20040182387), the disclosures of which are incorporated herein by reference in their entirety for all they disclose regarding dry powder inhalers, can generate primary drug particles or suitable inhalation plumes during an inspiratory maneuver by deagglomerating the powder formulation within a capsule. The amount of fine drug discharged from the inhaler's mouthpiece during inhalation is largely dependent on the interparticulate forces in the powder formulation (between drug and drug particles or between drug and excipient particles) and the efficiency of the airflow as measured by pressure drop and flow rate entering and exiting the dry powder dispenser. The benefits of delivering drugs via the pulmonary circulation are numerous and include, rapid absorption into the arterial circulation, avoidance of drug degradation by liver metabolism, ease of use, i.e., lack of discomfort of administration by other routes of administration.
[0007] Dry powder inhaler products developed for pulmonary inhalation have met with limited success to date, due to lack of practicality. Some of the persistent problems observed with prior art inhalers, include ruggedness of device, inconsistency in dosing, inconvenience of the equipment, and/or lack of patient compliance. Therefore, the inventors have designed and manufactured a dry powder inhaler with consistent drug delivery properties, ease of use without discomfort, improved ruggedness, and discrete geometries which would allow for better patient compliance.
SUMMARY
[0008] Dry powder inhaler systems for pulmonary delivery of pharmaceuticals are disclosed. The dry powder inhalation systems comprise a dry powder inhalation device or inhaler and at least one cartridge containing a pharmaceutical formulation comprising at least one active ingredient for delivery to the pulmonary circulation. The present inhalation systems provide rugged devices which are reusable, use pre-metered unit dose cartridges and can be separated into their principal component parts for ease of cleaning. The devices also provide high resistance inhalation systems which enable deagglomeration of dry powder particles, have consistent airflow and are simple and easy to use.
[0009] In one embodiment, a dry powder inhaler comprises a housing, and a mouthpiece, wherein the housing comprises a mouthpiece engaging section structurally configured to engage with the mouthpiece, and the mouthpiece being removable at predetermined positions relative to the housing, and having a conduit permitting airflow between an air inlet and an air exit port, and comprising a chamber and an oral placement section; the mouthpiece further being structurally configured to be moveable within the housing in an engaged position and releasable from the housing at a predetermined position. The dry powder inhaler mouthpiece is structurally configured to receive, hold and/or release a medicament containing cartridge in the chamber.
[0010] In another embodiment, the housing comprises a container structurally configured to adapt to the mouthpiece and has one or more openings for allowing air intake into the mouthpiece chamber. In such an embodiment, the housing has securing mechanisms to hold the mouthpiece chamber and permit the mouthpiece assembly to be moveable within the housing to a storage position, to a cartridge loading/unloading position, mouthpiece separable position, to an inhalation position and in reversed order.
[0011] In still another embodiment, the mouthpiece assembly engages the mouthpiece at the mouthpiece engaging section of the housing. The housing can comprise an air intake section having an air conduit with one or more first openings to allow ambient air intake and a second opening in communication with the mouthpiece engaging section which allows airflow through the air conduit and out into the housing engaging section, the engagement of the mouthpiece substantially prevents ambient air from entering the conduit except at the one or more first openings in the housing for air intake. In one embodiment, the housing also comprises a mouthpiece storage section.
[0012] In yet another embodiment, the dry powder inhaler mouthpiece assembly can move relative to the housing and the movement of the mouthpiece within the housing can reconfigure a cartridge seated in the inhaler from a closed configuration to an open configuration, or from an open to a closed configuration. Movement of the mouthpiece within the housing can be of various types, such as translational or rotational. In one such embodiment, movement about the housing is rotational, and can be restricted at predetermined locations relative to the housing to provide registration of positions of the mouthpiece in use. In one embodiment, for example, movement of the mouthpiece assembly is rotational and the mouthpiece can rotate from the storage position to a cartridge loading/unloading position to an inhalation position. In another embodiment, the mouthpiece further comprises a mouthpiece oral placement section and a medicament containing cartridge receiving section; the cartridge receiving section configured to permit and direct air flow through and around the cartridge.
[0013] In a further embodiment, the air conduit of the air intake section of the housing is in communication with the air exit port of the mouthpiece when the cartridge is in an open configuration. The airflow conduit is established between one or more first openings in the housing; then air passes through the airflow conduit within the housing and exits a second opening of the mouthpiece engaging section and enters into the mouthpiece chamber wherein a percentage of intake air volume goes through the cartridge and a percentage of intake air volume goes around the cartridge during an inhalation maneuver. In this embodiment, the airflow path then enters the mouthpiece chamber and enters and exits the conduit of the mouthpiece oral placement section. In a further embodiment, with a cartridge containing medicament placed in the chamber, airflow entering the chamber from the housing outlet port is diverted so that a percentage of the airflow volume goes through the cartridge and a percentage of the airflow volume goes around the cartridge. Both air flow volumes, exiting the cartridge with a medicament and airflow around the cartridge, converge prior to entering and exiting the air exit port of the mouthpiece of the oral placement section.
[0014] In another embodiment, a dry powder inhaler is provided comprising a housing, and a mouthpiece assembly, the housing having a top wall, a bottom wall, side walls; a mouthpiece engaging section, a mouthpiece storage section, and an air intake section having a conduit with a first opening to allow ambient air intake and a second opening in communication with the mouthpiece engaging section which allows air flow therethrough; the mouthpiece subassembly being removable and comprising a chamber structurally configured to house a cartridge and to engage with the mouthpiece engaging section of the housing; an oral placement section extending from the chamber and having an air inlet which communicates with the chamber and an air outlet in communication with ambient air.
[0015] In embodiments described herewith, a breath-powered inhaler is provided comprising, an inhaler with resistance values that can be tunable or changed as required by the patient being an adult or a child. In one embodiment, the resistance values of the inhaler can be altered by changing the geometries or configuration of the air conduits so that airflow distribution through the cartridge and around the cartridge can vary. In one embodiment, inhaler resistance values can range between 0.08 and 0.15 √kPa/liters per minute. In certain embodiments, flow balance distribution can range from about 10% to about 30% through the cartridge and from about 70% to 90% going around the cartridge.
[0016] In still a further embodiment, the dry powder inhalation system comprises a breath-activated dry powder inhaler, a cartridge containing medicament, wherein the medicament can comprise a diketopiperazine and an active agent. In some embodiments, the active agent comprises peptides and proteins. In another embodiment, the inhalation system comprises a cartridge containing medicament wherein the peptide or protein can be an endocrine hormone: including, insulin, glucose-like peptide (GLP-1), parathyroid hormone, parathyroid hormone related protein (PTHrP), and the like.
[0017] In one embodiment, the dry powder inhalation system can comprise a cartridge including a formulation for pulmonary delivery which can be provided for use with different dosage strengths, wherein the system can deliver the dosage with consistency and in a linear manner. In this embodiment, for example, multiple cartridges of a single dose to be administered to a subject can be interchangeably replaced or substituted by providing the system with a single cartridge of the sum of the dosage strength of the multiple cartridges, wherein the system can deliver a bioequivalent dose with a single cartridge.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] FIG. 1 illustrates a three dimensional side view of an embodiment of a dry powder inhaler in a storage position.
[0019] FIG. 2 illustrates the back side view of the dry powder inhaler of FIG. 1 showing the mouthpiece subassembly moved from the storage position to a cartridge loading position wherein the cap is opened. In this embodiment, this is also the position at which the mouthpiece can be separated.
[0020] FIG. 3 illustrates the back side view of the dry powder inhaler of FIG. 1 showing the mouthpiece subassembly has been moved to the inhalation position for use.
[0021] FIG. 4 illustrates the back side view of the dry powder inhaler of FIG. 1 showing the mouthpiece subassembly has been moved to an unloading position after inhalation.
[0022] FIG. 5 illustrates the dry powder inhaler of FIG. 1 , showing the housing subassembly and the mouthpiece subassembly disengaged from one another.
[0023] FIG. 6 illustrates a top view section of a housing subassembly of a dry powder inhaler.
[0024] FIG. 7 illustrates the dry powder inhaler shown in FIG. 3 in cross-section.
[0025] FIG. 8 illustrates the dry powder inhaler of FIG. 1 , showing an exploded view of the housing subassembly.
[0026] FIG. 9 illustrates the dry powder inhaler of FIG. 1 , showing the mouthpiece subassembly removed from the housing component.
[0027] FIG. 10 illustrates the dry powder inhaler of FIG. 1 , showing an exploded view of the mouthpiece subassembly.
[0028] FIG. 11 illustrates an alternate embodiment of the dry powder inhaler system showing the inhaler in a cartridge loading position. FIG. 1 also depicts a cartridge embodiment for use with a dry powder inhaler according to the present description.
[0029] FIG. 12 illustrates the embodiment of FIG. 11 with a cartridge loaded into the dry powder inhaler with the cap open.
[0030] FIG. 13 illustrates the embodiment of FIG. 11 showing the dry powder inhaler in an inhalation position.
[0031] FIG. 14 illustrates the embodiment of FIG. 13 showing the dry powder inhaler in inhalation position as a cross-section through the mid-longitudinal axis.
[0032] FIG. 15 illustrates a cross-section of an embodiment wherein the dry powder inhaler is shown in the dosing position and containing a cartridge.
[0033] FIG. 16 illustrates an embodiment of a three dimensional side view of a cartridge for use with the dry powder inhalation system.
[0034] FIG. 17 illustrates an embodiment of a three dimensional back side view cartridge for use with the dry powder inhalation system.
[0035] FIG. 18 illustrates an embodiment of an exploded three dimensional view of the cartridge for use with the dry powder inhalation system.
[0036] FIG. 19 illustrates a mean baseline-corrected GIR (glucose infusion rate) for two 15 U cartridges and one 30 U cartridge of an inhalation powder comprising insulin and fumaryl diketopiperazine, and for 10 IU of RAA.
[0037] FIG. 20A depicts a schematic representation of a cartridge loaded into a cartridge rig in cross-section for measuring pressure across the cartridge. FIG. 20B illustrates a diagram of a resistance circuit illustrating the various resistors associated with the cartridge rig illustrated in FIG. 20A .
[0038] FIG. 21A illustrates a schematic representation of a portion of the inhaler in cross-section showing components parts. FIG. 21B illustrates a diagram of a resistance circuit of an inhaler embodiment of FIG. 21A used for measuring the resistance and pressure of the device.
[0039] FIG. 22 depicts a linear regression plot illustrating the resistance measured through an exemplary cartridge rig tested or R 3 , at flow rates between 2 and 9 liters/min.
DETAILED DESCRIPTION
[0040] In embodiments disclosed herein, there are disclosed dry powder inhalation systems for delivering pharmaceutical medicaments to the pulmonary circulation. The inhalation systems comprise a breath-powered or breath activated, dry powder inhaler, one or more cartridges containing a pharmaceutical formulation comprising one or more pharmaceutically active substances or active ingredients, and a pharmaceutically acceptable carrier.
[0041] One embodiment of a dry powder inhaler is shown in FIG. 1 . Therein, dry powder inhaler 100 comprises housing 102 , and removable mouthpiece assembly or subassembly 104 . FIG. 1 illustrates dry powder inhaler 100 in a closed or storage position, wherein mouthpiece oral placement section 106 (illustrated in FIG. 2 ) is stowed away under cover 108 . FIG. 1 also illustrates cover or lid 110 over mouthpiece chamber 112 (illustrated in FIG. 2 ). In one embodiment of FIG. 1 , housing 102 is structurally configured to be relatively rectangular in shape and has top wall 114 , bottom wall 116 , back wall 118 , first side wall 120 , second side wall (not illustrated), mouthpiece engaging section 122 , mouthpiece storage section 124 , and an air intake section as part of housing 102 .
[0042] FIG. 2 illustrates dry powder inhaler 100 from FIG. 1 , showing the inhaler in a cartridge loading/unloading position with lid 110 open to allow a mating cartridge to be inserted into the central cavity of mouthpiece chamber 112 . FIG. 2 also illustrates removable mouthpiece subassembly 104 is movable from the storage position in the housing to about 90° relative to longitudinal x-axis 202 of housing 102 rotated about y-axis 204 . In certain embodiments, the cartridge loading/unloading position of mouthpiece assembly 104 can be any predetermined angle as desired. As illustrated in FIG. 2 , mouthpiece engaging section 122 of housing 102 is relatively circular in shape on the side wall and is shorter in height compared to the rest of housing 102 to accommodate mouthpiece chamber 112 and can form one end of inhaler 100 . Housing 102 can also comprise an air conduit with one or more first openings to allow ambient air intake and a second opening in communication with mouthpiece engaging section 122 which allows air flow from the intake section through the conduit into mouthpiece chamber 112 in the inhalation position.
[0043] FIG. 3 depicts dry powder inhaler 100 illustrated in FIG. 1 , showing removable mouthpiece assembly 104 in an extended or inhalation position. In this embodiment, removable mouthpiece assembly 104 is at about 180° angle relative to the longitudinal x-axis 202 of housing 102 rotated about y-axis 204 . In some embodiments, the inhalation position of mouthpiece assembly 104 can be varied depending on the structural configuration of the cartridge design to be adapted with the inhaler, and the rotational degrees a cartridge may be rotated to properly align apertures that allow air to enter and exit the cartridge carrying a plume of medicament into mouthpiece exit port 302 .
[0044] FIG. 4 illustrates dry powder inhaler 100 of FIG. 1 showing removable mouthpiece assembly 104 being moveable about the loading/unloading position after use. It should be noted that lid 110 remains closed during movement of removable mouthpiece assembly 104 about housing 102 . FIG. 4 also illustrates mouthpiece oral placement section 106 can be configured with tongue depressor 402 which acts to properly depress the tongue of a user.
[0045] FIG. 5 illustrates dry powder inhaler 100 of FIG. 1 comprising the component parts, removable mouthpiece assembly 104 and housing 102 . Removable mouthpiece assembly 104 comprising mouthpiece chamber 112 structurally configured with cartridge holder area 502 , one or more belts 504 and one or more flanges 506 , lid 110 and air inlet port 508 which communicates with the housing second opening to engage with mouthpiece engaging section 122 of housing 102 ; mouthpiece oral placement section 106 extending from mouthpiece chamber 112 and having air inlet port 508 which communicates with mouthpiece chamber 112 and mouthpiece exit port 302 which is in communication with ambient air. Drive key 510 structurally configured to have indicator 512 , for example, in the shape of a tear drop for proper placement of a cartridge in dry powder inhaler 100 is also shown in FIG. 2 and FIG. 5 . Proper alignment of a cartridge in the inhaler indicates the correct relative rotational orientation and determines successful cartridge seating, insertion and emptying in use. In such an embodiment, a cartridge cannot be properly seated unless tear drop 1602 of cartridge 1600 ( FIG. 11 ) and drive key 510 align with one another.
[0046] Lid 110 is positioned over mouthpiece chamber 112 and is mechanically connected to removable mouthpiece assembly 104 by hinge 514 . Lid 110 has an outer surface and an inner surface and it is structurally configured with an anvil in its inner top surface and relatively centered within the top. Lid 110 can only be opened when removable mouthpiece assembly 104 is in the loading/unloading position. When removable mouthpiece assembly 104 is engaged into housing 102 an interlocking mechanism prevents movement to a dosing/inhalation position or to a storage position when lid 110 is opened or raised. The interlocking mechanism can comprise, for example, one or more belts or flexible radial arms, which are incorporated into the walls of mouthpiece chamber 112 and act as a self-synching mechanism 602 in FIG. 6 . The interlocking mechanism allows removable mouthpiece assembly 104 to obtain proper registration of the various positions when dry powder inhaler 100 is in use. Lid 110 can be maintained in a closed position by a locking mechanism, for example, a spring loaded boss such as a lock-out button which can engage a receiving detent within housing 102 . In an alternate embodiment, the locking mechanism comprises an upward extension of the housing wall. The locking mechanism 602 can also serve to secure the mouthpiece subassembly against further rotation. Position registration of removable mouthpiece assembly 104 allows the inhaler to be properly used and prevents movement of removable mouthpiece assembly 104 to the dosing position without lid 110 being depressed.
[0047] FIG. 5 also illustrates housing 102 separated from removable mouthpiece assembly 104 showing mouthpiece engaging section 122 having an opening or cavity 516 with top wall 114 partially discontinuous to adapt, receive and hold removable mouthpiece assembly 104 and structurally configured to accommodate the mouthpiece. Housing 102 is configured to have an upward projection of the wall or second flange 518 around the top outer portion of mouthpiece engaging section 122 and a protrusion configured as a drive key in its bottom wall configured to mate with a keying structure of a cartridge. The proper alignment of a cartridge within dry powder inhaler 100 is dependent on drive key 510 having an indicator 512 and one or more indentation 126 ( FIG. 2 ) in removable mouthpiece assembly 104 and drive key 510 and of housing 102 .
[0048] Housing 102 comprises mouthpiece engaging section 122 having an outer wall, an inner wall and a bottom wall contiguous with the side and bottom walls respective of housing 102 , and configured to adapt to the mixing section of removable mouthpiece assembly 104 . FIG. 6 illustrates a parallel cross-section through the mid-longitudinal plane of housing 102 containing a portion of mouthpiece chamber 112 . FIG. 6 also illustrates interlocking mechanism 604 (belts 504 in FIG. 5 ); chamber inner wall 606 defining a space for housing a cartridge. Circular structure or plug 608 is the wall of the air conduit of housing 102 which is continuous with back wall 118 of housing 102 .
[0049] FIG. 7 illustrates a cross sectional view of dry powder inhaler 100 in a dosing or inhalation position. As seen in FIG. 7 , housing 102 has a substantially rectangular shape, however other shapes are also suitable. Housing 102 comprises one or more inlet ports or first openings 702 , air conduit 704 housing piston 706 and spring 708 , and outlet port 710 opening into mouthpiece engaging section 122 and aligns with the inlet port of mouthpiece chamber 112 . Air conduit 704 has one or more openings 712 that allow airflow to enter.
[0050] Mouthpiece engaging section 122 is partially configured in the shape of a cup further comprising second drive key 802 as seen in FIG. 8 from bottom wall 116 configured to receive and hold a medicament containing cartridge. FIG. 7 also shows the engagement between flange 506 of mouthpiece chamber 112 in housing 102 ; hinge 514 , lid 110 and mouthpiece oral placement section 106 with tongue depressor 402 and airflow conduit 714 of removable mouthpiece assembly 104 .
[0051] FIG. 8 depicts an exploded view of housing 102 illustrating integral components of dry powder inhaler 100 , including plug 608 , piston 706 and spring 708 which assemble into air conduit 704 ; housing 102 outer structure comprising back wall 118 , side wall 120 , top wall 114 , and bottom wall 116 ; mouthpiece engaging section 122 with second drive key 802 , and slide door 804 which covers the storage compartment for mouthpiece oral placement section 106 . Air conduit 704 is configured to have an aperture or opening 712 which allows and directs airflow entering housing 102 into mouthpiece engaging section 122 during an inspiratory maneuver. Mouthpiece engaging section 122 can also comprise a securing mechanism which can comprise protrusions or projections from the inner wall of the chamber which mates with flange 506 and mating structure 902 as seen in FIG. 9 of mouthpiece chamber 112 . In this embodiment, piston 706 and compression spring 708 act as an indicator mechanism positioned in air conduit 704 of housing 102 structurally configured to indicate inspiratory effort. Piston 706 and spring 708 can be placed at other positions in the airflow pathway of dry powder inhaler 100 . During an inspiratory maneuver, airflow entering the air conduit 704 within housing 102 goes around piston 706 , and moves piston 706 to compress spring 708 . This airflow control mechanism during inhalation indicates inspiratory effort through a tactile sensation. In one embodiment, the mechanism indicates inspiratory effort through an audible click. In another embodiment, the mechanism indicates inspiratory effort through a tactile sensation and/or an audible click. Mouthpiece engaging section 122 of housing 102 has one or more protrusions such as mating structures 902 that mates with mouthpiece chamber 112 to secure mouthpiece when dry powder inhaler 100 is in use.
[0052] In operation, removable mouthpiece assembly 104 is rotated from a storage position to a cartridge loading/unloading position wherein lid 110 is opened and a cartridge containing medicament is placed into mouthpiece chamber 112 and securely seated. Lid 110 contains an anvil 1102 ( FIG. 11 ) inside which, if a cartridge is inserted in the correct position, the anvil will further insure the cartridge achieves a proper vertical alignment. A downward push of lid 110 closes the cover and removable mouthpiece assembly 104 can rotate to the dosing position, wherein a registration securement holds removable mouthpiece assembly 104 in place. If the proper vertical alignment is not achieved lid 110 cannot be fully closed and subsequent removable mouthpiece assembly 104 rotation cannot occur. This provides an interlock mechanism.
[0053] FIG. 9 illustrates removable mouthpiece assembly 104 which has been separated from housing 102 . Removable mouthpiece assembly 104 comprises mouthpiece chamber 112 , lid 110 articulated to removable mouthpiece assembly 104 so that in a closed position lid 110 covers mouthpiece chamber 112 , and mouthpiece oral placement section 106 having airflow conduit 714 with mouthpiece exit port 302 . Mouthpiece chamber 112 comprises air inlet port 508 , one or more flanges 506 having gaps and mating structure 902 for mating with and securing removable mouthpiece assembly 104 with housing 102 . Flange 506 positioned at the bottom end of mouthpiece chamber 112 is provided which is structurally configured to engage with housing 102 , and comprises multiple segments having gaps in between the segments; the gaps section contains mating structure 902 for mating with housing 102 . The multiple segments of flange 506 and gaps between the segments can be position at predetermined positions of mouthpiece chamber 112 to effectuate proper securement of removable mouthpiece assembly 104 in housing 102 .
[0054] FIG. 10 is an exploded view of removable mouthpiece assembly 104 . Mouthpiece chamber 112 comprises drive key 510 with indicator 512 , lid 110 , mouthpiece oral placement section 106 , cartridge securing mechanism 1002 , a radial spring 1004 , one or more belts 504 and interlock detents 1006 .
[0055] In embodiments described herein, dry powder inhaler 100 is structurally configured to effectuate a tunable airflow resistance, which is modular. The resistance of dry powder inhaler 100 can be modified, by varying the cross-sectional area at any section of air conduit 704 of the inhaler. In one embodiment, dry powder inhaler 100 can have a airflow resistance value of from about 0.08 to about 0.13 square root of kPa/liters per minute.
[0056] In an alternate embodiment illustrated in FIGS. 11-14 , dry powder inhaler 100 comprises alternate housing 1104 configured to be compact and comprises a square-shape configuration which snuggly fits with removable mouthpiece assembly 104 . Removable mouthpiece assembly 104 is similar in structure, if not identical in some embodiments, to the embodiment described with respect to FIGS. 1-10 . FIG. 11 depicts alternate dry powder inhaler 1100 in the cartridge load/unload position with lid 110 open, mouthpiece oral placement section 106 , mouthpiece exit port 302 , anvil 1102 , mouthpiece chamber 112 and interlocking mechanism 604 ( FIG. 6 ). Cartridge 1600 has tear drop 1602 indicator for aligning to the indicator 512 of mouthpiece chamber 112 for proper insertion. Alternate housing 1104 in this embodiment, has an air inlet located in one of the side walls; however, in alternate embodiments the air inlet can be one or more holes placed in other positions, for example, in alternate housing bottom wall 1106 . Alternate dry powder inhaler 1100 can have one or more openings in the housing of variable size or shape and locations.
[0057] Cartridges such as cartridge 1600 can be adapted to the dry powder inhaler containing a dry powder medicament for inhalation, and are configured to deliver a single unit dose of a medicament. In one embodiment, cartridge 1600 can be structurally configured to contain a dose of, for example, 0.5 mg to about 30 mg of dry powder for inhalation.
[0058] FIG. 12 illustrates an alternate dry powder inhaler 1100 with cartridge 1600 loaded and ready for closure of lid 110 . As can be seen, lid 110 is in the open position, mouthpiece chamber 112 and alternate housing 1104 with alternate air inlet 1202 . FIG. 13 depicts the dry powder inhaler system of FIG. 12 in the dosing position and ready for inhalation.
[0059] FIG. 14 depicts a cross-section of alternate dry powder inhaler 1100 of FIG. 13 , showing the internal features of the inhaler and cartridge system. Lid 110 securely holds cartridge 1600 by way of anvil 1102 , which is then securely installed in mouthpiece chamber 112 . The airflow conduit 714 of mouthpiece oral placement section 106 with mouthpiece inlet port 1402 and mouthpiece exit port 302 .
[0060] In some embodiments, as shown in FIG. 15 , dry powder inhaler 100 comprises a removable mouthpiece assembly 104 comprising lid 110 over cartridge holder area 502 movable from a closed to an open position, having anvil 1102 which engages with cartridge 1600 in a closed position, wherein the housing further comprises an air flow control mechanism comprising check valve 1502 .
[0061] In embodiments described herein, the dry powder inhaler system in use has a predetermined airflow distribution around and through a cartridge operably configured to mix a medicament with air forming a powder plume for delivery to a patient's pulmonary system. Predetermined airflow distribution through the cartridge can range from about 10 to about 30% of total airflow volume entering the dry powder inhaler during inhalation. Predetermined airflow distribution around the cartridge can range from about 70 to about 90% of total airflow volume. Predetermined cartridge bypass airflow and exiting airflow through the cartridge converge to further shear and deagglomerate the powder medicament prior to exiting the mouthpiece outlet port.
[0062] In one embodiment, the medicament containing cartridge 1600 as shown in FIGS. 16-18 can comprise a structure with a defined shape having a wall with one or more first apertures 1604 , second aperture 1702 and third aperture 1802 , tear drop 1602 , grasping feature 1606 , and first inhaler keying mechanism 1608 and second inhaler keying mechanism 1610 . Cartridge 1600 has a closed configuration moveable to an open configuration for dosing a powder medicament or from an open to a closed position after use. Cartridge 1600 further comprises an outer surface and an inner surface defining an internal volume; wherein the closed configuration restricts communication, such as air transit to or through the internal volume, and the open configuration forms an air passage through the internal volume to allow a powder medicament contained therein to be aerosolized and delivered to a patient in an airflow stream created by the user. The open configuration is established by providing one or more apertures (e.g. first aperture 1604 , second aperture 1702 and third aperture 1802 ), holes, slits or windows in the cartridge walls that can have beveled edges to direct airflow. In one embodiment, cartridge 1600 can be configured of two elemental parts, for example, two segments (e.g. first segment 1804 and second segment 1806 ) that can have apertures in their walls that can align with one another in the open configuration and in opposing positions where the apertures at not in alignment. In one embodiment, for example, cartridge 1600 can be structurally configured as two separate elements which can fit into one another and be moveable about one another; each having openings which can align with one another, similarly as the capsules described in U.S. Pat. No. 7,305,986, which is fully incorporated herein by reference as if part of this specification. In this embodiment, however, cartridge 1600 is designed to integrally function with the dry powder inhaler and can be moved within the inhaler to predetermined positions
[0063] In one embodiment, a method of delivering an active ingredient comprising: a) providing a dry powder inhaler comprising, a housing and a mouthpiece, the mouthpiece comprising a chamber containing a cartridge with a dry powder formulation comprising a diketopiperazine and the active agent; the inhaler having a flow distribution of about 10% to 30% of the airflow going through the cartridge, and b) delivering the active ingredient to an individual in need of treatment by inhaling deep and rapidly for about 4 to 6 seconds and optionally repeating step b).
[0064] In embodiments described herein, the dry powder inhaler can deliver a dose of a dry powder formulation to a patient at pressure differentials between 2 and 20 kPa.
[0065] In still yet a further embodiment, the method of treating hyperglycemia and/or diabetes comprises the administration of an inhalable dry powder composition comprising a diketopiperazine having the formula 2,5-diketo-3,6-di(4-X-aminobutyl)piperazine, wherein X is selected from the group consisting of succinyl, glutaryl, maleyl, and fumaryl. In this embodiment, the dry powder composition can comprise a diketopiperazine salt. In still yet another embodiment of the present invention, there is provided a dry powder composition, wherein the diketopiperazine is 2,5-diketo-3,6-di-(4-fumaryl-aminobutyl)piperazine (FDKP), having the structure:
[0000]
[0000] with or without a pharmaceutically acceptable carrier, or excipient.
[0066] In one embodiment, the inhalation system comprises a breath-activated dry powder inhaler, a cartridge containing medicament, wherein the medicament can comprise a diketopiperazine and an active agent. In some embodiments, the active agent comprises peptides and proteins. In another embodiment, the inhalation system comprises a cartridge containing medicament wherein the peptide or protein can be an endocrine hormone, including, insulin, GLP-1, calcitonin, parathyroid hormone, parathyroid hormone related protein (PTHrP), and analogs thereof and the like.
[0067] In another embodiment, the dry powder medicament may comprise a diketopiperazine and a pharmaceutically active ingredient. In this embodiment, the pharmaceutically active ingredient can be any type. In certain embodiments, the active ingredient comprises a peptide, a protein, a hormone, analogs thereof or combinations thereof, wherein the active ingredient is insulin, parathyroid hormone 1-34, glucagon-like peptide-1 (GLP-1), oxyntomodulin, peptide YY, interleukin 2-inducible tyrosine kinase, Bruton's tyrosine kinase (BTK), inositol-requiring kinase 1 (IRE1), heparin, or analogs thereof. In a particular embodiment, the pharmaceutical composition comprises fumaryl diketoperazine and insulin.
[0068] In a particular embodiment, the dry powder inhalation system can comprise a cartridge including a formulation for pulmonary delivery comprising FDKP and a peptide including, for example, insulin or GLP-1, which can be provided for use in different dosage strength in a single or multiple cartridges. In one embodiment, the system can deliver the dosage efficiently, with consistency and in a linear manner. In this embodiment, for example, multiple cartridges of a single dose to be administered to a subject can be interchangeably replaced or substituted by a providing the system with a single cartridge having the sum of the dosage strength of the multiple cartridges. In further embodiment, the system can deliver a proportional, bioequivalent dose with a single cartridge. In an exemplary embodiment using the system for treating diabetes with inhalable insulin powders, the system can use two 15 U cartridges of an inhalation powder comprising insulin and FDKP or the system can use one 30 U single cartridge containing an inhalation powder comprising FDKP and deliver bioequivalent doses of insulin to a patient. Similarly, the system can be used to deliver higher doses, for example, three 15 U cartridges of an inhalation powder comprising insulin and FDKP can be used, or one 15 U cartridge plus one 30 U cartridge, or a single 45 U cartridge containing the inhalable insulin and FDKP formulation; or four 15 U cartridges of an insulin and FDKP formulation can be interchangeable with one 60 U cartridge of insulin and FDKP formulation. Alternatively, two 30 U cartridges containing an inhalable insulin and FDKP formulation can be interchanged for one 60 U cartridge of the insulin and FDKP formulation.
[0069] In the embodiments described herein, the dry powder inhalation system accomplishes insulin exposure proportional to a dosage so that the dosages are interchangeable. In an embodiment, the dosage can be provided as filled dose.
EXAMPLES
[0070] The following examples are included to demonstrate certain embodiments of the invention. It should be appreciated by those of skill in the art that the techniques disclosed in the examples elucidate representative techniques that function well in the practice of the present invention. However, those of skill in the art should, in light of the present disclosure, appreciate that many changes can be made in the specific embodiments that are disclosed and still obtain a like or similar result without departing from the spirit and scope of the invention.
Example 1
Dosage Strength Interchangeability
[0071] The study was conducted in subjects with type 1 diabetes mellitus. This study was conducted to determine if a formulation for pulmonary delivery comprising insulin and a diketopiperazine in the formulation, 1) could be delivered consistently using different dosage strengths and 2) if linearity of dosing could be achieved with proportional doses, given that interchangeability of dosage strengths can be important for patient safety. A prior art marketed inhaled insulin did not achieve this and dose combinations were nonequivalent leading to a potential risk of incorrect dosing. Therefore, an important goal in the development of the pulmonary delivery system with a formulation comprising insulin and FDKP (insulin-FDKP) was to achieve dose linearity across the therapeutic dose range.
[0072] In the study, comparisons of insulin exposure following inhalation of two 15 U cartridges of an insulin inhalation powder to one 30 U cartridge of insulin inhalation powder were made. In addition, insulin bioavailability from a 30 U cartridge of insulin-FDKP inhalation powder was calculated, compared to a 10-IU subcutaneous (sc) injection of insulin lispro (rapid acting analogue [RAA]).
[0073] A phase I, open-label, single-dose, repeat administration study in subjects with type 1 diabetes (T1DM) was conducted to assess the pharmacokinetic profile or PK of 30 U of insulin-FDKP dosed as a single 30 U cartridge and compared to two 15 U cartridges administered with the present inhalation system. A 10 U subcutaneous injection of the rapid acting insulin analogue (RAA, HUMALOG® (Eli Lilly and Company, Indianapolis, Ind.)) was also tested. Subjects (age: 19-61 yrs) were randomized to 1 of 6 sequences. Fasted subjects received insulin-FDKP or RAA 4 to 6 hrs after initiating a hyperinsulinemic-euglycemic clamp. Randomization determined the order of insulin-FDKP dosing (first 2 treatment (tx) visits), and the location of the RAA injection (abdomen, arm or leg; 3 rd tx visit). After dosing blood samples were taken and analyzed for insulin, insulin lispro and fumaryl diketopiperazine (FDKP (insulin-FDKP tx only)). When studying insulin-FDKP, the basal insulin infusion was performed with HUMALOG®, and when studying HUMALOG®, regular human insulin was used. The analytical methodologies enabled the independent measurement of each insulin tested.
[0074] Table 1 shows the results from the study. The mean insulin exposures (AUC 0-360 ) of a single 30 U cartridge or two 15 U cartridges were comparable. FDKP mean exposure (AUC inf ) was also similar. Insulin and FDKP exposure, t max and t 1/2 (FDKP) were the same regardless of the number of cartridges. Due to the significantly different PK profiles of insulin-FDKP and RAA, the mean relative exposure (AUC) ratio is dependent upon the time interval studied. The mean relative insulin exposure (insulin-FDKP: HUMALOG® AUC, dose normalized geometric means) when assessed at time intervals of 0-180 min and 0-360 min was 24% to 18%.
[0000]
TABLE 1
2 × 15 U TI
1 × 30 U TI
cartridges
cartridge
10 IU Humalog
Insulin PK parameters
AUC 0-360 (μU * min/mL)
3337
3397
5915
AUC 0-180 (μU * min/mL)
3121
3199
4432
C max (μU/mL)
65.72
69.08
42.60
t max (min)
10
10
60
90% CI (Geometric Mean
0.846, 1.141
ND
Ratio: AUC 0-360 )
FDKP PK parameters
AUC 0-480 (ng * min/mL)
19552
20159
—
AUC 0-inf (ng * min/mL)
23146
24355
—
C max (ng/mL)
118
131
—
t max (min)
6
5
—
90% CI (Geometric Mean
0.867, 1.084
—
Ratio: AUC 0-480 )
[0075] This study also evaluated the effects of the dosages administered and the glucose infusion rate (GIR) requirements of the patients in the study. FIG. 19 illustrates the results of the GIR evaluation. The data show the mean baseline-corrected glucose infusion rate (GIR) for two 15 U cartridges and one 30 U cartridge of insulin-FDKP inhalation powder and for the 10 IU of RAA. GIRs after both treatments of insulin-FDKP inhalation powders reached a maximum level by approximately 30 minutes after administration, whereas GIR peaked approximately 150 minutes after administration of sc RAA. The GIRs for insulin-FDKP inhalation powder returned toward baseline by approximately 180 minutes versus 300 minutes for RAA. In conclusion, the glucose-lowering effect of insulin-FDKP inhalation powder of both dosage forms tested was comparable based on GIR AUC, GIR max , and GIRt max .
Example 2
Dry Powder Inhaler Resistance Value Measurements
[0076] The total inhaler and cartridge resistance can be measured due to inlet and outlet ports of a cartridge acting as resistors in series. First, the resistance due to the inlet port is measured in the cartridge rig. The representation of a circuit diagram form for the cartridge rig is illustrated in FIGS. 20A and 20B , wherein the cartridge sits in the holder in an open configuration and the circuitry is defined such that R 3 represents the resistance to airflow into the cartridge; R 4 represents the resistance to airflow leaving the cartridge; Pa is the pressure differential across the cartridge and P represents the pressure measured across the inlet and outlet ports. Secondly, the resistance due to the inhaler system comprising the inhaler and cartridge is determined as illustrated in FIGS. 21A and 21B , wherein R 1 represents the resistance due to the float or valve; R 2 represents the resistance to air flow around the cartridge; R 3 represents the resistance to airflow through the cartridge; R 4 represents the resistance to airflow leaving the cartridge; P represents the measured pressure; Pa represents the pressure across the system and F represents the total flow measurement. Once values are determined for the resistors and having pressure drop measurements, the flow balance distribution through and around the cartridge can be determined.
[0077] Measurements were made of the cartridge and cartridge/inhaler system dosing configuration and the resistance to airflow through the cartridge, R 3 was determined from the formula:
[0000]
R
3
=
P
F
[0078] Based on the measurements made as illustrated in FIGS. 20A-21B , the resistance due to the inlet and outlet ports were determined and the values used to calculate the flow balance of the system in particular the flow balance through the cartridge using the formula above, which is determined as the √P divided by R 3 . The flow balance distribution through the cartridge for the present inhaler and cartridge system was calculated to be in the range from about 10% to about 30% with an average of approximately 15.92%.
[0079] The resistance for the inhaler cartridge system tested herewith can be determined experimentally from the values obtained in the same manner. The resistance for the present inhalers when calculated from the measurements resulted in airflow resistance values of between 0.08 and 0.15 √kPa/liters per minute. FIG. 22 depicts a linear regression plot illustrating the resistance measured through an exemplary cartridge rig tested or R 3 , at flow rates between 2 and 9 liters/min. As shown in FIG. 22 , the resistance through the cartridge (R 2 ) tested was determined as equaling to 0.999 √kPa/liters per minute.
[0080] Therefore, the inhalers can be structurally configured to have tunable airflow resistance by varying the cross-sectional area at any section of the airflow pathway of the inhaler and cartridge system.
[0081] The preceding disclosures are illustrative embodiments. It should be appreciated by those of skill in the art that the techniques disclosed herein elucidate representative techniques that function well in the practice of the present disclosure. However, those of skill in the art should, in light of the present disclosure, appreciate that many changes can be made in the specific embodiments that are disclosed and still obtain a like or similar result without departing from the spirit and scope of the invention.
[0082] Unless otherwise indicated, all numbers expressing quantities of ingredients, properties such as molecular weight, reaction conditions, and so forth used in the specification and claims are to be understood as being modified in all instances by the term “about.” Accordingly, unless indicated to the contrary, the numerical parameters set forth in the specification and attached claims are approximations that may vary depending upon the desired properties sought to be obtained by the present invention. At the very least, and not as an attempt to limit the application of the doctrine of equivalents to the scope of the claims, each numerical parameter should at least be construed in light of the number of reported significant digits and by applying ordinary rounding techniques. Notwithstanding that the numerical ranges and parameters setting forth the broad scope of the invention are approximations, the numerical values set forth in the specific examples are reported as precisely as possible. Any numerical value, however, inherently contains certain errors necessarily resulting from the standard deviation found in their respective testing measurements.
[0083] The terms “a,” “an,” “the” and similar referents used in the context of describing the invention (especially in the context of the following claims) are to be construed to cover both the singular and the plural, unless otherwise indicated herein or clearly contradicted by context. Recitation of ranges of values herein is merely intended to serve as a shorthand method of referring individually to each separate value falling within the range. Unless otherwise indicated herein, each individual value is incorporated into the specification as if it were individually recited herein. All methods described herein can be performed in any suitable order unless otherwise indicated herein or otherwise clearly contradicted by context. The use of any and all examples, or exemplary language (e.g., “such as”) provided herein is intended merely to better illuminate the invention and does not pose a limitation on the scope of the invention otherwise claimed. No language in the specification should be construed as indicating any non-claimed element essential to the practice of the invention.
[0084] Groupings of alternative elements or embodiments of the invention disclosed herein are not to be construed as limitations. Each group member may be referred to and claimed individually or in any combination with other members of the group or other elements found herein. It is anticipated that one or more members of a group may be included in, or deleted from, a group for reasons of convenience and/or patentability. When any such inclusion or deletion occurs, the specification is deemed to contain the group as modified thus fulfilling the written description of all Markush groups used in the appended claims.
[0085] Certain embodiments of this invention are described herein, including the best mode known to the inventors for carrying out the invention. Of course, variations on these described embodiments will become apparent to those of ordinary skill in the art upon reading the foregoing description. The inventor expects skilled artisans to employ such variations as appropriate, and the inventors intend for the invention to be practiced otherwise than specifically described herein. Accordingly, this invention includes all modifications and equivalents of the subject matter recited in the claims appended hereto as permitted by applicable law. Moreover, any combination of the above-described elements in all possible variations thereof is encompassed by the invention unless otherwise indicated herein or otherwise clearly contradicted by context.
[0086] Furthermore, numerous references have been made to patents and printed publications throughout this specification. Each of the above-cited references and printed publications are individually incorporated herein by reference in their entirety.
[0087] Specific embodiments disclosed herein may be further limited in the claims using consisting of or and consisting essentially of language. When used in the claims, whether as filed or added per amendment, the transition term “consisting of” excludes any element, step, or ingredient not specified in the claims. The transition term “consisting essentially of” limits the scope of a claim to the specified materials or steps and those that do not materially affect the basic and novel characteristic(s). Embodiments of the invention so claimed are inherently or expressly described and enabled herein.
[0088] In closing, it is to be understood that the embodiments of the invention disclosed herein are illustrative of the principles of the present invention. Other modifications that may be employed are within the scope of the invention. Thus, by way of example, but not of limitation, alternative configurations of the present invention may be utilized in accordance with the teachings herein. Accordingly, the present invention is not limited to that precisely as shown and described.
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Dry powder inhaler systems for pulmonary delivery of pharmaceuticals are disclosed. The dry powder inhalation systems comprise a dry powder inhalation device or inhaler and a cartridge containing a pharmaceutical formulation comprising an active ingredient for delivery to the pulmonary circulation. The present devices provide rugged devices which are reusable, use pre-metered unit dose cartridges which deliver a medicament in a liner manner, and can be disassembled for cleaning. The devices also provide a high resistance inhalation system which enables deagglomeration of dry powder particles, have a consistent airflow, are easy to manufacture and are simple and relatively easy to use.
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FIELD OF THE DISCLOSURE
The present disclosure relates in general to apparatus and methods for introducing fluids into a casing string or other tubular element during well construction operations, and for removing fluids from the casing string. In particular, the disclosure relates to apparatus and methods for introducing a fluid such as drilling mud or cement slurry into a casing string at a selected depth by means of a tubular inner string.
BACKGROUND
Typical construction of an oil or gas well includes the operations of assembling a casing string, inserting the casing string into a wellbore, and cementing the casing in place in the wellbore. Casing assembly involves connecting multiple individual lengths of pipe (or “joints”) to form an elongate casing string. Threaded connections are usually used to join the individual lengths of pipe, requiring the application of torque to “make up” the connections, or to “break out” the connections should the string need to be disassembled. After a wellbore has been drilled to a desired depth into a subsurface formation, by means of a rotating drill bit mounted to the end of a drill string, the drill string is withdrawn and the casing string is then inserted essentially coaxially within the wellbore.
In the alternative method known as casing drilling (or “drilling with casing”), the wellbore is drilled with a drill bit mounted to the bottom of the casing string, eliminating the need for a separate drill string. After the well is drilled, the casing remains in the wellbore. As used in this patent document, the term “drill string” is to be understood, in the context of the drilling phase, as referring to the casing string for purposes of well construction operations using casing drilling methods.
During the drilling phase of well construction, a selected drilling fluid (commonly called “drilling mud”) is pumped under pressure downward from the surface through the drill string, out through ports in the drill bit into the wellbore, and then upward back to the surface through the annular space that forms between the drill string and the wellbore (due to the fact that the drill bit diameter is larger than the drill string diameter). The drilling fluid, which may be water-based or oil-based, carries wellbore cuttings to the surface, and can serve other beneficial functions including drill bit cooling, and formation of a protective cake to stabilize and seal the wellbore wall.
Once the well has been drilled to a desired depth and the casing is in place within the wellbore, the casing is cemented into place by introducing a cement slurry (commonly referred to simply as “cement”) into the wellbore annulus. This is typically done by introducing an appropriate volume of cement into the casing string (i.e., a volume corresponding to the volume of the wellbore annulus), and then introducing a second and lighter fluid (such as drilling mud or water) into the casing under pressure, such that the second fluid will displace the cement downward and force it out and around the bottom of the casing, and up into the wellbore annulus. In the typical case, this operation is continued until the cement has risen within the wellbore annulus up to the top of the casing. Once thus cemented, the casing acts to structurally line the wellbore and provide hydraulic isolation of formation fluids from each other and from wellbore fluids.
In some applications it is desirable to introduce cement into the casing through a tubular “inner string” inserted into the casing bore and arranged to extend from the proximal (i.e., upper) end of the casing string to a selected depth, typically near the distal (i.e., lower) end of the casing string or near what is referred to as the “casing shoe”. The inner annulus between the inner string and casing is left fluid-filled and sealed near the proximal end of the casing so that cement pumped through the inner string is then introduced into the casing near the shoe. The fluid filling the inner annulus tends to prevent cement flow up the inside of the casing and instead the cement is urged to immediately enter the casing wellbore annulus during pumping. This is known in the art as an “inner string cement job” and typically requires an adaptor nubbin, sealingly connecting between the casing and the inner string. On top-drive-equipped rigs, the adaptor nubbin also connects to the top drive, facilitating the functions of rotation and reciprocation during cementing to further promote distribution of the cement in the casing to the wellbore annulus.
It is increasingly common in the drilling industry to use top-drive-equipped drilling rigs instead of traditional rotary table rigs, and to install casing (an operation commonly referred to as “casing running”) and/or to drill with casing directly using the top drive. Casing running tools (CRTs), such as the “Gripping Tool” described in U.S. Pat. No. 7,909,120, connect to the top drive quill and support these well construction operations by engaging the upper end of the tubular string (i.e., drill string or casing string, as the case may be) so as to allow transfer of axial and torsional loads between the tubular string and the top drive, and to allow the flow of fluids (such as drilling mud and cement) into or out of the casing string through a central passage or bore in the tool. Such tools thus enable the top drive to be used for make-up and break-out of connections between joints of pipe, hoisting and rotation of tubular strings, casing fill-up, circulation of drilling mud, and cementing of casing.
BRIEF SUMMARY
The present disclosure teaches embodiments of cementing adaptor tools for sealingly connecting an inner string to the distal (lower) end of a CRT while also facilitating the functions of reciprocation and rotation, so that the CRT can be used to replace the function of the adaptor nubbin without the need to engage with the casing threads, thus providing a sealed flow path for cement into the inner string and thereby enabling the CRT to be used perform an “inner string cement job”. This has the advantages of exploiting the existing capacity of the CRT to grip and seal with the casing, obviating the need for an adaptor nubbin customized to the casing thread (and thus removing the risk of damage to the casing thread), and eliminating the need to rig down the CRT after running the casing to replace it with the adaptor nubbin, thus saving time and reducing risk of damage.
Cementing adaptors in accordance with the disclosure are provided with a swivel connection for limiting torque that will typically arise during rotation of the inner string casing assembly as a result of frictional interaction between the inner string and the casing as they are rotated in wellbores having at least some deviation from vertical, thus inducing lateral loading between the casing's inner surface and tubular inner string's outer surface. It will be apparent to persons skilled in the art that right-hand rotation of the casing relative to the wellbore will tend to cause left-hand torque to build toward the proximal (upper) end of the inner string, which torque tends to back off the connections between the joints comprising the inner string (which are normally provided as right-hand-threaded connections).
The swivel connection further limits the torque that might otherwise overload the CRT or the connection between the cementing adaptor and the CRT. It will be apparent to persons skilled in the art that the swivel may take various forms and use various means to transfer loads from the inner string to the CRT while minimizing friction in the connection. Such alternative means may include (without being limited to) plain bushings, rolling element bearings, and pressurized fluid chambers.
To provide further protection for the CRT and the cementing adaptor against the risk of overload from bending loads that might arise from lateral gravity loads on the inner string in applications such as slant drilling (or other operations tending to displace the inner string away from substantially concentric alignment with the casing), suitable centralizers can be mounted to the inner string elements to act between the tubular inner string and the inside of the casing at selected locations along the length of the inner string to adequately support the inner string to a depth sufficient to prevent excess bending at the attachment point to the CRT or at any point in the inner string. It will be apparent to persons skilled in the art that the length and lateral stiffness of the inner string elements connecting the centralizers to the cementing adaptor can be selected to minimize bending loads at the attachment point.
Cementing adaptors in accordance with the present disclosure also provide means for sealing the annular space between the outer surface of the inner string and the inner surface of the casing, to prevent fluid in this annular space from being displaced out of the casing when cement is being pumped down the inner string, such that the cement is urged into the annular space between the outer surface of the casing and the wellbore.
Alternative embodiments of cementing adaptor tools in accordance with the present disclosure may also be adapted for use in conjunction with a plug-dropping manifold tool. A plug-dropping manifold tool, as is known to the art, has means to provide a swivel fluid entry to an inner string bore or tool bore, plus means for releasing one or more plugs (which may be ball plugs, wiper plugs or other similar devices), and include means for positively indicating the dropping of such plugs, while facilitating the functions of reciprocation and rotation by providing means for transferring axial and torsion loads from a top drive to the various tubulars used in oil well drilling and construction. In such embodiments, the cementing adaptor is attached to the distal (lower) end of a CRT mounted to the distal end of the plug-dropping manifold tool. The bores of the CRT and the inner string cementing tool are sized and aligned so that plugs released from the plug-dropping manifold tool will pass through the cementing adaptor and the inner string to provide functions including:
separation of displacing fluids from displaced fluids; positive wiping of the inner surfaces of the casing to further enhance complete fluid displacement; and engagement with their intended targets located downhole from the inner string.
Downhole targets may include devices such as cement staging tools or subsea cementing wiper plug launchers where the casing wiper plug is carried at the distal end of the cementing string and launched when a dropped ball or dart is pumped down and into engagement with the device in a manner known in the art of well cementing. Cementing adaptor tools adapted for use with plug-dropping manifold tools provide the advantage of not having to rig out the CRT to launch plugs or to perform ball drops, and also facilitate side-entry fluid injection (mud or cement), which is desirable in cases where operators prefer not to have certain fluids or slurries (such as cement) run through the top drive.
BRIEF DESCRIPTION OF THE DRAWINGS
Embodiments in accordance with the present disclosure will now be described with reference to the accompanying Figures, in which numerical references denote like parts, and in which:
FIG. 1 is a cross-sectional view of an embodiment of a cementing adaptor tool in accordance with the present disclosure, shown fitted with a stab guide/thread protector to allow for normal casing running operations with the cementing adaptor attached.
FIG. 2 is a cross-sectional view of the cementing adaptor tool in FIG. 1 , shown as it would appear disposed between and attached to a casing running tool and an inner string.
FIG. 3 is a cross-sectional view of the assembly in FIG. 2 , disposed within a tubular casing string with the casing running tool grippingly engaging the casing string.
FIG. 4 is a cross-sectional view of an assembly generally as in FIG. 2 , but with an inner string centralizing pup mounted between the inner string and the lower end of the cementing adaptor tool.
DETAILED DESCRIPTION
FIGS. 1 through 4 illustrate embodiments of a cementing adaptor tool 100 in accordance with the present disclosure. Cementing adaptor 100 is of an elongate and generally cylindrical configuration, with a proximal (upper) end 101 that can be rigidly attached to a casing running tool (CRT) and a distal (lower) end 103 that can be rigidly attached to a tubular inner string. Cementing adaptor 100 is provided with an internal flow path FP and configured such that flow path FP will be continuous with and sealed to an internal flow path in the CRT after cementing adaptor 100 has been mounted to the CRT. This internal flow path FP generally runs the length of the tool and allows for flow of fluid from the CRT through the cementing adaptor from the proximal end to the distal end.
Disposed between the proximal and distal ends of cementing adaptor 100 is a swivel element which allows an inner string attached to the distal end of cementing adaptor 100 to rotate independently of the CRT, and to minimize torque build-up within the inner string and thus minimize torque transfer from the inner string to the CRT. The distal end of cementing adaptor 100 typically will incorporate the male end of a shouldering threaded connection designed to threadingly and sealingly engage the female (or box end) of an inner string (which typically will be made up from oilfield drill pipe). Cementing adaptor 100 further incorporates a casing seal assembly designed to seal the annular space between cementing adaptor 100 and a casing string.
Referring now to FIG. 1 , cementing adaptor 100 with a proximal (upper) end 101 , a middle interval 102 , and a distal (lower) end 103 is shown in cross-sectional view with a stab guide 110 attached to distal end 103 . Cementing adaptor 100 comprises an elongate and generally cylindrical carrier 120 , a generally cylindrical swivel element 140 , a generally cylindrical connector 160 , and a generally cylindrical casing seal assembly 180 . Carrier 120 extends between proximal end 101 and middle interval 102 of cementing adaptor 100 and has an upper end 121 , a middle interval 122 , and a lower end 123 , with middle interval 122 and lower end 123 being separated or demarcated by an annular shoulder rib 127 extending radially outward from carrier 120 . Swivel 140 is coaxially and rotatably disposed about middle interval 122 of carrier 120 , above shoulder rib 127 . A load thread 124 and a seal 125 are provided at upper end 121 of carrier 120 . A plurality of seal grooves 126 are disposed along the outside surface of middle interval 122 . Annular shoulder rib 127 defines an upward facing shoulder 128 and a downward facing shoulder 129 . Lower end 123 is formed with a plurality of seal grooves 130 .
In the illustrated embodiment, casing seal assembly 180 includes a packer cup 181 of a type common to many oilfield casing seal assemblies. Casing seal assembly 180 is coaxially carried by carrier 120 , and sealingly engaged with one or more of seal grooves 126 on middle interval 122 of carrier 120 . It is understood that the performance criteria for seal assembly 180 will vary depending on casing weights and pressure requirements and may be changed from job to job as required. It is also to be understood that various options exist for alternative casing seal arrangements, and that cementing adaptors in accordance with the present disclosure are not limited to the use of the illustrated casing seal arrangement or any other particular casing seal arrangement.
In the illustrated embodiment, swivel element 140 has an upper end 141 , a lower end 142 with a lower end face 147 , and an internal surface 143 defining a downward-facing annular shoulder 144 near upper end 141 . Threads 145 are provided in a lower region of internal surface 143 , and pins 146 are provided through openings in the cylindrical wall of swivel 140 below threads 145 . Upper end 141 of swivel 140 sealingly engages a seal groove 126 on carrier 120 above shoulder rib 127 . Downward-facing shoulder 144 is parallel and adjacent to upward facing shoulder 128 on shoulder rib 127 , Shoulders 128 and 144 are separated by and mutually abutted by a friction-reducing bushing 150 . Connector 160 has an upper end 161 , a lower end 162 , an inside cylindrical surface 167 and an annular upper face 168 at upper end 161 , and an outer surface 163 , with threads 164 on an upper region of outer surface 163 for mating engagement with threads 145 on swivel 140 . A plurality of pockets 165 are formed into outer surface 163 for engagement with pins 146 . Tapered threads 166 are provided on outer surface 163 at lower end 162 .
It to be is understood that cementing adaptors in accordance with the present disclosure are not limited to embodiments incorporating the illustrated shouldering threaded connection. Depending on the application, this style of connection to the inner string may be modified either by providing a different connector or by providing a crossover to adapt the tool to a different size or style of connection.
Inside surface 167 at upper end 161 of connector 160 sealingly engages seals 132 disposed in seal grooves 130 on lower end 123 of carrier 120 , while thread 164 engages thread 145 on swivel 140 and pins 146 engage pockets 165 to prevent thread disengagement and to react any torque generated through friction on shoulder 144 . Upper face 168 of connector 160 abuts downward-facing shoulder 129 of carrier 120 . Stab guide 110 , with lower tapered face 111 , upper shoulder 112 , tapered internal thread 113 , and locking pins 114 , loosely threadingly engages tapered thread 166 on connector 160 . Locking pins 114 engage pockets 169 on lower end 162 of connector 160 to prevent thread disengagement and to react any incidental torque.
With reference now to FIG. 2 , cementing adaptor 100 is shown disposed between and rigidly attached to the lower end 201 of a casing running tool (CRT) 200 (such as, by way of example only, a “Gripping Tool” as described in U.S. Pat. No. 7,909,120) and the upper end 301 of an inner string 300 . Carrier 120 of cementing adaptor 100 is rigidly attached to and in sealing engagement with the inside surface 202 on the lower end of CRT 200 . In this embodiment, the attachment method is a threaded and pinned arrangement wherein axial load is carried by thread 124 on carrier 120 and the mating thread on CRT 200 , and torque is reacted in shear through a plurality of cap screws 203 in holes 133 on carrier 120 . A seal 125 engages a seal face 204 on CRT 200 to provide a continuous sealed bore through the CRT 200 and adaptor 100 . Still referring to FIG. 2 , tapered and shouldered thread 166 of connector 160 is shown engaged with a female tapered shouldering thread 302 on the upper end 301 of an inner string 300 , providing rigid attachment and sealing engagement.
Referring now to FIG. 3 , cementing adaptor 100 is shown disposed between and rigidly attached to lower end 201 of CRT 200 and upper end 301 of inner string 300 . CRT 200 is shown engaged with and gripping a casing string 400 . Packer cup 181 is shown engaged with the inner surface 401 of casing string 400 , sealing off the annular space below packer cup 181 between cementing adaptor 100 and inner surface 401 of casing string 400 from the annular space above packer cup 181 between CRT 200 and inner surface 401 of casing string 400 . As thus arranged, CRT 200 is able to hoist, rotate, and reciprocate the casing, with any incidental relative rotation as a result of the tumbling action of inner string 300 within casing 400 (such as in a deviated wellbore) being relieved through the action of swivel 140 . This arrangement thus facilitates and enables the functions required for running an inner string cementing job, including rotation and reciprocation of the casing string, taking into consideration the hoisting and torque capacities of both the system as a whole and its individual components.
Referring now to FIG. 4 , cementing adaptor 100 is shown disposed between and rigidly attached to lower end 201 of CRT 200 and upper end 301 of inner string 300 , with CRT 200 engaging and gripping casing string 400 , generally as seen in FIG. 3 . In this arrangement, however, an inner string pup 500 with a centralizing flange 501 is disposed between and attached to connector 160 and inner string 300 , and a side load bushing flange 190 is disposed between upward-facing shoulder 168 on connector 160 and lower end face 147 of swivel 140 . Both the outer diameter of bushing flange 190 and centralizing flange 501 are selected to be close to the minimum allowable casing diameter (or “drift”). The arrangement of these centralizing flanges prevents side loads induced by slant-drilling operations (or other forces tending to displace the inner string eccentric from substantially coaxial alignment with the casing) from overloading carrier 120 in bending, which would typically occur in the region of minimum section near upper end 121 of carrier 120 . It to be is understood that when significant side load is anticipated during an inner string cementing job, the axial spacing of these flanges can be selected in consideration of the compliance of both the cementing adaptor and the inner string, and in consideration of the clearance between the outer diameter of the flanges and the inner diameter of casing 400 , to prevent excessive bending stresses in cementing adaptor 100 and CRT 200 .
It will be readily appreciated by those skilled in the art that various modifications of cementing adaptor tools in accordance with the present disclosure may be devised without departing from the scope and teaching of the present disclosure, including modifications which may use equivalent structures or materials hereafter conceived or developed. It is to be especially understood that the disclosure is not intended to be limited to any described or illustrated embodiment, and that the substitution of a variant of a claimed element or feature, without any substantial resultant change in function or operation, will not constitute a departure from the scope of the disclosure. It is also to be appreciated that the different teachings of the embodiments described and discussed herein may be employed separately or in any suitable combination to produce desired results.
In this patent document, any form of the word “comprise” is to be understood in its non-limiting sense to mean that any item following such word is included, but items not specifically mentioned are not excluded. A reference to an element by the indefinite article “a” does not exclude the possibility that more than one of the element is present, unless the context clearly requires that there be one and only one such element.
Any use of any form of the terms “connect”, “engage”, “attach”, “mount”, or any other term describing an interaction between elements is not meant to limit the interaction to direct interaction between the subject elements, and may also include indirect interaction between the elements such as through secondary or intermediary structure.
Relational terms such as “parallel”, “concentric”, and “coaxial” are not intended to denote or require absolute mathematical or geometrical precision. Accordingly, such terms are to be understood as denoting or requiring general or substantial precision only (e.g., “generally parallel” or “substantially parallel”) unless the context clearly requires otherwise.
Wherever used in this document, the terms “typical” and “typically” are to be interpreted in the sense of representative or common usage or practice, and are not to be understood as implying invariability or essentiality.
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A cementing adaptor includes a cylindrical carrier carrying a casing seal, a middle interval and a lower end separated by an annular rib, and a cylindrical swivel element disposed around and coaxially rotatable relative to the middle interval. A cylindrical connector has an upper end rotatably disposed around the carrier's lower end and non-rotatably connected to the swivel element, plus a lower end connectable to an inner tubular string. With the carrier's upper end connected to a casing running tool (CRT), this assembly can be disposed within a casing string with the casing seal engaging the casing and preventing fluid flow into the casing annulus below the seal when cement is pumped down the inner string, such that the cement is urged into the wellbore annulus. The swivel connection limits torque transfer that might otherwise overload the CRT or its connection to the cementing adaptor.
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BACKGROUND OF THE INVENTION
The present invention relates to a control circuit for an electromagnetically driven programming shutter of a camera.
An electromagnetically driven programming shutter suffers from a large variation in its performance caused by the variation in the voltage or the current of the electric source energizing the shutter. Therefore, it has been the practice in the heretofore proposed electromagnetically driven programming shutter to provide a constant voltage circuit or a constant current circuit so as to prevent the variation in the performance of the shutter caused by the variation in the voltage or the current of the electric source energizing the shutter. However, the constant voltage circuit or the constant current circuit is very complex in construction and expensive to manufacture, while the voltage or the current supplied from such a constant voltage circuit or a constant current circuit is not used under the completely efficient conditions of the electric source but rather in a very low efficiency of the electric source in order to obtain the constant voltage or the constant current. Therefore, it is disadvantageous to use such a constant voltage circuit or a constant current circuit in an electromagnetically driven programming shutter requiring a rather large current.
On the other hand, an electromagnetically driven programming shutter suffers from a large variation in its performance caused by the variation in the temperature resulting in the variation of the voltage or the current supplied by the electric source to the shutter. Therefore, an expensive constant voltage circuit or an expensive constant current circuit has been required in the shutter in order to avoid the variation in the performance caused by the variation in the temperature. This has been a disadvantage in the heretofore proposed electromagnetically driven programming shutter.
SUMMARY OF THE INVENTION
It is, therefore, an object of the present invention to provide a novel and useful control circuit for an electromagnetically driven programming shutter which is simple in construction and inexpensive to manufacture and has a superior performance wherein the electric source can be utilized in the most efficient manner and the accurate operation of the shutter is insured even though the voltage of the electric source varies.
The other object of the present invention is to provide a novel and useful control circuit for an electromagnetically driven programming shutter which is simple in construction and inexpensive to manufacture and has a superior performance wherein the electric source can be utilized in the most efficient manner and the accurate operation of the shutter is insured even though the temperature varies.
The above object is achieved in accordance with the present invention by providing a control circuit for an electromagnetically driven programming shutter having magnets and shutter blade driving coils provided on the respective shutter blades of said shutter and electromagnetically cooperating with the magnets, the shutter blades being actuated for opening and/or closing operation when the driving coils are energized, the control circuit having an electric source for energizing the driving coils, a scene light information detecting circuit including a photoelectric element adapted to receive the scene light in coupled relationship to the opening and closing operation of the shutter blades so as to generate a scene light information indicating output voltage, a reference voltage generating circuit adapted to be energized by the electric source so as to generate a reference output voltage for obtaining a proper exposure of the shutter by comparing the same with the scene light information indicating output voltage, and a comparator adapted to receive the scene light information indicating output voltage and the reference output voltage and compare the former with the latter so as to generate a controlled proper exposure defining output pulse, the controlled proper exposure defining output pulse being supplied to the shutter blade driving coils so that the shutter is actuated for the proper exposure in cooperation with the magnets, the control circuit being characterized in that the reference voltage generating circuit comprises a voltage compensating circuit capable of varying the reference output voltage as a function of the variation in the voltage of the electric source thereby permitting the controlled proper exposure defining output pulse to be modified so as to compensate for the variation in the actuation of the shutter blades caused by the variation in the electromagnetic force generated by the shutter blade driving coils due to the variation in the voltage of the electric source.
With the above described control circuit of the present invention, the variation in the actuation of the shutter blades due to the variation in the voltage of the electric source can be positively compensated for in order to achieve the proper exposure of the shutter by taking advantage of the variation in the voltage per se of the electric source so as to modify the duration of the controlled proper exposure defining pulse without the need of providing any expensive constant voltage or current circuit.
The voltage compensating circuit may comprise a circuit for varying the duration of the controlled proper exposure defining output pulse in response to the variation in the voltage of the electric source.
The electromagnetically driven programming shutter may comprise springs for urging the respective shutter blades to the closed position of the shutter, the shutter blades being driven in the shutter opening direction against the action of said springs when the shutter blade driving coils are energized by the controlled proper exposure defining output pulse.
In accordance with another feature of the present invention, it provides a control circuit for an electromagnetically driven programming shutter having magnets and shutter blade driving coils provided on the respective shutter blades and electromagnetically cooperating with the magnets, the shutter blades being actuated for opening and/or closing operation when the driving coils are energized, the control circuit having an electric source for energizing the driving coils, a scene light information detecting circuit including a photoelectric element adapted to receive the scene light so as to generate a scene light information indicating output voltage, a reference voltage generating circuit adapted to be energized by the electric source so as to generate a reference output voltage for obtaining a proper exposure of the shutter by comparing the same with the scene light information indicating output voltage, and a comparator adapted to receive the scene light information indicating output voltage and the reference output voltage and compare the former with the latter so as to generate a controlled proper exposure defining output pulse, the controlled proper exposure defining output pulse being supplied to the shutter blade driving coils so that the shutter is actuated for the proper exposure in cooperation with the magnets, the control circuit being characterized in that the reference voltage generating circuit comprises a voltage compensating circuit capable of varying the reference output voltage as a function of the variation in the voltage of the electric source thereby permitting the controlled proper exposure defining output pulse to be modified so as to compensate for the variation in the actuation of the shutter blades caused by the variation in the electromagnetic force generated by the shutter blade driving coils due to the variation in the voltage of the electric source, and the control circuit further comprises a first digital conversion circuit for converting the scene light information indicating output voltage into a digital scnee light information indicating output signal, a second digital conversion circuit for converting the reference output voltage of the voltage compensating circuit into a digital reference output signal, and an operation processing circuit adapted to receive both the digital output signals so as to generate the controlled proper exposure defining output pulse by the operation processing circuit.
The control circuit described above may further comprise an information introducing circuit for introducing an exposure information such as the film sensitivity into the operation processing circuit.
In accordance with a still further feature of the present invention, it provides a control circuit for an electromagnetically driven programming shutter having magnets and shutter blade driving coils provided on the respective shutter blades and electromagnetically cooperating with the magnets, the shutter blades being actuated for opening and/or closing operation when the driving coils are energized, the control circuit having an electric source for energizing the driving coils, a scene light information detecting circuit including a photoelectric element adapted to receive the scene light so as to generate a scene light information indicating output voltage, a reference voltage generating circuit adapted to be energized by the electric source so as to generate a reference output voltage for obtaining a proper exposure of the shutter by comparing the same with the scene light information indicating output voltage, and a comparator adapted to receive the scene light information indicating output voltage and the reference output voltage and compare the former with the latter so as to generate a controlled proper exposure defining output pulse, the controlled proper exposure defining output pulse being supplied to the shutter blade driving coils so that the shutter is actuated for the proper exposure in cooperation with the magnets, the control circuit being characterized in that the reference voltage generating circuit comprises a voltage compensating circuit capable of varying the reference output voltage as a function of the variation in the voltage of the electric source thereby permitting the controlled proper exposure defining output pulse to be modified so as to compensate for the variation in the actuation of the shutter blades caused by the variation in the electromagnetic force generated by the shutter blade driving coils due to the variation in the voltage of the electric source, and the control circuit further comprises a first digital conversion circuit for converting the scene light information indicating output voltage into a digital scene light information indicating output signal, a second digital conversion circuit for converting the reference output voltage of the voltage compensating circuit into a digital reference output signal, an operation processing circuit adapted to receive both the digital output signals so as to generate a shutter blade opening signal and a shutter blade closing signal which is issued after a controlled time period from the issuance of the shutter blade opening signal corresponding to the scene light information indicating signal as well as to the variation in the voltage of the electric source, and a shutter blade actuating circuit adapted to receive the shutter blade opening signal and the shutter blade closing signal, the shutter blade driving coils being energized upon supply of the shutter blade opening signal to the shutter blade actuating circuit in the direction for driving the shutter blades in the shutter opening direction, while the shutter blade driving coils are switched upon supply of the shutter blade closing signal to the shutter blade actuating circuit so as to be energized in the direction for driving the shutter blades in the shutter closing direction, further comprising an information introducing circuit for introducing an exposure.
In accordance with a further feature of the present invention, it provides a control circuit for an electromagnetically driven programming shutter having magnets and shutter blade driving coils provided on the respective shutter blades of the shutter and electromagnetically cooperating with the magnets, the shutter blades being actuated for opening and/or closing operation when the driving coils are energized, the control circuit having an electric source for energizing the driving coils, a scene light information detecting circuit including a photoelectric element adapted to receive the scene light in coupled relationship to the opening and closing operations of the shutter blades so as to generate a scene light information indicating output voltage, a reference voltage generating circuit adapted to be energized by the electric source so as to generate a reference output voltage for obtaining a proper exposure of the shutter by comparing the same with the scene light information indicating output voltage, and a comparator adapted to receive the scene light information indicating output voltage and the reference output voltage and compare the former with the latter so as to generate a controlled proper exposure defining output pulse, the controlled proper exposure defining output pulse being supplied to the shutter blade driving coils so that the shutter is actuated for the proper exposure in cooperation with the magnets, the control circuit being characterized in that the reference voltage generating circuit comprises a voltage compensating circuit capable of varying the reference output voltage as a function of the variation in the voltage of the electric source, a scene light information compensating means for varying the brightness of the scene light received by the photoelectric element, and driving means controlled by the voltage compensating circuit for driving the scene light information compensating means so as to vary the brightness of the scene light received by the photoelectric element correspondingly to the output of the voltage compensating circuit, thereby permitting the controlled proper exposure defining output pulse to be modified so as to compensate for the variation in the actuation of the shutter blades caused by the variation in the electromagnetic force generated by the shutter blade driving coils due to the variation in the voltage of the electric source.
The scene light information compensating means may comprise a variable aperture diaphragm located in front of the photoelectric element, or it may comprise a variable density neutral gray wedge type filter located in front of the photoelectric element.
With the control circuit described above, the controlled proper exposure defining pulse can be modified so as to compensate for the variation in the actuation of the shutter blades caused by the variation in the voltage of the electric source in order to achieve the proper exposure by modifying the brightness of the scene light received by the photoelectric element correspondingly to the variation in the voltage of the electric source without the used of providing any expensive constant voltage or current circuit.
In accordance with the other feature of the present invention, it provides an electromagnetically driven programming shutter having magnets and shutter blade driving coils provided on the respective shutter blades of the shutter and electromagnetically cooperating with the magnets, the shutter blades being actuated for opening and/or closing operation when the driving coils are energized, the control circuit having an electric source for energizing the driving coils, a scene light information detecting circuit including a photoelectric element adapted to receive the scene light in coupled relationship to the opening and closing operations of the shutter blades so as to generate a scene light information indicating output voltage, a reference voltage generating circuit adapted to be energized by the electric source so as to generate a reference output voltage for obtaining a proper exposure of the shutter by comparing the same with the scene light information indicating output voltage, and a comparator adapted to receive the scene light information indicating output voltage and the reference output voltage and compare the former with the latter so as to generate a controlled proper exposure defining output pulse, the controlled proper exposure defining output pulse being supplied to the shutter blade driving coils so that the shutter is actuated for the proper exposure in cooperation with the magnets, the control circuit being characterized by a temperature detecting circuit having a predetermined temperature characteristics and arranged at a position where the temperature of the shutter blade driving coils can be detected thereby, the temperature detecting circuit being connected to the reference voltage generating circuit thereby permitting the reference output voltage to be modified by virtue of the temperature characteristics of the temperature detecting circuit so as to compensate for the variation in the actuation of the shutter blades caused by the variation in the electromagnetic force generated by the shutter blade driving coils due to the variation in the temperature.
With the control circuit described above, the accurate operation of the shutter is insured even though the temperature varies by virtue of the provision of the temperature detecting circuit for modifying the reference output voltage so as to compensate for the variation in the actuation of the shutter blades caused by the variation in the temperature.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a plan view showing the main portion of the electromagnetically driven programming shutter suitable for use with the control circuit of the present invention;
FIG. 2 is a cross-sectional view taken along line II--II in FIG. 1;
FIG. 3 is a plan view showing the shutter blade driving coil provided on the shutter blade of the shutter shown in FIG. 1;
FIG. 4 is a diagram showing an embodiment of the control circuit of the present invention;
FIG. 5 is a diagram showing the operation of the shutter of FIG. 1 controlled by the control circuit of FIG. 4 under the normal condition of the electric source generating the standard voltage;
FIG. 6 is a diagram similar to FIG. 5 but showing the operation of the shutter of FIG. 1 controlled by the control circuit of FIG. 4 under the condition of the electric source generating a lowered voltage than the standard voltage;
FIG. 7 is a diagram showing another embodiment of the control circuit of the present invention;
FIG. 8 is a diagram showing the operating voltage of the control circuit of FIG. 7;
FIG. 9 is a fragmentary circuit diagram showing a further embodiment of the control circuit of the present invention wherein both the opening and closing operations of the shutter blades are effected by the electric pulses;
FIG. 10 is a diagram showing a still further embodiment of the control circuit of the present invention wherein a scene light information compensating means is utilized so as to modify the proper exposure defining pulse in response to the variation in the voltage of the electric source;
FIG. 11 is a diagram showing the other embodiment of the control circuit of the present invention;
FIG. 12 is a diagram showing an embodiment of the control circuit o present invention wherein the reference voltage is modified by the temperature detecting circuit in response to the variation in the temperature which affects the actuation of the shutter blades;
FIG. 13 is a diagram showing the variation in the reference voltage as compensated for by the temperature detecting circuit in response to the variation in the temperature; and
FIG. 14 is a diagram showing the variation in the operation of the control circuit of FIG. 12 as well as the variation in the operation of the shutter blades.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to FIGS. 1 and 2 showing the electromagnetically driven programming shutter suitable for use with the control circuit of the present invention, it comprises a lower magnetizable yoke 1 having a central light transmitting opening 1b and a plurality of guide rollers 2 provided thereon, shutter blades 3 and 4 located above the lower yoke 1 with their side edges and elongated slot 3i formed in the shutter 3 being guided by the guide rollers 2 for reciprocal movement of the shutter blades 3 and 4, each of the shutter blades 3 and 4 being formed of a light intercepting material such as a glass fiber embedded epoxy resin having an electrically insulating property so as to serve as a base plate of a printed coil and having a teardrop-shaped light transmitting window 3b, 4b with the sharpened tip 3a, 4a thereof being oriented in facing relationship to each other as shown, a pair of permanent magnets 5 and 6 secured on the inner surface of the lower yoke 1 beneath the shutter blades 3, 4 and each having a vertically oriented but inverted magnetic polarity to each other, and an upper magnetizable yoke 7 arranged above the shutter blades 3, 4 and having a central light transmitting opening 7a with its opposite end edges abutting against the respective upwardly bent lugs 1a of the lower yoke 1.
The location of the magnets 5 and 6 is defined by stoppers 8, 9 arranged in the lower yoke 1 which serve also as the motion limiting means for the shutter blades 3 and 4.
Electrically conducting tension springs 10, 10 are stretched between electrically conducting pins 3d, 3e secured to the shutter blade 3 and electrically conducting pins 10a, 10b secured to a base plate (not shown) of the shutter, respectively. In like manner, electrically conducting tension springs 11, 11 are stretched between electrically conducting pins 4d, 4e secured to the shutter blade 4 and electrically conducting pins 11a, 11b secured to the base plate of the shutter, so that the shutter blade 3 is normally urged to the right in FIG. 1 to abut against the stopper 8 while the shutter blade 4 is normally urged to the left to abut against the stopper 9. In this position, the sharpened tips 3a, 4a of the windows 3b, 4b are moved spaced apart from each other so that the light transmitting openings 1b and 7a are fully covered by the shutter blades 3, 4 thereby preventing the light from passing through the openings 1b and 7a.
When the shutter blade 3 is urged to the left and the shutter blade 4 is urged to the right simultaneously and symmetrically to the shutter blade 3 against the action of the springs 10, 11 by the operation of the shutter to be described later, the sharpened tips 3a, 4a move toward each other and begin to overlap with each other so that a small light transmitting aperture is formed by the tips 3a, 4a at the center of the window 1b, and the size of this small light transmitting aperture becomes greater as the shutter blade 3 continues to move to the left and the shutter blade 4 continues to move to the right symmetrically to the shutter blade 3 until the shutter blade 3 abuts against the stopper 9 and the shutter blade 4 abuts against the stopper 8, at which positions the windows 3b, 4b and the opening 1b are concentric to each other and the shutter blades 3, 4 form the fully opened aperture.
When the movement of the shutter blades 3, 4 is reversed to the shutter closing direction before they reach the fully opened aperture, the shutter operates as a programming shutter.
The magnetic circuit of the magnets 5, 6 is completed through the magnet 5 - the yoke 7 - the magnet 6 - the yoke 1 - the magnet 5.
In order to move the shutter blades 3, 4 in the shutter opening direction against the action of the springs 10, 11, a shutter blade driving coil 13 in the form of a printed coil is provided on the shutter blade 3 and a shutter blade driving coil similar to the driving coil 13 is provided on the shutter blade 4. Therefore, it will suffice to describe only the shutter blade driving coil 13 in detail for the understanding of the shutter blade driving coil provided on the shutter blade 4.
As shown in FIG. 3, the shutter blade driving coil 13 is formed over one surface or both surfaces of the shutter blade 3 by adhesion of a metallic foil such as a copper foil thereon or by vacuum vaporization of a metal such as copper thereon and, thereafter, by effecting etching process so as to form the desired configuration of the coil. In case the coil is formed only on one surface, the ends of the coil is connected to the pins 3d, 3e, respectively, while, in case the coil is formed on both surfaces, one end of the coil on one surface is connected to the pin 3d and the other end is connected to an electrically conducting pin 3c passing through the shutter blade 3 and the pin 3c is connected to one end of the coil on the opposite surface of the shutter blade 3 and the other end of this coil is connected to the pin 3e so that the coil 13 can be energized by the control circuit to be described below through the pin 10a, the spring 10, the pin 3d and through the pin 3e, the spring 10, the pin 10b, thereby permitting an electromagnetic force to be generated by the coil 13 in cooperation with the magnets 5, 6 so as to move the shutter blade 3 against the action of the springs 10 in the shutter opening direction. When the coil 13 is deenergized by the operation of the control circuit, the shutter blade 3 is moved to the shutter closing position by the action of the springs 10. In the similar manner, the shutter blade 4 is moved in symmetrical relationship to the shutter blade 3 by the energization of the coil provided thereon by the control circuit through the pin 11a, the spring 11, the pin 4d and through the pin 4e, the spring 11, the pin 11b in cooperation with the magnets 5, 6 and the deenergization of the coil by the action of the springs 11 under the control of the control circuit. Therefore, a proper exposure is achieved by the shutter by the operation of the control circuit.
It is preferred to provide wear-resisting areas 3f, 3g made of the same material as that of the shutter blade driving coils on both surfaces of the shutter blades at the same time and by one and the same process as the shutter blade driving coils are formed. The areas 3f, 3g significantly improve the wear-resisting property of the relatively sliding portions of the shutter.
Further, it is also preferred to provide a metallic light intercepting area (as shown by the reference numeral 3h in FIG. 3) made of the same material as that of the shutter blade driving coil at the same time and by one and the same process as the shutter blade driving coils are formed. The area 3h serves to significantly improve the light intercepting property of the shutter blades which otherwise could not be achieved by the shutter blades made of a resin.
Now, an embodiment of the control circuit of the present invention will be described below with reference to FIG. 4.
The control circuit shown in FIG. 4 includes a photoelectric element 14 located in the recess 1c formed in the lower yoke 1. The photoelectric element 14 is covered or shielded by a shielding lug 3j extending obliquely outwardly from the shutter blade 3 so as to prevent the scene light from being received by the photoelectric element 14 when the shutter blades 3, 4 are in the shutter closing position, but, as the shutter blades 3, 4 begin to move in the shutter opening direction, the shielding lug 3j begins to gradually uncover the photoelectric element 14 so that it begins to receive gradually increasing quantity of the scene light in coupled relation to the movement of the shutter blade 3, and it is again covered by the shielding lug 3j when the shutter blades 3, 4 move to the shutter closing position.
The control circuit comprises a scene light information detecting circuit consisting of an operational amplifier 15 having input terminals connected to the photoelectric element 14 and having a logarithmic diode or a logarithmically suppressing diode 16 connected between the output terminal of the operational amplifier 15 and the inverted input terminal thereof for feeding back the output of the operational amplifier 15 to the inverted input terminal, a logarithmic extension transistor or a logarithmically stretching transistor 17 having its base connected to the output teminal of the operational amplifier 15 and having its emitter grounded, a capacitor 18 connected between a constant voltage source V 2 and the collector of the transistor 17 and a trigger switch 19 connected in parallel to the capacitor 18 between the constant voltage source V 2 and the collector of the transistor 17, the trigger switch being normally closed bit being adopted to be opened in advance of the receipt of the scene light by the photoelectric element 14 in coupled relationship to the opening operation of the shutter blades 3, 4.
The output voltage of the scene light information detecting circuit is supplied to the non-inverted input terminal of a comparator 20, while a reference output voltage V 2 of a reference voltage generating circuit is supplied to the inverted input terminal of the comparator 20 so that both the output voltages are compared with each other in the comparator 20 thereby determining the level of the output of the comparator 20 depending upon the scene light brightness for controlling the energization and the deenergization of the shutter blade driving coils for achieving the proper exposure of the shutter as described in detail hereinbelow.
The reference voltage generating circuit comprises a voltage dividing circuit including a pair of series connected resistors 21, 22 for dividing the voltage V cc of the electric source such as a battery at the connecting point C for providing a divided voltage V 1 thereat, an operational amplifier 23 having its non-inverted input terminal connected to the connecting point C of the voltage dividing circuit and its inverted input terminal connected to one end of a resistor 24 the other end of which is grounded, and a feed-back resistor 25 connected between the output terminal of the operational amplifier 23 and the inverted input terminal thereof. The output terminal of the operational amplifier 3 is connected to one input terminal of an AND gate 26 for supplying the reference output voltage V 2 thereto. One end of a resistor 27 is connected to the electric source Vcc while the other end thereof is connected to one end of a release switch 28 the other end of which is grounded. The connecting point d of the resistor 27 and the release switch 28 is connected to the other input terminal of the AND gate 26. The output terminal of the AND gate 26 is connected to one end of a resistor 29 the other of which is connected to the base of a transistor 30. The collector of the transistor is connected to one end each of the shutter blade driving coils of the shutter blades 3, 4, the other end of which is connected to the electric source Vcc, while the emitter of the transistor 30 is grounded. The connection of the driving coils, i.e. the direction of the current to be flown through the driving coils when they are energized is so determined that the shutter blades 3, 4 are driven in the shutter opening direction against the action of the springs 0, 11.
The release switch 28 is normally closed and it is opened when the release button of the camera is operated for the photographing operation.
The operation of the control circuit as described above is as follows. Prior to the actuation of the release button of the camera, both the release switch 28 and the trigger switch 19 are closed and, therefore, the non-inverted input terminal of the comparator 20 receives the constant voltage V 2 which is higher than the reference voltage V 2 supplied to the inverted input terminal of the comparator 20 so that the output of the comparator 20 is at the H level which is supplied to one input terminal of the AND gate 26, but the other input terminal of the AND gate 26 is at the L level because the release switch 28 is held closed so as to ground the electric source. Thus, the output of the AND gate 26 is at the L level so that the transistor 30 is in the non-conductive condition and no current is flown through the shutter blade driving coils thereby maintaining the shutter blades 3, 4 in the shutter closing positions.
When the release button is actuated for operating the shutter, the release switch 28 is opened so that the voltage V cc of the electric source is supplied to the above described other input terminal of the AND gate 26 the above described one input terminal of which has been kept at the H level as described previously, and, therefore, the AND gate 26 is opened so as to render the output thereof to be at H level thereby rendering the transistor 30 to be conductive to flow the current through the shutter blade driving coils. Thus, the shutter blades 3, 4 are moved in the shutter opening direction against the action of the springs 3, 4.
As the shutter blades 3, 4 move to open the shutter, the trigger switch 19 is opened before the photoelectric element 14 begins to receive the scene light. And then, as the shielding lug 3j of the shutter blade 3 uncovers the photoelectric element 14, it receives gradually the scene light while the sharpened tips 3a, 4a of the shutter blades 3, 4 begin to overlap to form a gradually increasing light transmitting aperture to allow the scene light to pass through the openings 1b and 7a.
Thus, the photoelectric current is generated in the photoelectric element 14 which is amplified by the operational amplifier 15 wherein a suppressed voltage proportional to the logarithm of the photoelectric current of the photoelectric element 14 is generated at the output terminal of the operational amplifier 15 by virtue of the feed-back connection of the logarithmic diode 16 to the operational amplifier 15. Therefore, a current proportional to the photoelectric current is flown into the logarithmic extension transistor 17 so that an electric charge corresponding to the integrated value of the quantity of the scene light received by the photoelectric element 14 begins to be stored in the capacitor 18.
Therefore, the voltage V 3 at the end of the capacitor 18 connected to the collector of the transistor 17, i.e. at the point a which is connected to the non-inverted input terminal of the comparator 20 begins to be lowered gradually until the decreasing voltage V 3 becomes to be equal to the reference voltage V 2 supplied to the inverted input terminal of the comparator 20 at which time the output of the comparator 20 is inverted to the L level so that the AND gate 26 is closed to render the output thereof to be at the L level and render the transistor 30 to be non-conductive so as to cut off the current flowing through the shutter blade driving coils thereby moving the shutter blades 3, 4 to their shutter closing positions by the action of the springs 10, 11 for completing the proper exposure of the shutter.
In the operation described above, when the voltage of the electric source Vcc varies or is lowered from the predetermined rating voltage for some reasons, the electromagnetic force generated by the driving coils is weakened so that the shutter speed is lowered thereby tending to result in the underexposure of the shutter.
In the present invention, however, the reference voltage V 2 supplied to the inverted input terminal of the comparator 20 is also varied or lowered as the voltage Vcc of the electric source varies or is lowered, and, therefore, the time period until the output of the comparator 20 is inverted from the H level to the L level is made longer correspondingly to the variation or lowering of the voltage of the electric source in comparison with the time period occurring in the case of the normal rating voltage of the electric source so as to compensate for the lowered shutter speed. Therefore, the time period during which the shutter blade driving coils are energized is made longer correspondingly and the lowered shutter speed is compensated for to achieve the proper exposure of the shutter regardless of the variation or the lowering of the voltage of the electric source.
The reference voltage V 2 of the reference voltage generating circuit of the present invention is: ##EQU1## where: R 24 =the resistance value of the resistor 24
R 25 =the resistance value of the resistor 25.
On the other hand: ##EQU2## where: R 21 =the resistance value of the resistor 21
R 22 =the resistance value of the resistor 22.
Substituting the equation (2) for the equation (1): ##EQU3##
As seen in the equation (3), the reference voltage V 2 varies depending upon the variation in the voltage Vcc of the electric source. In this case, the operational amplifier 23 and the resistors 24, 25 serve to set the reference voltage V 2 to the optimum condition for achieving the proper exposure of the shutter.
The scene light information indicating voltage V 3 at the point a is: ##EQU4## where: i=the electric current
c=the capacity of the capacitor 18
t=the time as measured from the opening of the trigger switch 19
V 2 =the constant voltage supplied by a simple type constant voltage circuit.
As described previously, the shutter is closed for the proper exposure when V 2 =V 3 , wherein it is seen that the time t varies correspondingly to the variation in the voltage of the electric source while the reference voltage V 2 varies as the voltage of the electric source varies so that the proper exposure is achieved regardless of the variation in the voltage of the electric source.
FIG. 5 shows the operation of the shutter as controlled by the above described control circuit under the condition of the normal rating voltage of the electric source. As shown, after some mechanical time lag T L after the shutter blades have been opened by the energization of the driving coils during the time T 1 , the shutter blades commence to reverse their movement to the shutter closing direction so that the operation of the shutter blades is completed for the proper exposure wherein the integrated area S assumes the area representing the proper exposure.
FIG. 6 shows the operation of the shutter blades by the central of the control circuit of FIG. 4 under the condition that the voltage Vcc of the electric source is lowered from the normal rating voltage. In this case, it is seen that the shutter speed is lowered in comparison with the case of FIG. 5 but the time T 2 of energizing the driving coils is made correspondingly longer than the time T 1 of the case of FIG. 5 so as to render the integrated area S to be equal to that of the case of FIG. 5 thereby achieving the proper exposure of the shutter.
FIG. 7 shows another embodiment of the control circuit of the present invention constructed as a digital control circuit.
The control circuit of FIG. 7 comprises in like manners as that shown in FIG. 4 a scene light information detecting circuit consisting of a photodiode or a photoelectric element 14, an operational amplifier 15 having a feed-back diode 16 of the logarithmically suppressing type, and a resistor 29 and a transistor 30 connected to the shutter blade driving coils, all the above components being similar to those shown in FIG. 4. The control circuit of FIG. 7 comprises a first digital conversion circuit 31 having its input terminal connected to the output of the scene light information detecting circuit for converting the scene light information indicating output voltage into a digital scene light information indicating output signal B V , a second digital conversion circuit 32 for converting the variation in the voltage Vcc of the electric source into a digital frequency variation indicating signal, a transistor 33 having its base connected through a resistor to the output of the second conversion circuit 32 and its collector connected through a resistor to the electric source Vcc with its emitter being grounded, an encoding circuit 34 having its input terminal connected to the collector of the transistor 33 for counting and encoding the digital frequency variation indicating signal from the conversion circuit 32 so as to generate an output signal ΔE V for compensating for the variation in the voltage Vcc of the electric source, and an exposure factor or information introducing circuit 35 for generating an exposure information signal S V such as the film sensitivity, and an operation processing circuit 36 having its input terminals connected to the output signal of the digital scene light information conversion circuit 31, the encoding circuit 34 and the exposure information introducing circuit 35, respectively.
Thus, the operation processing circuit 36 carries out the operation on the basis of the input signals S V , B V and ΔE V so as to obtain an output E V =S V +B V +ΔE V thereby permitting the shutter blade driving pulse corresponding to the E V by virtue of the predetermined program set in the circuit 36 which is supplied through the resistor 29 to the transistor 30 for energizing the shutter blade driving coils to actuate the shutter blades 3, 4 for the proper exposure in like manner as in the case of the control circuit of FIG. 4.
The above described source voltage frequency conversion circuit 32 includes an operational amplifier 37 which receives the voltage Vcc of the electric source at its inverted input terminal through a resistor R S and receives the reference voltage Va at its non-inverted input terminal while a capacitor C is connected between its output terminal and its inverted input terminal, and a comparator 39 having its inverted input terminal connected to the output terminal of the operational amplifier 37 through a resistor and its non-inverted input terminal connected to the voltage dividing point a of a voltage dividing circuit consisting of series connected resistors R 1 , R 2 for dividing the reference voltage Va with its output terminal connected to the base of a transistor 38 through a resistor. The emitter of the transistor 38 is connected to the base of the transistor 33 and to the voltage dividing point a of the voltage dividing circuit consisting of the resistors R 1 , R 2 , while the collector of the transistor 38 is connected to the inverted input terminal of the operational amplifier 37.
Thus, the conversion circuit 32 can provide pulsating output voltage of the operational amplifier 37 and periodical input voltage to the non-inverted input terminal of the comparator 39 as illustrated in FIG. 8.
The time T of the input voltage to the non-inverted input terminal of the comparator 39 shown in FIG. 8 is: ##EQU5## where: C=the capacity of the capacitor C
R S =the resistance value of the resistor R S
R 1 =the resistance value of the resistor R 1
R 2 =the resistance value of the resistor R 2
Va=the reference voltage
i=the current flowing through the resistor R S .
The shutter blades 3, 4 are urged to the shutter closing positions by means of the springs 10, 11 and are moved in the shutter opening direction by the energization of the shutter blade driving coils, but, in this case, the photoelectric element 14 receives the scene light at all times independently of the movement of the shutter blades 3, 4.
FIG. 9 shows a further embodiment of the control circuit of the present invention wherein the shutter blades are moved to the shutter closing positions and in the shutter opening direction without the action of the springs by supplying to the shutter blade driving coils the electric current in the forward direction and in the reverse direction so as to achieve the proper exposure.
In FIG. 9, the operation processing circuit 40 receives in like manner as in the case of FIG. 7 the output B V of the scene light information detecting digital conversion circuit 31, the output ΔE V of the source voltage variation encoding circuit 34 and the output S V of the exposure information setting circuit 35 and carries out operations according to the program set therein so as to generate a shutter opening output pulse S o and, after a predetermined time t after the issuance of the shutter opening output pulse S o depending upon the brightness of the scene light, a shutter closing output S c . The pulse S o is connected to the base of a transistor 41 of the N type, for example, through an inverter and a resistor and also to the base of a transistor 42 of the P type, for example, through a resistor, while the pulse S c is connected to the base of a transistor 43 of the P type, for example, through an inverter and a resistor and also to the base of a transistor 44 of the N type, for example, through a resistor, the emitters of the transistors 41, 44 being connected to the electric source Vcc and the emitters of the transistors 42, 43 being grounded.
The collectors of the transistors 41, 43 are connected to one end each of the shutter blade driving coils while the collectors of the transistors 42, 44 are connected to the other end each of the driving coils. The connection of the driving coils are so selected that, when the current is flown therethrough by the issuance of the pulse S o as described below, the shutter blades are moved in the shutter opening direction, while the shutter blades are moved to the shutter closing positions when the current is flown through the driving coils by the issuance of the pulse S c .
With the control circuit described above, when the pulse S o is issued by the operation of the shutter, the transistors 41, 42 are rendered to be conductive, while the transistors 43, 44 are held non-conductive insofar as the pulse S c is not yet issued, so that current from the electric source Vcc is flown in the direction from the transistor 41 through the driving coils to the transistor 42 thereby moving the shutter blades 3, 4 in the shutter opening direction. After the predetermined time t after the issuance of the pulse S o as determined by the brightness of the scene light, the pulse S c is issued, and the transistors 43, 44 are switch into the conductive state while the transistors are rendered to be non-conductive so that the direction of the current flown through the driving coils is reversed thereby closing the shutter blades for completing the proper exposure.
FIG. 10 shows a still further embodiment of the control circuit of the present invention, wherein the reference voltage per se is not compensated for the variation in the voltage of the electric source, but the brightness of the scene light received by the photoelectric element 14 is varied correspondingly to the variation in the voltage Vcc of the electric source so as to control the duration of the shutter blade driving pulse for achieving the proper exposure.
In FIG. 10, the general construction of the circuit shown is similar to that shown in FIG. 4 except that the inverted input terminal of the comparator 20 receives a constant reference voltage as given by a constant current circuit 45 and a scene light information compensating means 46 of the well known teardrop-type variable aperture or of the well known wedge-type variable density neutral gray filter is arranged in the optical path to the photoelectric element 14, and the scene light information compensating means 46 is controlled through a well known actuating means (not shown) by the output voltage V 2 of the operational amplifier 23 which varies correspondingly to the variation in the voltage of the electric source Vcc thereby lowering, for example, the brightness of the scene light received by the photoelectric element 14 in case the voltage Vcc of the electric source is lowered, for example, for elongating the duration of the energization of the driving coils so as to achieve the proper exposure.
FIG. 11 shows the other embodiment of the control circuit of the present invention similar in general construction to that of FIG. 4 wherein, however, the constant voltage V 2 in FIG. 4 is changed to the source voltage Vcc in FIG. 11.
In this case, the current i, flowing through the resistor 24 is: ##EQU6## where: R 24 =the resistance value of the resistor 24
R 25 =the resistance value of the resistor 25
V 1 =the constant voltage.
The collector voltage V 4 of the transistor 49 is: ##EQU7## where: R 47 =the resistance value of the resistor 47
R 48 =the resistance value of the resistor 48
i 2 =the current flowing through the collector-emitter of the transistor 49
V BE =the base-emitter voltage of the transistor 49.
Therefore, ##EQU8##
Since the voltage V 4 is supplied to the inverted input terminal of the comparator 20, the output thereof is inverted when the input voltage V 3 supplied to the non-inverted input terminal of the comparator 20 becomes equal to the voltage V 4 . ##EQU9## where: i=the current flowing through the transistor 17
C=the capacity of the capacitor 18
t=the time elapsed from the opening of the trigger switch 19.
Therefore, ##EQU10##
Since the voltage V BE is substantially constant,
t∝V.sub.2 ∝-V.sub.cc
Thus, the time t is made longer as the voltage Vcc decreases resulting in the lowered speed of the shutter blades, thereby compensating for the lowered shutter speed so as to achieve the proper exposure.
FIG. 12 shows an embodiment of the control circuit of the present invention wherein the proper exposure, i.e. the accurate operation of the shutter is insured regardless of the variation in the ambient temperature affecting the resistance value of the shutter blade driving coils which results in the variation in the electromagnetic force or in the variation in the shutter speed.
The control circuit shown in FIG. 12 is similar in general construction to that shown in FIG. 4 except that a voltage dividing circuit 50 consisting of a pair of series connected resistors is connected to a simple type constant voltage circuit V c so as to provide a divided reference voltage V 5 which is supplied to the inverted input terminal of the comparator 20 as well as to the capacitor 18 as shown.
The characteristic feature of this control circuit lies in the fact that a temperature detecting circuit 51 is connected to the divided reference voltage V 5 as shown in FIG. 12 and the temperature detecting circuit 51 is located in a position where the temperature of the shutter blade driving coils can be exactly detected.
The temperature characteristics of the temperature detecting circuit 51 is so selected that the divided reference voltage V 5 is lowered as the ambient temperature varies from the lower temperature to the higher temperature under a predetermined appropriate condition as illustrated in FIG. 13.
Thus, when the shutter release button is actuated for the operation of the shutter as described previously, the shutter opening 1b and the photoelectric element 14 are uncovered so that the capacitor 18 begins to be charged. Therefore, the input voltage V 3 supplied to the non-inverted input terminal of the comparator 20 is gradually lowered from the constant voltage V c , and, when the lowered voltage is made equal to the divided reference voltage V 5 , the output of the comparator 20 is inverted and the shutter blades 3, 4 are moved to the shutter closing positions so as to achieve the proper exposure in the manner described previously.
When the temperature of the shutter blade driving coils is lowered, for example, so that the resistance value thereof is reduced resulting in the increased current flowing therethrough and, hence, in the increased electromagnetic force thereby increasing the shutter speed, the reference voltage V 5 is also increased by virtue of the provision of the temperature detecting circuit 51. Therefore, the time required until the scene light information detecting voltage V 3 is lowered to reach the reference voltage V 5 is shortened correspondingly to the lowered temperature, and the time of energization of the driving coils is shortened so as to compensate for the increased shutter speed thereby achieving the proper exposure.
FIG. 14 shows the operation of the control circuit of FIG. 12 and the operation of the shutter controlled thereby. In FIG. 14, (1) shows the conditions of operation under the normal temperature, and (2) shows those at a lowered temperature, while (3) shows those at a higher temperature.
In the above description, the duration of the shutter blade driving pulse is varied in response to the variation in temperature. However, it is also possible to convert the voltage informations into digital frequency varying informations.
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The electromagnetically driven programming shutter includes magnets and shutter blade driving coils provided on the respective shutter blades of the shutter and electromagnetically cooperating with the magnets and the shutter blades are actuated for opening and/or closing operation when the driving coils are energized. The present invention provides a votage compensating circuit used as the reference voltage generating circuit which is capable of varying the reference output voltage as a function of the variation in the voltage of the electric source, thereby permitting the controlled proper exposure defining output pulse to be modified so as to compensate for the variation in the actuation of the shutter blades caused by the variation in the electromagnetic force generated by the shutter blade driving coils due to the variation in the voltage of the electric source. Alternatively, a temperature detecting circuit may be provided for detecting the temperature of the shutter blade driving coils indicative of the variation in the current flowing through the driving coils and, hence, indicative of the variation in the electromagnetic force given to the shutter blades, and the temperature detecting circuit is connected to the reference voltage generating circuit. The temperature detecting circuit has such a temperature characteristics that the reference output voltage is modified by the temperature detecting circuit in response to the variation in the temperature thereby permitting the variation in the actuation of the shutter blades caused by the variation in the temperature to be compensate for in order to obtain a proper exposure of the shutter.
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BACKGROUND OF INVENTION
This invention relates generally to surface mounted perimeter raceway for the distribution of electrical and data/telecommunication cables in buildings that have a need for Protective Distribution Systems (PDS) as described in National Security Telecommunication and Information Systems Security Instruction No. 7003. This NSA instruction provides guidelines for facility design and installation of data distribution systems in various environments.
While the preferred embodiment of the present invention satisfies these guidelines, the features of the invention may also be applicable to any raceway that must be secured against intrusion, and that can be inspected for the detection of any attempted intrusion, short of that dictated by the needs of the National Security Agency (NSA), and as set forth in publication No. 7003.
Conventional two-piece metal raceway typically includes a channel-shaped base of U-shaped cross-section having opposed longitudinally extending side walls that are adapted to flex in order to allow the raceway cover to be snapped in place on the base. More particularly, the base side walls have inwardly and rearwardly projecting marginal edge flanges that are adapted to receive depending flanges on the back side of the raceway cover for this purpose. Such raceway is sold by Wiremold Co. of West Hartford, Conn., under the following Wiremold trademarks: 4000, 6000, and ANY SIZE two-piece metal raceway.
SUMMARY OF INVENTION
In a presently preferred embodiment of the invention, a channel-shaped raceway base having a cross-section similar to that described above, that is having opposed relatively flexible side walls with longitudinally extending inwardly and rearwardly projecting marginal edge flanges, is provided in standard lengths. Each such base member has, at one end an overlap coupling spot welded to the raceway base, and at the opposite end is configured to receive such a coupling on an adjacent base member. Thus, interlocking of these base members as they are mounted on a wall structure is the first step in the installation process.
Raceway covers are so configured as to preclude snap fitting of the cover onto these base members, and instead the covers are designed so that the cover must be slid into the base member at assembly in a subsequent step of the installation process.
Once installation of these raceway covers into associated base members is provided on a wall surface it is not possible to spread the base side walls apart and pull the cover off the base as in prior art 4000 raceway. This design requires sliding of each cover through an open end of each raceway base for access.
The present invention also contemplates provision for a mid-span box of sufficient length to receive a raceway cover at the mid-span box and then sliding the covers outwardly of the mid-span box onto the base member. The end portions of the mid-span box are designed for mating with either the male or female end of the adjacent raceway base members.
As with the base, the raceway covers are provided with overlap coupling elements spot welded to one end of each cover, and each cover is configured at the opposite end to receive such a cover coupling element of an adjacent cover. This configuration prevents access to the interior wireway or wireways within the raceway once the raceway covers have been assembled with the raceway base members.
Each raceway cover further includes clips, integrally formed or spot welded to the underside of the raceway cover, along its marginal edges. These clips include longitudinally spaced wing portions that project through openings provided for this purpose in the rearwardly projecting flanges of the cover so that the raceway cover must be slid into the base member and not snapped onto the base. The wing portions of the cover clips nest behind the inwardly and rearwardly directed flanges of the base, precluding removal of the cover except by the same sliding motion of the cover relative to the base member as used at installation. These clips also provide greater rigidity for the cover itself.
The clips further include projecting leg portions that extend well inside the base members and terminate in closely enough spaced relationship to the inner or rear wall of the base member so as to preclude any possibility of the raceway cover being forced inwardly of the raceway base, thereby preventing unauthorized access to the wireway(s) defined between the raceway cover and base member.
Authorized access to the wireway or interior of the assembled raceway is then limited to the aforementioned mid-span box. Drop out fittings are provided at selected locations along the raceway for feeding of power and data/communication lines to selective workstations. Access to the interior of the assembled raceway base and cover at these drop out fitting locations is preferably limited so that these cables run through the rear wall of the base, to preclude unauthorized wireway access.
The drop out fitting comprises an L-shaped housing which provides communication between the interior of the raceway and the interior of the L-shaped housing. The L-shaped housing is in turn welded to a square metal tube in order that wiring from within the raceway may be carried through the rear wall of the base into the L-shaped housing and then through the welded tube to a work station or the like.
It is a further feature of the present invention that the raceway be provided in a “stand-off” relationship to the wall surface from which it is supported. This configuration for the raceway allows inspection of the raceway, not only from the front, but also allows inspection of the back side of the raceway (a requirement under the abovementioned NSA publication).
Finally, the raceway base and cover assembly can be finished with a termination box that includes an open end portion for receiving the end of the raceway. The termination box further includes a lockable cover so as to provide authorized access only to the raceway run.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a cross-section through the raceway base member, and illustrates the mounting screws and stand-off collars for providing the assembled raceway in a position that allows for inspection 3600 around the raceway assembly in order to detect any unauthorized entry or attempts at entry to the wireway there within.
FIG. 2 is a perspective view showing the raceway base member with an overlap coupling provided at one end, and an open opposite end for receiving the coupling of an adjacent raceway base member.
FIG. 2A is a perspective view showing abutting raceway base members, with a coupling 18 at the joint between them, and support screws S,S provided at this compliment.
FIG. 3 is a perspective view of a raceway cover member, the cover member also including a cover overlap coupling at one end and the opposite end being free to receive such a coupling member on an adjacent raceway cover.
FIG. 3A shows the components that make up the cover of FIG. 3 , these components being illustrated in exploded relationship to one another.
FIG. 3B shows the components of FIG. 3A assembled with one another.
FIG. 4 shows in cross-section the assembled raceway base end cover member, and illustrates the clip construction provided along the marginal edges of the cover flanges, these clip portions defining upper wing portions that nest behind the projecting flanges of the base, and the clip configuration also including depending leg portions extending well within the wireway and terminating adjacent the inside or inner wall of the C-shaped base member.
FIG. 4A is similar to the sectional view of FIG. 4 , but also shows a U-shaped reinforcing clip 100 .
FIG. 4B shows the clip 100 at the junction or seam between two end-to-end cover components.
FIG. 5 is a view of the raceway base and cover members after the later has been slip into the former so as to provide the cover overlap in its relationship to the base overlap coupling at the “male” end of this subassembly.
FIG. 6 is a perspective view of the raceway mid-span box base portion as designed to receive each of the raceway covers for slidable assembly with the raceway base members after the base members have been provided on the wall by the stand-off mounting bolts, and after the cabling has been provided inside the wall mounted base members.
FIG. 7 is a detailed view of the left-hand end portion of the mid-span box of FIG. 6 , the opposite or right-hand end portion being a mirror image thereof.
FIG. 8 is a perspective view of the mid-span box cover for use with the mid-span box of FIGS. 6 and 7 .
FIG. 9 is a side elevation view of the box cover of FIG. 8 .
FIGS. 10A , 10 B, 10 C and 10 D illustrate the assembly step for the raceway cover as it is placed over the raceway box, and positioned for placement of a suitable seal device.
FIG. 11 shows the assembled raceway base member and cover together with a drop out fitting box and associated conduit for providing wiring from within the raceway to a workstation of the like.
FIG. 12 shows the components of the drop out fitting in FIG. 11 , but in exploded relationship to one another.
FIG. 13 shows the components of the drop out fitting also in exploded relationship to one another, without the raceway assembly attached thereto.
FIG. 14 is a rear elevation view of the raceway and drop-out fitting of FIGS. 11-13 .
FIG. 15 is a sectional view taken on the line 15 - 15 of FIG. 14 .
FIG. 16 is a perspective view of an end of the raceway termination box without the box cover, and with the cover clamp not in place.
FIG. 17 is a view of the assembled box of FIG. 16 .
FIGS. 18-21 show details on the box and cover of FIGS. 16 and 17 .
FIG. 22 shows a “slack box” for use between raceway base members that are not butted, and accommodate a gap in their associated raceway covers so the covers can be slid relative their respective base members to provide authorized access to the wireway(s) inside the raceway assembly.
FIG. 23 shows the lockable cover for the “slack box” of FIG. 22 .
FIG. 24 shows the welded internal corner configuration for use in a secure raceway with lockable access according to the invention.
DETAILED DESCRIPTION
Turning now to the drawings of the preferred embodiment as disclosed in FIGS. 1-24 , the components of the raceway will now be described in detail.
FIG. 1 shows a wall structure W that represents the perimeter of the space within which a raceway of the present invention is to be used. Mounting screws S,S are anchored in the wall structure W, by any secure well-known method, and access to these screws is confined to the interior of the raceway of the present invention. Once the raceway assembly has been installed as shown, access is precluded.
Standoff collars C,C are provided on these screws S,S to provide visual access to the rear of the raceway after it has been so mounted on the wall structure W. This configuration allows periodic inspection of the raceway to assure that no unauthorized access has been attempted or achieved.
In accordance with the present invention, the raceway comprises a base 10 and cover 12 , which are designed to be slidably assembled with one another, and it is an important feature of the present invention that each base member preferably has at least one cover associated therewith that results in an assembly such as shown in FIG. 5 . Each base member generally will have one cover, but may have more than one as the covers can be shorter than the base. Such a situation can occur, for example, where a cover is cut to fit in a mid span box 20 as described below. By way of example and not limitation, the base components will have a length (L) in the range of 4-6 feet and the covers are preferably 2-3 feet in length so as to have a standard length L/2. Thus, if the base be shortened by less than the length L, one of two covers must be cut for use with a cover L/2 in length, these two covers can be butted together. Such an assembly can benefit from a reinforcing clip at the junction or seam between these covers. See FIGS. 4A and 4B .
FIG. 2 is a perspective view of the raceway base 10 , which base has a forwardly open generally channel or C-shaped cross section with forwardly projecting legs 10 a and 10 b that can be flexed relative to the rear or back wall of the base. Thus, the base 10 may be similar to 4000 Wiremold raceway, for example.
The raceway base 10 is thus similar to prior art two piece steel base, except that base members 10 are preferably designed to fit within one another. Coupler 18 is provided at one end of each base 10 for this purpose. The coupler 18 can be seen from FIG. 2 as including upstanding leg portions 18 a and 18 b as well as locating posts 18 c and 18 d designed to receive the opposite, or female end portion of a raceway base 10 . As shown coupler 18 is attached to the end of the base 10 . Two base members might also be coupled with a clip (not shown) similar to the cover clip 100 (to be described).
FIG. 4 shows this feature in greater detail, and illustrates the cover of FIG. 3 mounted in the base 10 as suggested by the assembly of FIG. 5 .
FIGS. 4A and 4B show a clip 100 having leg portions 100 a and 100 b and an intermediate portion 100 c that provide a U-shape designed to reinforce the junction or seam between two butting cover components 12 a and 12 b . Portion 100 c of clip 100 supports the underside of both covers to reinforce this assembly.
Turning next to a detailed description of the raceway cover 12 of the present invention, FIG. 3A shows the various components of a raceway cover in exploded relationship, each cover 12 including a cover overlap or coupling 28 provided at one end, and an open, or female opposite end, for receiving the coupling element of an adjacent raceway cover. Each cover 12 may be associated with an adjacent raceway base 10 , as described above. The cover 12 of FIG. 3A further includes longitudinally extending clips 14 and 16 , which clips include projecting wing portions 14 a and 16 a , respectively, that fit within openings provided for this purpose along the marginal edges of the raceway cover 12 . The base 10 has flanges 10 c , 10 d for slidably receiving raceway cover marginal edges 12 a , 12 b . FIG. 3B shows these components in assembled relationship, with the wing portions 14 a provided in the openings of the cover 12 , and with the coupling element 28 provided in place at one end of the cover 12 .
These clips 14 and 16 are designed to prevent the cover 12 from any substantial movement relative to the base (save sliding movement as described below). More particularly, the wing portions 14 a and 16 a prevent prying the cover 12 from the raceway base 10 (in the manner made possible with Wiremold 4000 raceway base) by spreading of the base side walls 10 a and 10 b . These clips also include projecting leg portions 14 b and 16 b that extend into the base far enough to prevent the cover from being pushed into the base. These leg portions inhibit disassembly of the cover from its base except by sliding the cover relative its base.
In order to install the raceway of the present invention, the base members are mounted in alignment and along the wall, and preferably each raceway cover must be slid in place on its associated base during the process of installation.
Where a wall is so configured as to deny access to the end of a raceway base, a mid-span box such as that depicted in FIG. 6 at 20 is provided. This box 20 is designed so that its opposite end portions can receive raceway base members such as described above, and more importantly, the box 20 is somewhat larger in size than an assembled raceway and covers so that the open front side of the mid-span box 20 can receive these covers. Each cover can be slid into place into an adjacent raceway base. The base need not be of the same length as the cover at the end fitting into the box 20 because the base end is secure without any need for the base coupling 18 . Further, the need for a cover coupling at the junction between the box 12 and the assembled cover is obviated as well. See FIG. 17 .
Once the cover or covers have been so assembled with an associated base as a result of utilizing the mid-span box of FIGS. 6 and 7 , a locking bar similar to that shown in FIG. 17 at 31 can be provided over the assembled raceway base and cover at each end of the mid-span box 20 .
The forwardly open mid-span box 20 must then itself be provided with a cover 30 , such as depicted in FIGS. 8 and 9 , in the manner suggested for the assembly of the mid-span box and cover as depicted in FIGS. 10A-10D , inclusively.
The mid-span box 20 , best shown in FIGS. 6 and 7 , has identical configurational geometries provided at either end, and therefore can be used to slide covers either to the left or to the right for assembling a raceway system of the present invention on a wall structure.
Once assembled, with the retaining bars 31 , 31 screwed in place, the mid-span box cover 30 can be assembled with the box 20 as suggested in FIGS. 10A-10D . The cover 30 has a projecting L-shaped flange 30 a at its upper edge for insertion in a slot provided for this purpose on the top of the box 20 . The cover flange 30 a fits inside an enclosed space defined for this purpose by an enclosure 20 a inside the box 20 .
Finally, the last step in the assembly process of the mid-span box 20 is to secure the box by means of a padlock, or other suitable locking device.
In order to afford authorized access to the cables within the raceway, at pre-selected work stations, within the work space bounded by the wall structure W, a drop down fitting, such as that illustrated in FIG. 11 , is provided in communication with the interior of the raceway for this purpose. The drop down fitting includes a vertically extending tube 40 welded to an L-shaped enclosure 50 , as best shown in FIG. 13 . The L-shaped enclosure 50 includes a rear leg portion 50 a , which fits behind the raceway, as shown in FIGS. 11 and 12 . Mounting screws S,S are provided for securing the L-shaped housing 50 to the rear wall of the raceway base. A grommet G is provided to protect the cables running from the interior of the raceway into the drop down fitting housing 50 . A T-shaped protective shield 60 is provided between the upstanding leg 50 a of the L-shaped housing and the rear wall of the raceway base, as suggested in FIGS. 12 and 13 . The interior of the raceway base is provided with a reinforcement plate 70 , which serves to further anchor the drop down fitting to the raceway structure.
FIGS. 14 and 15 illustrate the drop down fitting both from the front and the side, the front view illustrating the raceway cover removed, the sectional view of FIG. 15 showing the raceway cover in place.
Turning next to a detailed description of FIGS. 16-21 , a termination box is shown having a configuration not unlike that of the end portion for the mid-span box 20 . More particularly, and as best shown in FIG. 17 , the termination box is adapted to receive an assembled raceway base and cover, with a locking bar 31 utilized to anchor these components together. The termination box 80 is fitted with a cover 90 that is adapted to enclose the open end portion 80 a of the termination box 80 , as best shown in FIG. 19 for example. Thus, the cover 90 includes an end wall 90 a which fits together with the end wall of the termination box 80 for this purpose. Finally, the termination box can be secured, as by a padlock (not shown), similar to that described previously with reference to the mid-span box 20 .
FIG. 22 shows a “slack” box, the cover being shown in FIG. 23 . This box accommodates short gaps in the raceway base/cover installed on walls requiring use of such a box as a coupling device. The structures of the box and cover are similar to the ends of the mid-span box 20 and therefore need not be described in detail. The term access box is adopted in the appended claims to connote any “box” such as the mid-span box 20 or the slack box of FIG. 22 , or any box that provides authorized access to the raceway interior. Amid span box might have only one end to connect with the raceway base and cover. The other end can them be made per FIGS. 19-21 .
FIG. 24 shows an internal elbow having a male and female end for use with the raceway and cover assembly described above. This elbow has the same male and female configurations as provided in these raceway/cover assemblies. The male end being fitted with posts that are received in slots provided in the female ends to securely connect these end portions and provide a secure raceway system.
The material from which these raceway system components are preferably formed is metal, and more particularly a rolled sheet steel of at least 1.3 mm thickness for the base, and at least 1.0 mm for the cover and it's clips with the wing portions and the leg portions also of at least 1.0 mm thicknesses. All of these components are preferably galvanized and painted, with a proprietary (SCUFFCOAT) polyester topcoat applied over the painted surface.
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A raceway system having forwardly open channel-shaped base members with opposed longitudinally extending side walls, and the side walls including inwardly and rearwardly projecting marginal edge flanges, the improvement wherein the raceway covers must be slid into these elongated base members to define at least one wireway therebetween, the covers including clips with wing portions adapted for nesting relationship between the base side walls and the base marginal edge flanges, whereby the covers cannot be disassembled from the base members as a result of flexing the base side walls, but must be disassembled by sliding them apart. These clips also include leg portions that extend well inside the base to prevent attempts to push the cover into the base, and thereby spread the base side walls to gain access to the interior wireway(s).
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BACKGROUND OF THE INVENTION
In operation, piston engines, in particular piston internal combustion engines, are excited to vibrate by the changing events in the cylinder chamber, such as the course of combustion, but also by mechanical influences; the vibrations are also radiated as noise at the surfaces of the piston engine in the form of airborne noise and/or are transmitted via the bearings of the piston engine into the substructure or the body in vehicles as structure-borne sound.
Abatement of noise emissions of this kind is sought, because of their disadvantageous effects on man and the environment. German Patent Disclosure DE-A-28 49 613 attempts to produce a noise shield by providing an elastic acoustical insulation enclosure, which is attached to the engine block of a piston internal combustion engine. Furthermore, German Patent Disclosure DE-A-28 01 431 suggests supporting the entire piston internal combustion engine in an outer tublike casing with the aid of support elements, which insulate structure-borne sound. A disadvantage of such an acoustical insulation measure is that it contains a large part of the machine and therefore hinders the installation of add-on parts and/or additional units, such as engine mounts, starter, generator, or gas supply lines and gas exhaust lines. In this connection, in many cases, it is impossible to prevent the breaching of acoustical insulation enclosures of this kind in order to install add-on parts of this kind and/or additional units, which reduces its effectiveness. Furthermore, acoustical insulation measures of this kind reduce the heat tolerance of a piston internal combustion engine.
On account of the above mentioned disadvantages, there have been attempts to combat noise propagation by seeking to prevent or at least to reduce the generation of noise. In addition to reducing sources of excitation, for example by optimizing the combustion process, it makes sense primarily to reduce the noise transmission and noise radiation at the surfaces of the piston engine. This is achieved by embodying the piston engine as rigidly as possible, particularly making it resistant to bending or torsionally rigid, especially in its thin-walled regions; the oscillatory faces are embodied to be as small and/or thick-walled as possible with regard to airborne noise radiation. Not only is there then an undesired increase in weight, particularly resulting from an increase in wall thickness, primarily in cast components, but increased casting defects such as bubbles or pores or the like also occur. That is why German Patent Disclosure DE-A-35 44 215 has already suggested improving the rigidity of the engine block as a whole with a system of reinforcement ribs on the side walls in the cylinder region. As a result, undesired casting defects can be prevented by embodying the ribs in this way, and high rigidity of the cylinder block can be achieved.
German Patent Disclosure DE-A-40 17 139 suggests the concept of achieving the required rigidity of the engine block via the purposeful installation of bands and ribs. According to this proposal, this is achieved in particular by binding the crankshaft bearings to the cylinder block and to the side walls of the crankcase via a multitude of reinforcing ribs, so that the rigidity of the engine block structure as a whole is increased. However, this entails a corresponding increase in weight. From an economical standpoint, a weight increase is to be avoided.
SUMMARY OF THE INVENTION
The object of the invention, now, is to reduce the vibration and noise generation of a piston engine, in particular of a piston internal combustion engine, by the configuration of the engine block structure; the overall weight must not be increased, if at all possible.
The object is attained according to the invention with a piston engine, in particular a piston internal combustion engine, in which cylinders, pistons, crankshaft, and crankshaft bearings are disposed in an engine block, and regions on the engine block are provided with cap- and/or cup-shaped coverings and in which the walls of the engine block and/or the coverings, are firmly connected, at least in some regions, with reinforcing components which are embodied of a component material that differs from the base material of the engine block and/or the coverings and that has a higher modulus of elasticity than the base material. The particular advantage of the attainment according to the invention is that materials can be chosen for the component material, which, in addition to having a much higher modulus of elasticity than the base material, have a lower density, depending upon the base material used. The achievement is thus that while the overall weight of the piston engine remains the same, the rigidity in the relevant regions is increased and/or the overall weight can even be reduced. In terms of the present invention, the coverings include, for example, the cylinder head cover, control drive coverings, the crankcase or oilpan, and similar elements of the engine structure. With a view to reducing noise, which is the present object, in particular in piston internal combustion engines, the transmissions connected to them also have to be taken into account, since even the walls of a flange mounted transmission case, for example, can radiate noise. Here, too, a vibration reducing reinforcement can be achieved with an arrangement of components in the wall. In the same manner, the intake and/or exhaust pipes can be reinforced in a vibration reducing manner on the inside with tubular components and/or on the outside with strut- or rib-shaped components, so that via these structures that in the broad sense belong to the engine block, no noise radiation or only slight noise radiation is produced.
In a preferred embodiment, ceramic materials, in particular oxide ceramic materials, are provided for the component material. These have a much higher modulus of elasticity than the standard gray cast iron or cast aluminum used for the base material. In the event that gray cast iron is used as the base material, the density of ceramic materials is essentially lower than the density of the base material. With the use of cast aluminum, the density of the ceramic materials is approximately the same. Because of these material properties, reinforcing components of ceramic materials, with the same mass, can produce approximately twelve times the rigidity compared to a structurally similar embodiment of gray cast iron. For the same rigidity, for example, ribs of a ceramic material have approximately 70% less mass than ribs of gray cast iron. A further advantage is that with a rib-shaped embodiment of such components, with a predetermined equal rigidity given the higher modulus of elasticity, the geometric dimensions are reduced compared to a rib of the base material, so that the structural volume of the engine is reduced. Reinforcing measures for noise reduction can therefore be effectively introduced into the components, even with an existing production system.
In an advantageous embodiment of the invention, it is further provided that the components are each at least partly enclosed by the base material, with a positive fit. In that case, in a practical embodiment of the invention, it is provided that the reinforcing components are connected to the base material by at least partial recasting with it. The particular advantage of recasting is that already during the casting process, the base material flows around the corresponding components, in particular ceramic components, which are held in the forms, so that greater dimensional tolerances on the part of the ceramic components can be accepted. This makes it possible to use ceramic components of this kind the way they come from the firing process, without any finishing. The ceramic components are held under compressive strain in the base material, since during the cooling phase, the base material contracts more intensely than the inserted ceramic components. This is particularly advantageous for brittle ceramic material.
In another advantageous embodiment of the invention, it is provided that the reinforcing components are firmly connected to the base material via auxiliary materials. Here, organic or inorganic glues come under consideration as the auxiliary materials, or soldering-on of the ceramic components by means of metallic or non-metallic solder, for example glass or enamel solder can be considered.
In an advantageous embodiment of the invention, it is further provided that in the region of the crankshaft bearings, the reinforcing components are embodied as strut-shaped and connect the bearing region with the wall of the engine block. This disposition is particularly effective since the installation space available here is definitely predetermined by the rotating counterweights connected to the crankshaft. A further increase in the rigidity of the bearing region through the connection of neighboring walls of the engine block via this kind of strut-shaped supports is therefore possible only through the use of materials with a higher modulus of elasticity than the base material used, in particular through the use of ceramic materials. As a result, the vibrations of the crankshaft bearing, which are critical for the transmission of structure-borne sound, are effectively suppressed both in the longitudinal direction of the engine and in the direction of the lateral engine axis and the vertical engine axis.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be described in further detail in conjunction with schematic drawings of exemplary embodiments.
FIG. 1 shows an engine block of a piston internal combustion engine with reinforcing, rib-shaped components disposed in the longitudinal direction,
FIG. 2 shows an engine block with reinforcing components in the region of the crankcase,
FIG. 3 shows a modification of the embodiment form according to FIG. 1,
FIG. 4 shows a support of the crankshaft bearing on the crankcase via reinforcing, strut-shaped components,
FIG. 5 shows a partial detail of an engine block wall with a subsequently installed reinforcing component,
FIG. 6 shows a sectional representation of different exemplary embodiments for rib-shaped components cast integrally with the base material of the engine block,
FIG. 7 shows a sectional representation of a rib-shaped ceramic component, which is completely enclosed by the base material,
FIG. 8 shows a preferred embodiment form of an integrally cast rib,
FIG. 9 shows the rib shape according to FIG. 8 in a soldered-in embodiment form.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 shows an engine block 1 of a four-cylinder piston internal combustion engine whose upper section 2 constitutes the cylinder block and whose lower section 3 constitutes the upper part of the crankcase. The crankcase is enclosed on the underside with a tublike crankcase bottom (oil pan), not shown here. The cylinder block 2 and the crankcase 3 are embodied as one component, particularly in vehicle engines. To reinforce the structure, rib-shaped components 4, which extend in the longitudinal direction of the engine, are installed on the cylinder block 2 and likewise on the crankcase 3. These rib-shaped components 4 are comprised of a material which has a higher modulus of elasticity than the base material, preferably a ceramic material. If the engine block 1 is made for example of gray cast iron, then the components 4 have for example approximately three times higher a modulus of elasticity compared to the gray cast iron base material and about half the density of the base material. The thermal expansion coefficient is similar to that of gray cast iron so that a composite of gray cast iron and ceramic is not problematic from this standpoint. If aluminum is used as the base material, the components 4, for example with the use of aluminum oxide ceramic, have five times higher a modulus of elasticity than the base body at a similar density. Thus for example when gray cast iron is used for the base body, this kind of ceramic rib-shaped component 4, as shown in the drawing, has around 70% less mass than ribs of gray cast iron, with the same inherent stability. Rib-shaped components of this kind can be disposed on the crankcase 3, both on the outer wall and on the inner wall. In the apparatus shown, the rigidity of the engine block increases globally and above all locally, in particular with regard to the vertical engine axis, so that the production of vibrations is hindered and the amplitude of the vibrations produced by the engine block is decreased.
FIG. 2 shows an engine block in which, next to a rib-shaped component 4 of oxide ceramic which extends in the longitudinal direction of the engine and which is intended to reinforce the crankcase wall, ribs 5 and 6 are disposed, which criss-cross one another and which can also be made of ceramic.
FIG. 3 shows a modification of the form of embodiment according to FIG. 1. Here, the longitudinally extending rib-shaped components 4 are interrupted, i.e., segmented, in their longitudinal direction; the breaks are preferably provided in the region of the connecting points of the bearing walls with the outer walls of the engine block. By this means, the free oscillatory outer faces of the engine block structure are reduced in size, and the acoustic behavior of the engine block structure is audibly improved. Ribs of this kind lead to an increased impedance discontinuity at the break points 7 and consequently in particular to a reduction of the structure-borne sound transmission. The geometry of the break points can be embodied as wedge-shaped or trapezoidal, as shown for the region 7.1, or rounded, as shown for the region 7.2. This construction with short, segmented ribs takes into account the particular conditions of the brittle ceramic material. The construction with segmented ribs is also advantageous, however, in purely cast constructions.
FIG. 4 shows a vertical section through an engine block 1 in which the cylinder block 2 and the crankcase 3 are connected to each other in one piece. In this case, the support 8 for the main bearing is firmly connected to the engine block via a bearing wall 9, which is reinforced with ribs 10, 11, and is firmly connected to the wall of the crankcase 3 via additional strut-shaped ribs 12, 13, 14 so that an additional reinforcing is produced here. To increase the rigidity while at the same time reducing weight, it is provided that at least a part of the strut-shaped ribs 12, 13, and/or 14 is comprised of a ceramic material. Preferably the reinforcing ribs which are disposed perpendicular to the bearing wall 9 are either reinforced with ceramic material or are embodied entirely of ceramic material. As a result, the vibrations of the crankshaft bearing, which are critical for the transmission of structure-borne sound, are effectively suppressed both in the longitudinal direction of the engine and in the direction of the lateral engine axis and the vertical engine axis, and the input impedance at the main bearing is markedly increased. Moreover, this Figures shows the components 4 also being disposed on the coverings 20, 21.
FIG. 5 schematically represents a possibility of the connection of a rib-shaped component 4 to the wall of an engine block, for example with the wall of the crankcase 3. In this embodiment form, the component 4 is mounted subsequently on the crankcase 3; the connection is produced via an auxiliary material, for example a glue and/or by soldering or welding. In this connection, as FIG. 9 shows, it can be practical in manufacture to provide a channel-shaped recess in the wall of the engine block, into which recess the rib-shaped component 4 is inserted and attached to the corresponding wall region of the engine block by gluing, soldering, or welding.
As FIG. 6 shows, rib-shaped components 4 of this kind can already be introduced into the base material upon manufacture of the engine block by means of recasting a component of this kind. As the cross sectional form 4.1 shows, in this connection, the edge that is to be molded for the rib-shaped component has to be embodied as correspondingly thickened, and the thickening must be embodied as rounded, so that as a result, the stresses arising here become effective to a large extent in the form of compression of the surface of the component 4.1.
In the cross sectional form as shown for the rib-shaped component 4.2, an increase in rigidity of the ribs is produced by the fact that the freely exposed edge 16 is embodied as correspondingly thickened, so that a higher geometrical moment of inertia is produced with regard to the wall to be reinforced of the internal combustion engine. A further advantage of this embodiment is that an outer edge 16, which is thickened in this way, simultaneously produces good fixing-in in the form material. As FIG. 8 shows, the thickened region is imbedded in the form material 17 of the casting form so that only the end which is to be enclosed by the base material of the engine block to be produced protrudes from it. In this connection, the casting form has to be provided such that if possible, the wall thickness in the recasting region 18 is essentially constant, so that a "recasting crease" is produced, which encloses the rib-shaped component 4.2 with positive fit like a "molly screw".
This kind of rib-shaped component 4.2 of ceramic material, though, can also be affixed directly to the model so that the form sand surrounds the ribs having positive fit. Here, the undercuts can be filled by an easily vaporizable material, e.g. by wax, in order to prevent the penetration of sand. In a similar manner, ceramic components of this kind can also be integrated in sand cores or metal forms (permanent mold casting, die casting). In the lost foam process, the rib-shaped components 4 are inserted directly into the positive made of foam material.
Furthermore, FIG. 6 shows a cross section of a rib-shaped component 4.3.
The cross section according to FIG. 7 shows a rib-shaped reinforcement 19 in which a ceramic component 4 is completely enclosed by casting material. In this embodiment form, the complete enclosing is not provided over the entire length, since the component 4 of ceramic material to be recast must be fixed in the form, at least in its end regions.
In order to prevent so-called thermal shock when integrally casting components 4 of this kind, it is practical if the components 4 that are to be entirely or partially recast are heated immediately before casting. With electrically conductive ceramic materials, the preheating of the ceramic components in the sand form can be carried out inductively.
In the region of the cylinder block 2, the teaching according to the invention can be used not only by mounting ceramic components as shown in FIG. 1. In this region, it is also possible to dispose reinforcing components of ceramic material, for example cast integrally and suitably embodied, in the vicinity of the threaded vent, so that apart from the increase in rigidity with regard to dynamic stresses, an increase in rigidity with regard to static stresses is also produced. As a result, therefore, cylinder tube warping as a result of screwing forces can for example be minimized.
Oxide ceramic materials, in particular mixed ceramics or dispersion ceramics based for example on aluminum oxide, silicium oxide, or zirconium oxide and/or mixtures of these can be used as ceramic materials for the components. In addition to that, silicium nitrite (Si 3 ) or silicium carbide come under consideration, as well as FRC's (fiber reinforced ceramics) in general. The choice depends not only on the cost for these materials, but also on the stress involved.
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A piston engine which includes an engine block composed of a base material. The engine which block has a cylinder block with at least one cylinder formed therein, a piston located in the cylinder, and a crankshaft connected to the piston and being mounted on crankshaft bearings disposed in a crankcase of the engine block. The engine further includes a plurality of reinforcing components connected to the walls of the engine block. The reinforcing components are composed of a component material that is different from the base material and has a higher modulus of elasticity than the base material.
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BACKGROUND OF THE INVENTION
The present invention relates to a new and improved method of, and apparatus for, fabricating a substantially U-shaped body, especially a bifurcated or fork-type joint for a Cardan or universal joint from a blank or unfinished part, which is worked by cold impact or press forming while using dies and punches.
Different techniques are known in the art for fabricating a U-shaped body. In particular, such bodies are forged from one piece. This is associated with the drawback that the body subsequently must be heat-treated or tempered and there is required considerable material-removing finishing work, for instance it is necessary to subsequently carry out face milling and drilling operations.
Also, it is known to stamp such type bodies from sheet metal. Yet, this is associated with the drawback that the body does not possess adequate rigidity for many fields of application.
Additionally, it is also known to fabricate such bodies from two parts which are subsequently welded together. This, however, is associated with the disadvantage that the welding operation requires a relatively large amount of work.
Finally, it is also part of the state-of-the-art to fabricate such type bodies by cold impact or press forming techniques, for instance, as disclosed in U.S. Pat. Nos. 1,925,721 and 2,120,118. However, with these techniques the forming work is maintained as small as possible, so that equally the strength which is achieved by such cold working is relatively small. Moreover, splitting of the blank for forming both legs or leg members is associated with the disadvantage that there are formed sharp edges requiring a further machining operation.
SUMMARY OF THE INVENTION
Hence, it is a primary object of the present invention to provide a new and improved method of, and apparatus for, fabricating a substantially U-shaped body or part in a manner not associated with the aforementioned drawbacks and limitations of the prior art proposals.
Another and more specific object of the present invention is directed to avoiding the aforementioned drawbacks and devising a fabrication method, by means of which it is possible to produce relatively inexpensively, with very little subsequent machining work, and in large numbers, parts having great strength and accurate shape.
Still a further significant object of the present invention concerns a new and improved method of, and apparatus for, fabricating parts from a blank in an extremely efficient, reliable and accurate manner, with extreme production economies and conductive to mass-production operations.
Now in order to implement these and still further objects of the invention, which will become more readily apparent as the description proceeds, the method the present development is manifested by the features that during a first method step there is pressed-out or extruded from a substantially parallelepiped-shaped blank two legs or leg members with the aid of a first die and a first punch, and that during a second method step the extruded legs are brought into the final shape with the aid of a second die and a second punch.
Not only is the invention concerned with the aforementioned method aspects, but also relates to apparatus for the performance thereof. This apparatus, according to a first exemplary embodiment, is manifested by the features that for both method steps the die completely corresponds to the shape of the legs which are to be formed of the fork-type body, and that the part of the punch contacting the blank is flat. Further, according to a second exemplary embodiment of apparatus, it is contemplated that for both method steps the shape of the legs to be formed of the fork-type body is partially imparted by the dies and partially by the punch.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be better understood and objects other than those set forth above, will become apparent when consideration is given to the following detailed description thereof. Such description makes reference to the annexed drawings wherein:
FIG. 1 is a perspective view of a substantially U-shaped body or body member, in a semi-finished condition, and produced according to a first method of the invention;
FIG. 2 illustrates the same body as shown in FIG. 1 but in its finished state;
FIG. 3 illustrates in perspective view a different body, shown in a semi-finished state, and fabricated according to a second method of the invention;
FIG. 4 illustrates the same body as shown in FIG. 3, but in its finished condition or state;
FIG. 5 illustrates a die and a punch for carrying out the first method step during the production of the body or part illustrated in FIGS. 1 and 2;
FIG. 6 illustrates a die and a punch used during the second method step for fabricating the body or part illustrated in FIGS. 1 and 2;
FIG. 7 illustrates a die and a punch used during the third method step for the production of the body illustrated in FIGS. 1 and 2;
FIG. 8 illustrates a die and a punch used during the first method step for producing the body or part illustrated in FIGS. 3 and 4;
FIG. 9 illustrates a die and a punch used during the second method step for producing the body illustrated in FIGS. 3 and 4; and
FIG. 10 illustrates a die and a punch used during the third method step for producing the body illustrated in FIGS. 3 and 4.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Describing now the drawings, the substantially U-shaped body or part depicted in FIG. 1 will be seen to comprise two short legs or leg members 10 and an interconnecting web 12. The web 12 possesses at the side opposite both of the legs 10 a completely flat or planar fork base or bottom 13. The fork saddle 14 of the web 12, and which is located opposite the fork base 13, is markedly rounded both at the transistion to the legs or leg members 10 as well as also at the transition to the side surfaces 15.
Continuing, the substantially U-shaped fork-type body of FIG. 2 is formed by carrying out a further method step upon the body of FIG. 1. The legs 10 will be seen to possess at their lower region a portion 16 of smaller rectangular cross-section and at their top or upper region a portion 17 of larger rectangular cross-section. These cross-sections are rounded at all of the four corners. Also, at the transitions between the upper and lower portions or regions there are provided rounded portions. At the web 12 there is provided a blindhole bore 36. Also with this body there is present a completely flat fork base or bottom 13 having relatively sharp edges. All of the other edges are rounded.
The body or part shown in FIG. 3 will be seen to possess two legs or leg members 18, the free ends 19 of which have a smaller cross-section than the remaining cross-section of each such leg. The web 20 is arranged parallel to the legs 18 and has a bore 21. In contrast to the body shown in FIG. 1, with this body of the illustration of FIG. 3 the fork base 22 opposite the legs or leg members 18 is markedly rounded at all edges. Furthermore, the fork saddle 11 is constructed to be completely flat. The substantially U-shaped body shown in FIG. 4 has been produced by carrying out a further method step or operation upon the body depicted in FIG. 3. This body, which is produced according to a different method than the method employed in fabricating the body of FIG. 2, differs from the body of FIG. 2 by the following features:
(a) The fork base or bottom 22 is rounded at all four corners;
(b) The leg ends do not possess any flattened portions;
(c) The fork saddle 11 is completely flat.
Based upon the showing of FIGS. 5 to 10 there will be hereinafter described both of the manufacturing techniques for these U-shaped bodies or parts.
According to the showing of FIG. 5 there is formed between a die 23 and a punch 24, by cold working, a substantially parallelepiped body 26 from a cylindrical rod section. The punch 24 and the die 23 possess rounded portions 25 at their respective work surfaces, so that there are not formed any sharp edges during the forming work. The die 23 is secured by means of a ring-shaped holder 27 to a conventional and therefore not particularly illustrated press.
In FIG. 6 the parallelepiped-shaped body 26 has been introduced into a different die 28 and is cold worked by a punch 29 into a substantially U-shaped body or part. For this purpose, the die 28 possesses two recesses or depressions 30, corresponding to the shape of the legs or leg members 10. To facilitate removal of the U-shaped body out of the die 28 there is provided an ejector pin 31. The die 28, like the die 23, is attached in the holder 27.
As shown in FIG. 7, the U-shaped body produced in the described manner, is inserted during a further working or method step into another die 32. This die 32 possesses longer recesses 33, into which there is pressed or extruded the U-shaped body, by cold working, with the aid of a punch 34. This punch 34 contains a pin 35 for forming the blindhole bore 36. Pin 35 can be provided with teeth, by means of which it is possible to produce internal teech 36a in bore 36, as best seen by referring to FIG. 2. In order to remove the U-shaped body from the die 32 there are required the two ejector pins 37 or equivalent structure. The die 32 is surrounded by a ring 38 and inserted into the holder 27.
With this method the shape of the U-shaped body or part is essentially determined by the die 32. The punch 34 only produces the flat or planar surface 13. In contrast thereto, according to a different method, which will be described more fully hereinafter in conjunction with FIGS. 8 to 10, the shape of the body is determined both by the die as well as also by the punch.
With this other method there is formed, during a first method step, as best seen by referring to FIG. 8, again a substantially parallelepiped-shaped body 26 from a strand section, by cold working, with the aid of a die 39 and a punch 40.
In a second method step, shown in FIG. 9, the legs or leg members 18 are formed with the aid of a die 42 and a punch 43. For ejecting the workpiece there is required an ejector pin 44 or an equivalent structure. A pin member 45 can be provided with teeth, by means of which there is produced the internal teeth of the bore 21. To preserve clarity in illustration and to simplify the showing of the drawings the internal teeth have not been shown in FIGS. 3, 4 and 9 but may be similar to the teeth 36a of FIG. 2. The die 42 is either rounded in such a manner that also the leg ends 19 are rounded, or, during a subsequent method step, the leg ends 19 are rounded by stamping, as shown in FIGS. 3 and 4.
Finally, during a third method step the legs 18 are bent to the shape shown in FIG. 10. For this purpose there is provided a die 46 which, as illustrated, has a pin 50 for ejecting the finished body or part. For linearly guiding the body there is provided in the punch 47 a displaceable guide pin 48. Instead of upwardly ejecting the finished body out of the die 46 with the aid of the ejector pin 50, it is possible for the die to be open at its bottom, so that it is possible to push out the body with the aid of the punch 47 through the die 46. With this method step the web 20, as best seen by referring to FIG. 10, no longer is altered in its width. However, under certain circumstances it can be advantageous, during bending-up of the legs 18, to simultaneously decrease the width of the web 20. The die 46 preferably possesses grooves 51 into which there can be inserted the legs of the body as shown in FIG. 3.
This cold press or impact forming of U-shaped bodies, in contrast to heretofore known fabrication techniques has the following advantages:
(a) The requisite strength is attained by the cold working. A heat-treatment of the body is no longer necessary.
(b) Bores can be produced by cold working without any additional work operation.
(c) It is equally possible to produce by cold working, without any additional working step, the internal teeth.
(d) Such a U-shaped body can be formed to be more rigid, by cold working, than by stamping of sheet metal parts.
(e) Due to the cold press forming it is possible to avoid the need for the complicated heating of the body, which otherwise is necessary during forging. Hence, the dimensional accuracy or shape of the bodies is much greater.
(f) There is no need for removing burrs from forged parts.
The method aspects of the invention generally require the following method or working steps:
(a) Shearing of sections from round rod material or rods having a different cross-section;
(b) Flat pressing of the cylindrical sections into parallelepiped-shaped or flattened bodies;
(c) Pre-pressing these bodies into U-shaped bodies;
(d) Final pressing of the U-shaped body into its final shape and when necessary, erection of the legs from the position of FIG. 3 into the position of FIG. 4.
The pre-pressing can be dispensed with in certain instances.
While there are shown and described present preferred embodiments of the invention, it is to be distinctly understood that the invention is not limited thereto, but may be otherwise variously embodied and practiced within the scope of the following claims. ACCORDINGLY,
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A method of, and apparatus for, fabricating a substantially U-shaped body, especially a fork-type joint of a Cardan or universal joint from a blank which is worked by cold press forming while using dies and punches. During a first step there is extruded from a substantially parallelepiped-shaped blank two leg members with the aid of a first die and a first punch, and during a second step the pressed-out or extruded legs are brought into a final shape with the aid of a second die and a second punch.
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BACKGROUND
[0001] 1. Technical Field
[0002] The present disclosure relates to electrostatic discharge (ESD) protection, and particularly to an interface circuit with an ESD protection circuit.
[0003] 2. Description of Related Art
[0004] ESD protection is generally important in electrical device design to prevent or minimize damage to the device not from static electricity. ESD protection circuits are particularly important in interface circuitry.
[0005] Referring to FIG. 3 , a typical interface circuit 1 includes an interface 11 and two ESD protection circuits 12 . The interface 11 includes a first pin 110 and a second pin 111 . The two pins 110 , 111 are grounded via the two ESD protection circuits 12 , respectively.
[0006] The ESD protection circuit 12 includes a first diode 121 , a second diode 122 , a first Zener diode 123 , and a second Zener diode 124 . A positive electrode of the first diode 121 is connected to the positive electrode of the first Zener diode 123 . The second pin 111 is connected to a negative electrode of the first diode 121 and is grounded via the series connected first diode 121 and the first Zener diode 123 . The second pin 111 is also connected to a negative electrode of the second Zener diode 124 and is grounded via the series connected second Zener diode 124 and the second diode 122 .
[0007] In the interface circuit 1 , each pin needs an ESD protection circuit 12 , and each ESD protection circuit 12 includes two diodes and two Zener diodes. The Zener diode is expensive, and costs of the interface circuit 1 are increased, especially where many Zener diodes are needed.
[0008] What is needed, therefore, is an interface circuit with an ESD protection circuit that can overcome the described limitations.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] FIG. 1 is a circuit diagram of a first embodiment of an interface circuit with an ESD protection circuit according to the present disclosure.
[0010] FIG. 2 is a circuit diagram of a second embodiment of an interface circuit with an ESD protection circuit according to the present disclosure.
[0011] FIG. 3 is a circuit diagram of a conventional interface circuit.
DETAILED DESCRIPTION
[0012] Reference will now be made to the drawings to describe various embodiments of the present disclosure in detail.
[0013] Referring to FIG. 1 , an interface circuit with an electrostatic discharge (ESD) protection circuit 2 includes an interface 21 and an ESD protection circuit 22 . The interface 21 includes a first pin 210 and a second pin 211 . The interface 21 may be high definition multimedia interface (HDMI), video graphic array (VGA), digital visual interface (DVI), and/or USB interface.
[0014] The ESD protection circuit 22 includes a first polarity signal enable circuit 23 , a second polarity signal enable circuit 25 , and an ESD circuit 24 . The first pin 210 is grounded via the series connected first polarity signal enable circuit 23 and the ESD circuit 24 . The second pin 211 is grounded via the series connected second polarity signal enable circuit 25 and the ESD circuit 24 .
[0015] The first polarity signal enable circuit 23 includes a first positive polarity signal enable circuit 231 and a first negative polarity signal enable circuit 232 . The second polarity signal enable circuit 25 includes a second positive polarity signal enable circuit 251 and a second negative polarity signal enable circuit 252 . The ESD circuit 24 includes a positive ESD circuit 241 and a negative ESD circuit 242 . In this disclosure, the first positive polarity signal enable circuit 231 includes a first diode 221 . The first negative polarity signal enable circuit 232 includes a third diode 223 . The second positive polarity signal enable circuit 251 includes a second diode 222 . The second negative polarity signal enable circuit 252 includes a fourth diode 224 . The positive ESD circuit 241 includes a first Zener diode 225 , and the negative ESD circuit 242 includes a second Zener diode 226 .
[0016] A positive electrode of the first diode 221 and a negative electrode of the third diode 223 are both connected to the second pin 211 . A positive electrode of the second diode 222 and a negative electrode of the fourth diode 224 are both connected to the first pin 210 . A negative electrode of the first diode 221 and a negative electrode of the second diode 222 are both connected to a negative electrode of the first Zener diode 225 . A positive electrode of the third diode 223 and a positive electrode of the fourth diode 224 are both connected to a positive electrode of the second Zener diode 226 . A positive electrode of the first Zener diode 225 and a negative electrode of the second Zener diode 226 are both grounded.
[0017] A breakdown voltage of the first Zener diode 225 and the second Zener diode 226 is substantially higher than a normal working voltage of the first and the second pins 210 , 211 . With this parameter, the first and the second pins 210 , 211 are prevented from being grounded when the first and the second pins 210 , 211 are working normally.
[0018] In operation, positive electrostatic pulses of the first pin 210 are guided to ground via the second diode 222 and the first Zener diode 225 . Negative electrostatic pulses of the first pin 210 are guided to ground via the fourth diode 224 and the second Zener diode 226 . Positive electrostatic pulses of the second pin 211 are guided to ground via the first diode 221 and the first Zener diode 225 . Negative electrostatic pulses of the second pin 211 are guided to ground via the third diode 223 and the second Zener diode 226 .
[0019] Unlike the conventional interface circuit, in the interface circuit 2 , the first and the second pins 210 , 211 are grounded via the first polarity signal enable circuit 23 , the second polarity signal enable circuit 25 , and the ESD circuit 24 . The ESD circuit 24 is shared by the first and the second pins 210 , 211 . Therefore, the number of required Zener diodes is few, keeping the cost low.
[0020] FIG. 2 shows a second embodiment of an interface circuit 3 , differing from interface circuit 2 of the first embodiment only in the inclusion of an interface 31 including a first pin 310 , a second pin 311 , and a third pin 312 . Correspondingly, an ESD protection circuit 32 of the interface circuit 3 includes a first polarity signal enable circuit (not labeled), a second polarity signal enable circuit (not labeled), a third polarity signal enable circuit (not labeled), and a shared ESD circuit (not labeled). The interface circuit 3 has advantages similar to those of the interface circuit 2 . Furthermore, if an interface of an interface circuit has more pins, the interface circuit is more economical.
[0021] Further and/or alternative embodiments are described as follows. In the first embodiment, one of the four diodes 221 , 222 , 223 , 224 may be grounded via a third Zener diode rather than the ESD circuit 24 . For example, the first diode 221 may not be grounded via the first Zener diode 225 , but rather via a third Zener diode. In another embodiment, the first pin 210 is grounded via only the second diode 222 and the first Zener diode 225 , and the second pin 211 is grounded via only the first diode 221 and the first Zener diode 225 . That is, each of the first polarity signal enable circuit 23 and the second polarity signal enable circuit 25 includes only one diode, and the ESD circuit 24 includes only one Zener diode. The first polarity signal enable circuit 23 and the second polarity signal enable circuit 25 share the Zener diode.
[0022] It is to be understood that even though numerous characteristics and advantages of the present embodiments have been set out in the foregoing description, together with details of the structures and functions of the embodiments, the disclosure is illustrative only, and changes may be made in detail, especially in matters of shape, size, and arrangement of parts within the principles of the disclosure to the full extent indicated by the broad general meaning of the terms in which the appended claims are expressed.
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An exemplary interface circuit with an electrostatic discharge (ESD) protection circuit includes an interface and an ESD protection circuit. The interface includes at least two pins. The ESD protection circuit includes at least a first polarity signal enable circuit, a second polarity signal enable circuit, and an ESD circuit. The at least two pins are grounded via the at least first polarity signal enable circuit, the second polarity signal enable circuit, and share the same ESD circuit.
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BACKGROUND OF THE INVENTION
Information bearing cards are widely used for credit, fare and informational purposes, and it is common to locate the information bearing indicia upon magnetic strips attached to the card rear face. As such cards are carried in purses and billfolds, and repeatedly handled, the cards become bent, dirty, scratched, and otherwise damaged, and the magnetic strip often becomes damaged to the extent wherein the card is no longer useable to its intended purpose. The information indicia is magnetically stored upon the magnetic strips, and scratches and abrasions upon the strip can adversely affect the readability and interpretation of the information stored thereon as electronically sensed.
In order to protect information bearing cards utilizing magnetic strips a wide variety of card holders are available for use in pocket or purse, and while such holders provide greater protection than loosely carrying the card, holders specially designed to protect the magnetic strip have not been widely available, or used.
Card holding devices are known, such as shown in U.S. Pat. Nos. 2,090,856; 2,647,071 and 2,725,913, and the protective holder shown in U.S. Pat. No. 4,141,400 is especially designed to protect a card having a magnetic strip. However, protective card holders of the type previously known are either too expensive, bulky, or difficult to use, to be widely acceptable.
It is an object of the invention to provide a holder for information bearing cards which adds little bulk to the card, and may be readily utilized without requiring unusual handling or dexterity.
Another object of the invention is to provide a protective holder for information bearing cards wherein the holder may be economically produced, and the front face of the card is substantially fully visible while mounted in the holder permitting the card and holder to be filed and stored.
A further object of the invention is to provide a protective holder for information bearing cards utilizing a magnetic strip upon the reverse face wherein the magnetic strip is spaced from the holder structure to prevent abrasion and wear due to contact with the holder.
Another object of the invention is to provide a protective holder for information bearing cards wherein the holder and card may be used together in permanent files, or readily carried in purse or pocketbook, and in any use provides protection for information bearing magnetic strips attached to the card rear face.
Yet another object of the invention is to provide a protective holder for information bearing cards formed of a synthetic plastic extrusion, and wherein the holder includes means for firmly retaining the card therein, yet permits the card to be readily removed from the holder.
In the practice of the invention the card holder is formed of a synthetic plastic extrusion to define a body which includes a substantially flat primary wall portion having end edges and parallel lateral edges along the upper and lower regions of the body. The lateral edges each include a lip formed of the body material which is folded over 180° to define a cantilevered lip superimposed over the flat wall portion, and spaced therefrom, wherein the lips each define an elongated pocket which is open at each end of the holder body. The pockets are spaced from each other a distance to permit reception of the upper and lower edges of a conventional information bearing card, such as a credit or fare card, and the "thickness" of the pockets is such to firmly engage the card to frictionally maintain the assembly of the card and holder, and yet permit the card to be readily slipped from the confines of the holder.
Adjacent at least one of the lateral edges of the holder, and preferably located within a lateral edge pocket, is a card supporting projection in the form of a raised shoulder which engages the rear face of a card located within the holder adjacent the card lateral edge nearest the magnetic strip attached to the card rear face. The purpose of the shoulder surface is to hold the portion of the rear face of the card upon which the magnetic strip is located away from the body wall portion to protect the magnetic strip against contact and abrasion with the holder during insertion or removal of the card with respect to the holder, and while the card is stored therein.
The card is placed within the holder by inserting the card lateral edges within the holder pockets, and longitudinally sliding the card with respect to the holder. Removal of the card from the holder is, likewise, accomplished by sliding the card lengthwise with respect to the holder and pockets. Preferably, finger notches are defined in the end edges of the holder to facilitate grasping of the card for removal or insertion into the holder.
The shouldered surface for supporting the card rear face out of engagement with the body wall need only be located adjacent one of the holder lateral edges as long as the card is always inserted into the holder with the magnetic strip located adjacent the holder lateral edge having the shoulder surface. However, it is within the scope of the invention to locate a shouldered surface at each lateral edge of the holder, i.e. adjacent each holder pocket, and such a modification does not change the basic inventive concepts.
BRIEF DESCRIPTION OF THE DRAWINGS
The aforementioned objects and advantages of the invention will be appreciated from the following description and accompanying drawings wherein:
FIG. 1 is an elevational view of the holder, illustrating a typical information bearing card in alignment therewith prior to insertion into the holder,
FIG. 2 is an enlarged end view of the holder as taken along Section II--II of FIG. 1,
FIG. 3 is an enlarged, elevational, sectional, detail view of the upper holder lateral edge as taken along Section III--III of FIG. 1,
FIG. 4 is an enlarged, elevational, detail, sectional view of the lower holder lateral edge as taken along Section IV--IV of FIG. 1, and
FIG. 5 is an enlarged end view of the holder of the invention with an information bearing card mounted therein.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The overall appearance of the protective card holder in accord with the invention will best be appreciated from FIGS. 1 and 2. The holder comprises a synthetic plastic body 10, readily formed as an extrusion, wherein an elongated extruded strip having the cross sectional configuration of the holder is severed into the desired lengths to form a plurality of bodies 10 on a high production basis.
The holder body 10 includes a flat wall portion 12 having a flat inner surface 14, and a flat outer surface 16. Further, the body 10 includes an upper lateral edge 18, a lower lateral edge 20, and linear end edges 22 which are notched at 24 to facilitate grasping of a card within the holder, as will be later apparent.
The lateral edges 18 and 20 are parallel to each other, and are each defined by a folded-over lip portion which forms an elongated open-ended pocket. The upper lateral edge 18 includes a portion 26 transversely disposed to the plane of the wall portion 12, and the cantilevered lip 28 extends downwardly from the portion 26, and the lip end 30 is disposed obliquely "back" toward the plane of the wall portion. Thus, the lip 28 defines a pocket 32 opening downwardly which receives the upper edge of the card to be held, as later described.
The lower lateral edge 20 includes a portion 34 transversely disposed to the plane of the wall portion 12, and the cantilevered lip 36 extends upwardly from the portion 34 terminating in the free end 38. The lip 36 includes inner surface 40 upon which the elongated rib 42 is defined which projects from the inner surface toward the wall portion 12. It will be appreciated that the lip 36 and wall portion define an elongated open-ended lower pocket 44.
The upper region of the body 10, adjacent the upper lateral edge 18, includes a card supporting surface for holding the upper portion of the card in spaced relationship to the wall portion 12. In the preferred arrangement this card supporting projection comprises a shoulder surface 46, FIG. 3, located adjacent the edge 18 within the upper pocket 32. The shoulder surface 46 extends from the plane of the wall portion inner surface 14 a distance at least equal to, and preferably greater than, the distance that a magnetic strip protrudes from the rear face of the information bearing card retained within the holder. The surface 46 is of an elongated form extending throughout the length of the body 10, as formed during the extrusion thereof, and is spaced from the inner surface of the lip 28 and end 30 a distance slightly greater than the thickness of the information bearing card to be held within the holder.
The type of information card 48 with which the holder of the invention is utilized is shown at the right in FIG. 1, and is also represented in FIG. 5 as associated with the holder. The card is of a rectangular form having a flat body defined by an upper edge 50, a lower edge 52, and parallel end edges 54. The card includes a flat front face 56, a flat rear face 58, and a magnetic tape strip 60 is attached to the rear face of the card usually extending the length thereof, and disposed adjacent the upper edge 50 in parallel relationship thereto. The magnetic strip 60 constitutes the storage for magnetic information bearing portions whereby the strip may be "read" by conventional magnetic tape reading apparatus. Information bearing cards of the aforedescribed type are widely used in financial transactions as credit cards, transit fare cards, and for computerized accounting purposes.
To place the information bearing card 48 within the holder body 10 the card and holder are aligned in an end-to-end relationship. The alignment may be as shown in FIG. 1 wherein the upper and lower lateral edges of the card and holder are substantially aligned, or the lower edge 52 of the card adjacent the left edge 54 may be placed within the holder lower pocket 44 adjacent end 22, initially, and the card pivoted upwardly to insert the card upper edge 50 into the upper holder pocket 32. Once the upper and lower edges of the card are located within the holder upper and lower pockets 32 and 44, respectively, the card is slid within the pockets to substantially align the end edges of the card and holder wherein the card rear face 58 will be in superimposed relationship to the holder wall portion inner surface 14.
As will be appreciated from FIG. 5, the rear face of the card adjacent the upper edge 50 engages the holder shoulder surface 46 causing the upper portion of the card to be "tilted" forwardly with respect to the holder wall portion 12. This "tilting" of the card 48 within the holder produces sufficient clearance and spacing between the upper portion of the card rear face 58 and the holder inner surface 14 to prevent engagement of the magnetic strip 60 with the body inner surface 14, thereby preventing scratching and abrasion to the magnetic strip while it is being inserted into the holder, or removed therefrom.
The thickness of the pocket 32 is, preferably, slightly greater than the thickness of the card 48, while the "thickness" of the lower pocket 44 as defined by the distance between the rib 42 and the opposed portion of the body inner surface 14, is slightly less than the card thickness. Thus, a frictional engagement exists between the card and the holder within the pocket 44 preventing the card from accidentally slipping from the holder. However, the frictional engagement of the card as determined by the natural resiliency of the lip 36 does not produce such a force as to render insertion and removal of the card from the holder difficult.
With the card 48 assembled to the holder body 10 in the manner described above, the magnetic strip 60 is fully protected by the holder wall portion 12, and cannot be damaged even though the assembled card and holder are loosely carried within a pocket or purse. Further, as the lips 28 and 36 are of short length, the lip 36 being slightly longer than the lip 28, they "cover" only the marginal upper and lower edge regions of the card thereby permitting the front face 56 of the card to be fully visible, which is important if the assembled holder and card are stored within drawers or racks for accounting purposes.
The finger notches 24 aid in grasping the card for removing the same from the holder, however, these finger notches are not required. Also, it is anticipated that logos, advertising material, or similar indicia will be imprinted upon the body inner surface 14 for advertising and promotional purposes, which will aid the user in determining the orientation of the holder upper and lower edges.
In the disclosed embodiment only a single shoulder surface 46 is illustrated, i.e. adjacent the body upper lateral edge 18. However, it is within the scope of the invention to locate a similar card supporting shoulder surface within, or adjacent, the lower pocket 44 wherein specific orientation of the card to the holder is not required to insure that the card magnetic strip will be spaced from the body inner surface 14. Also, a variety of lip configurations, and pocket forms, could be utilized, and it is appreciated that further modifications to the disclosed embodiment may be apparent to those skilled in the art without departing from the spirit and scope of the invention.
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The invention pertains to a protective holder for information bearing cards, such as credit cards, wherein the card includes a magnetic strip affixed to the rear face upon which information is magnetically stored. The holder comprises a substantially flat body having folded-over lips at the upper and lower lateral edges which define pockets for receiving the lateral edges of the card. Adjacent at least one of the holder lateral edges is a card supporting surface projecting beyond the primary body surface of the holder which maintains a spacing between the rear of the card and the body surface to prevent contact of the card magnetic strip and holder and protect the strip.
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BACKGROUND OF THE INVENTION
This invention relates to the rinsing of surface-treated articles, and more particularly to a counterflow spray rinse process for surface-treated articles.
Articles, whose surfaces have been chemically or electrochemically treated, such as by electroplating or galvanizing, require rinsing in order to remove the residue or adhering substances from the articles, before further processing.
It is known in the art to utilize a plurality of rinse tanks filled with water so that the chemically treated article is rinsed in stages to gradually remove the concentrated solution or residue. In such a process, the first rinse tank gradually becomes more concentrated than each subsequent rinsing tank, because more residue is removed from the article in the first rinse tank than in any subsequent rinse tank. Eventually, the rinse tank has to be drained and refilled with substantially pure water. Moreover, as the original processing bath continues to receive and treat the article with the concentrated solution, the original processing solution becomes diluted, and the chemicals have to be replenished and the excess water removed, usually by draining. Sometimes the water is removed by evaporation.
It is also known in the the art to re-cycle the rinse water by processing it in an ion-exchange installation in order to detoxify the water. However, such recovery processes are expensive.
Other methods of rinsing articles whose surfaces have been treated with chemical or elector-chemical processes are shown in the following U.S. Pat. Nos:
3,734,108--Almegard et al--May 22, 1973
4,452,264--Kreisel et al--June 5, 1984
Both the Almegard and Kreisel patents disclose as prior art, a counterflow process, in which water flows in a cascade arrangement serially from one rinse tank to another in the direction opposite the movement of the treated article, so that the water in the rinse tank closer to the treatment tank becomes progressively enriched with the residual substance. When numerous rinse tanks are employed in the counterflow cascade process, pumps must be utilized in order to pump the water from one tank to the next. In such a cascade process, although conserving fresh water, the pumping of such large volumes of water becomes expensive.
Both the Almegard and Kreisel patents also disclose that it is old to spray-rinse an article whose surface has been chemically or electro-chemically treated. However, the spray processes disclosed in both Almegard and Kreisel utilize a single spraying chamber, and in some instances, the spray chamber is made mobile so that it can be utilized to spray-rinse articles at several different treatment tanks.
However, neither Amegard nor Kreisel, nor any other prior art known to the applicant, discloses a rinse process incorporating a pulse spray counterflow principle which is most applicable for rinsing chemically or electro-chemically treated articles, such as copper-, nickel-, zinc-, or chrome-plated articles.
Submersible pumps having a pump chamber with an inlet check valve for receiving a fluid in which the pump chamber is submerged, and also provided with a compressed air inlet for receiving compressed air to discharge the fluid from the pumps, are well known in the art, as shown in the following U.S. Pat. Nos:
129,353--Lytle--July 16, 1872
1,072,562--DeLissaBerg--Sept. 9, 1913
2,171,402--Muir--Aug. 29, 1939
3,552,884--Faldi--Jan. 5, 1971
However, none of the above patents disclose the above submersible pumps used in combination with a counterflow spray rinse process for surface treated articles.
SUMMARY OF THE INVENTION
It is therefore an object of this invention to provide a counterflow spray rinse process and apparatus for surface-treated articles, such as chemically plated articles, by establishing a plurality of sequential rinse tanks or baths, and spraying the article over each bath with a rinse solution of lesser concentration from the next succeeding bath.
In the process carried out in accordance with this invention, the spray apparatus is set up over each of the rinse tanks and optionally over the original chemical treatment or processing tank, and each sprayer is connected to a pump in fluid communication with the next succeeding bath having a more dilute rinse solution.
Also, in accordance with this process, the surface-treated article to be rinsed, is moved from the chemical process tank or bath to a position over a first rinse tank, where it is lowered and immersed in the first rinse bath for a predetermined time. The article is then lifted from the first rinse bath and simultaneously sprayed with the dilute solution from the next or second rinse bath. The article is then transported to a position over the second tank where the article is lowered and immersed in the second rinse bath. The article is subsequently sprayed, as it rises from the second bath, with a more dilute solution from the third rinse bath. This process is continued until the article is finally rinsed with substantially pure water.
The number of rinse baths or tanks and spray apparatus may vary, depending upon the concentration of the original processing solution and the degree of rinsing required.
In a preferred form of the apparatus utilized in the rinsing process in accordance with this invention, submersible pumps are preferably used in each of the rinse baths. A spray apparatus is located on the top of each bath with spray heads directed toward each other to spray both sides of an article in spraying position over the corresponding bath. Each spray apparatus is connected to a pump submerged in the next succeeding bath. The pumps are preferably powered by compressed air.
A transfer mechanism is utilized for transporting the articles from one bath to the next bath and for raising and lowering the article into and out of immersion in the corresponding bath.
The transfer mechanism and the spray apparatus are timed by appropriate timer controls so that the spray apparatus is actuated only as the article is lifted from its corresponding bath.
With a process utilized in accordance with this invention, pure water is applied to the article only by the final spray apparatus.
While the article to be rinsed sequentially encounters less concentrated rinsing solutions, the rinsing solutions are counterflowing in the opposite direction from the movement of the article. Thus, while each bath is receiving a more dilute solution from the discharging spray apparatus, the same bath is also receiving more concentrated solutions from the material removed from the immersed plate or article. Thus, when the spray heads discharge a rinse solution over the original processing bath, the processing bath is being replenished by some of the chemicals which it originally possessed. Accordingly, the supply of other replenishment chemicals may be reduced from the requirements of conventional surface treatment processes. Moreover, since the chemicals are being recycled, they need not be treated as waste products.
Furthermore, substantially reduced quantities of pure water are required for the entire rinsing process.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a fragmentary side elevation of an apparatus, shown schematically, for carrying out the counterflow rinse process in accordance with this invention;
FIG. 2 is a fragmentary top plan view of the apparatus disclosed in FIG. 1, with only a portion of the overhead conveyor disclosed, and illustrating the spray patterns over the respective baths; and
FIG. 3 is an enlarged sectional elevation of a submersible pump used in the counterflow spray system for carrying out this invention, with portions broken away.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to the drawings in more detail, FIGS. 1 and 2 disclose an apparatus 10 carrying out the counterflow spray rinse process in accordance with this invention. The apparatus 10 includes a surface treating tank, such as a metal plating tank or bath 11 filled with a chemical solution for treating an article, such as the metal plate 12.
Located in succession or series with the chemical processing tank 11 are a first rinse tank 13, a second rinse tank 14, a third rinse tank 15, and a subsequent process or treating tank 16. It will be understood that more or fewer rinse tanks may be employed, depending upon the requirements of the rinsing process. Each of the rinse tanks 13, 14, and 15 is originally filled with pure water. The chemical treatment bath or tank 11 is originally filled with the desired chemical solution at the desired concentration for the proper treatment, such as metal plating, of the article 12.
Mounted on top of the treatment tank 11, is a spray apparatus 18, including a pair of opposed spray heads 19 and 20. Each spray head 20 is directed toward an opposite side of the article 12, when the article 12 is in an elevated spray position above the tank 11 as disclosed in phantom in FIG. 1. The attitude of each spray head 19 and 20, as well as the width of its particular spray path, is such that each spray head 19 and 20 will discharge its solution in the spray patterns 21 and 22, illustrated in FIG. 2, to completely cover both sides of the article 12.
The spray heads 19 and 20 are connected by the respective branch fluid conduits 23 and 24 to a discharge conduit 25 from a submersible pump 26, submerged in the rinse bath of the first rinse tank 13, as illustrated in FIGS. 1 and 2. As best disclosed in FIG. 3, the discharge conduit 25 extends downward, almost to the bottom of the pump housing 27. The pump housing 27 includes a check valve, such as a diaphragm or a ball check valve 28, adapted to open and close a rinse solution inlet port 29. In the top of the pump housing 27 is an air inlet port 30 in fluid communication with an air supply conduit 31, which is supplied with compressed air from a source, not shown, but indicated in FIG. 1.
As best disclosed in FIGS. 1 and 2, the air line or conduit 31 preferably includes a pair of air filters 32 and 33, a pressure regulator 34, and a timer control solenoid valve 35. The solenoid valve 35 may be connected through the electrical line 36 to a timer control 37 of any conventional design, or to the transfer mechanism controls, not shown.
In the operation of the spray heads 19 and 20, when the solenoid valve 35 is open to admit the passage of compressed air, the compressed air enters the top of the pump housing 27, through the inlet 30, to force the check valve 28 to a closed position over the liquid inlet 29. The air forces the rinse solution contained within the housing 27 up through the discharge conduit 25, the branch conduits 23 and 24, and out through the spray heads 19 and 20 upon the opposite sides of the plate 12 as the plate 12 rises between the spray heads 19 and 20 over the treatment tank 11.
It will be noted, particularly in FIGS. 1 and 2, that the fluid discharged through the spray heads 19 and 20 is derived from the contents of the first rinse tank 13. Thus, since the liquid solution in the first rinse tank 13 is of lesser concentration than the checmical solution in the treatment tank 11, a dilute spray solution will be sprayed upon both sides of the plate 12 over the tank 11, as the plate 12 is lifted from immersion in the solution of the tank 11, to increase the rinsing efficiency. After the rinse solution impinges upon the surfaces of the article 12, it falls into the more concentrated chemical solution of the tank 11, thereby diluting the original chemical solution to some degree.
In a somewhat similar arrangement, a spray apparatus 18' with spray heads 19' and 20' is mounted on top of the first rinse tank 13, while its supply pump 26' is immersed in the next succeeding rinse tank 14, as disclosed in FIGS. 1 and 2. Like parts are identified with prime reference numerals.
Also, a similar spray apparatus 18" with spray heads 19" and 20" are mounted on top of the second rinse tank 14 with their supply pump 26" immersed in the rinse solution of the third rinse tank 15. In a similar manner, like parts are identified by double-prime reference numerals.
Each of the pumps 26' and 26" is supplied with compressed air through the air branch lines 31' and 31", respectively, each of which is connected to the main air supply line 31.
As disclosed in the drawings, another rinse spray apparatus 118 having spray heads 119 and 120 is mounted upon the third rinse tank 15 with the branch conduits 123 and 124, connected to a pure water supply line 125, which in turn is connected to a source of pure water, not shown. In order to control the flow of water through the water line 125 to the spray apparatus 118, a solenoid fluid valve 135 is mounted in the line and connected through electrical line 136 to the timer control 137, or to the transfer mechanism controls, not shown.
Thus, each of the spray apparatus 18' and 18" spray a rinse solution upon a plate or article 12 as the article rises through a spraying position over the particular rinse tank upon which the spray heads are mounted. However, the corresponding rinse solution is of lesser concentration than the concentration of the bath over which the article 12 is sprayed, because the rinse solution is supplied through a corresponding pump 26' or 26" in the next succeeding rinse tank.
On the other hand, the spray apparatus 118 sprays pure water upon the plate 12 as the plate rises from immersion in the tank 15. Thus, a rinse solution sprayed by the spray apparatus 118 is also of lesser or weaker concentration than the solution within the tank 15.
Because of the differences in the number of times the plate 12 is immersed as it advances from one successive rinse tank to the next, the concentration of each rinse solution is at any time, greater than the rinse solution in the next successive rinse tank.
The article or plate 12 may be advanced from the chemical processing or treatment tank 11 to each successive rinsing stage 13, 14, and 15 by any convenient type of transfer machanism, such as the overhead conveyor mechanism 40. The overhead cohveyor 40 may include an endless conveyor chain 41 from which are suspended a plurality of trolleys 42 having wheels 43 guided on an overhead rail 44. Each of the trolleys or brackets 42 may carry a small electrical motorand windlass 45 about which is wound a flexible cable 46. The lower end of each cable 46 is provided with a connector or clamp 47 for gripping a corresponding article or plate 12 as the plate 12 is being transported from one tank to another.
The chain or cable 41 may be moved by a sprocket or pulley 49 driven by the motor 50.
In carrving out the process according to this invention with the apparatus 10, a plate 12 is secured by a clamp 47 to one of the cables 46 of a windlass 45. The motor 50 is energized to drive the chain forward in the direction of the arrows disclosed in FIGS. 1 and 2. The plate 12 is moved by the trolleys 42 in an elevated position above the tanks 11-16.
When the plate 12 arrives at the desired position over the chemical plating or processing tank 11, the timer control 37 is actuated to stop the motor 50 and energize the windlass 45 to lower the plate 12 in the direction of the arrow, so that the plate 12 is immersed in the tank 11. The windlass motor 45 is then stopped for a predetermined time while the plate 12 is plated or treated while immersed in the tank 11. At the end of the predetermined time, the timer control 37 reverses the windlass motor 45 to lift the plate 12 to its original transport position as disclosed in FIG. 1. As the plate 12 rises above the liquid level of the bath 11, the timer control energizes both solenoid valves 35 and 135 to commence operation of the spray apparatus 18 and thereby spray both sides of the article 12 as it moves upward between the spray heads 19 and 20, as illustrated in FIGS. 1 and 2. When the plate 12 is elevated to the position disclosed in phantom in FIG. 1, the timer control 37 stops the actuation of the windlass 45 and the spray solenoids 35 and 135, and re-energizes the motor 50 to move the article 12 from its dashed-line position over the tank 11 to the solid-line position, illustrated in FIG. 1, over the first rinse tank 13.
The timer control 37 then stops the motor 50 and re-actuates the windlass 45 to lower the plate 12 into the tank 13 until it 13 reaches its phantom position 12' (FIG. 1) The plate 12 remains in its position 12' for a predetermined time while it soaks in the solution of the rinse tank 13. At the end of this time, the timer controls 37 reactuate the windlass 45 to reverse the winding of the cable 46. Again, as the plate 12 rises out of the first rinse bath 13, the solenoids 35 and 135 are re-opened to actuate the sprayer apparatus 18' so that both sides of the plate or article 12 are sprayed with rinse solution from the tank 14, which is of lesser concentration than that in the rinse solution of the tank 13. When the plate 12 is lifted to its transport position disclosed in solid lines in FIG. 1, the windlass 45 is stopped, the solenoid valves 35 and 135 closed, and the motor 50 re-energized to move the article to the position 12" over the second rinse tank 14, as disclosed in FIG. 1.
The timer operation is repeated. The motor 50 is stopped and the windlass 45 lowers the plate 12 into immersion in the tank 14. The plate 12 remains immersed for a predetermined time and is then lifted to its original transport position over the tank 14. During the lifting phase, the spray apparatus 18" is actuated to spray both sides of the plate 12".
This cycling of the timer control 37 and the operation of the motor 50 and the windlass 45 is continued until the plate 12 is elevated past the actuated sprayer apparatus 118 spraying both sides of the plate 12 with pure water. If desired, the conveyor apparatus 40 carries the water rinsed plate 12 from its position over the tank 15 to its position over the next processing tank 16 where the plate is lowered for a subsequent chemical treatment.
Instead of the timer control 37, limit switches, not shown, could be employed to actuate each sprayer apparatus during the article-lifting cycle, if desired.
As disclosed in FIG. 1, although the sequence of operations for a single plate 12 has been described, nevertheless, as disclosed in FIG. 1, a plurality of plates may be carried by the longitudinally spaced trolleys 42, and all of the plates 12 will be transported, stopped, lowered, soaked, and lifted through a spraying phase, simultaneously. Thus, plates will be raised and lowered simultaneously into every one of the tanks 11-15 as the cycle continues.
By utilizing the counterflow system of the progressive rinse tanks 13-15, and producing the counterflow by sequential pulse sprayer apparatus, substantial efficiency in rinsing is attained, and very little fresh pure water is required.
In actual operations to attain the same degree of rinsing for an apparatus 10 including only the process tank 11, one intermediate tank 13, and one final tank 15, with only two spray apparatus 18 and 118, it has been found that only 3 gallons of fresh water is required to replenish the rinse system for each 100 square feet of article surface rinsed.
For the same 100 square feet of article surface rinsed, 500 gallons of fresh water would be required for a single rinse tank 15, succeeding the processing tank 11, and without use of any sprays or counterflow.
If two rinse tanks 13 and 15 were employed with a process tank 11, with no counterflow of water and with no sprays, 30.6 gallons of water would be needed to feed both rinse tanks 13 and 15.
In a system in which the process tank 11 is utilized with rinse tanks 13 and 15 only, the water from the rinse tank 15 is counterflowed, such as by cascading to the rinse tank 13, 15.6 gallons of fresh water would be required to replenish the rinse system in order to rinse 100 square feet of the surface of an article 12.
The above volume comparisons of the requirements for fresh rinse water are applicable to the same flat plate article which was rinsed by all of the described processes.
It will be understood that the volume of rinse water will vary, depending upon the type of work being spray-rinsed. For example, wire goods would require little fresh water replenishment, while tubular goods would require more rinse water.
In a typical system, each cycle requires about 36 seconds. Six seconds are required to lower an article 12 from its overhead transport position into immersion within the tank. The article remains immersed within the tank for a dwell period of approximately 18 seconds. The lift cycle for elevating the plate from its immersed position within the tank to its elevated transport position, is about 6 seconds. Only during the lift cycle is the article sprayed. Then the article requires 6 seconds for transport from its position over one tank to the transport position over the next adjacent tank, for a total of 36 seconds.
It will thus be seen, that an apparatus 10 and process for a counterflow rinse system in which the rinsed article is pulse-sprayed for a brief period of time as it is lifted from the tank in which it is immersed, is a highly efficient system for thoroughly rinsing the article and also for the conservation of water.
It has been found that this counterflow spray-rinse process utilized even with only two rinse tanks, can save substantial volumes of water as well as eliminating all of the undesirable residual chemicals from the surfaces of the articles, to pemit the article to be further processed or utilized without any deleterious contaminants.
It has also been found, that, in many cases, the volume of rinse water is small enough to be added to the process or treating tank 11 in its entirety to replace evaporative losses. Such procedure has the advantage of saving the dragged-out chemicals, as well as avoiding a pollution problem.
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A process and an apparatus for rinsing a chemically treated or plated article by sequentially moving the article initially over a chemical solution bath and subsequently over a plurality of rinse baths, in which the article is sprayed as it rises from each successive bath with a less concentrated rinse solution from the next succeeding bath.
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CROSS REFERENCE TO RELATED APPLICATIONS
None.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a grapple of a type having arms that pivot about parallel axes of a frame for grasping and releasing objects and wherein the entire grapple, including the grapple arms, pivots about a pivotal axis transverse to such parallel axes, and more particularly to a grapple which is pivotally adjustable about such pivotal axis between a first position and can be locked in at least the first and second positions thereof. A heel is fixed to the frame for supporting an object being grasped by the grapple when the grapple is in the first pivotal position thereof.
2. Description of Related Art
Grapples with heels are well known, for example in U.S. Pat. No. 2,757,037 to Troyer, which is incorporated herein by reference, U.S. Pat. No. 4,486,136 to Howard and U.S. Pat. No. 6,551,051 to Perron et al. The known configuration, as disclosed in Troyer, Howard and Perron et al., includes a grapple, with two grapple arms that move about a common grapple arm pivot shaft. The grapple arm pivot shaft is supported in a structure that is mounted to a frame at a grapple pivot. A heel is also mounted to the frame. The grapple arm pivot shaft is able to freely move relative to the frame and the heel, due to freedom of motion provided by the grapple pivot. There are times when using this structure that the operator may want to control the orientation of the grapple with respect to the heel, for example to grasp a log with the grapple and then orient the log to a position wherein it will swing upwardly against the heel so that the heel prevents the end of the log adjacent the heel from pivoting upwardly with respect to the grapple. This is exceedingly difficult with the aforementioned prior art grapples which have no way to lock the grapple to prevent it from pivoting about the grapple arm pivot shaft.
Of course there are other times when it is desirable to orient the grapple in a predetermined pivotal position for any number of reasons, such as to use a prime mover having a grapple attached thereto to carry a log through a narrow gate; or, alternatively, to orient the log ninety degrees from such narrow gate orientation so that the center of gravity of the log is as close to the prime mover as possible.
There are other times when it may be desires to permit the grapple to freely pivot about a substantially vertical axis, so the preferred embodiment of the present invention can be used in that mode as well.
Accordingly there is a need for a grapple apparatus to overcome these aforementioned problems with prior art devices.
SUMMARY OF THE INVENTION
The present invention relates to a grapple of a type having arms that pivot about parallel axes of a frame for grasping and releasing objects and wherein the entire grapple, including the grapple arms, pivots about a pivotal axis transverse to such parallel axes, and more particularly to a grapple which is pivotally adjustable about such pivotal axis between a first position and can be locked in at least the first and second positions thereof. In some preferred embodiments a heel is fixed to the frame for supporting an object being grasped by the grapple when the grapple is in the first pivotal position thereof. In other preferred embodiments a tooth is also optionally attached to the frame for permitting manipulation of the position of an object when the grapple itself is not being used.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will be more fully understood from the detailed description below when viewed in conjunction with the accompanying drawings in which:
FIG. 1 is a side elevational view of the present invention mounted on a compact tool carrier and is show grasping and elevating a log above a trailer;
FIG. 2 is a perspective view of the grapple holding a log similar to the orientation shown in FIG. 1 ;
FIG. 3 is a perspective view in an orientation that is ninety degrees from the orientation of the log shown in FIG. 1 and showing how a heel helps to support the log by preventing the end of the log closest to the skid loader from pivoting upwardly;
FIG. 4 is a side elevational view of the present invention attached to the compact tool carrier of FIG. 1 , but showing how the grapple frame has a tooth on it which can be used to move or reorient an object such as the log shown by placing the tooth against the log and them moving the compact tool carrier, for example rearwardly, while the tooth is in engagement with the log;
FIG. 5 is a perspective view of the grapple apparatus of the present invention with the grapple arms closed and a sub-frame of the grapple in the pivotal position shown in FIG. 1 ;
FIG. 6 is another a perspective view of the grapple apparatus of the present invention with the grapple arms closed and a sub-frame of the grapple in the pivotal position shown in FIG. 3 ;
FIG. 7 is an exploded perspective in the orientation of FIG. 6 , but with the grapple arms open;
FIG. 8 is a side elevational view of the grapple apparatus with the grapple arms open but from the back side from the way it is shown in FIG. 6 ;
FIG. 9 is a top plan view of the grapple apparatus of the present invention;
FIG. 10 is and exploded perspective view of a universal connector plate that attaches a boom of a compact tool carrier an adapter plate of the grapple to form a quick connection coupler;
FIG. 11 is a view like FIG. 1 but with an alternate embodiment that does not have a heel on it;
FIG. 12 is a view like FIG. 1 but with an alternate embodiment that does not have a heel or a tooth on it;
FIG. 13 is an exploded perspective view of the frame showing how a pin 31 is biased downwardly, how it can move downwardly if pivoted to one position and how it is held up when not in such one position; and
FIG. 14 is a view like FIG. 1 but with an alternate embodiment that has a heel but not a tooth on it.
DETAILED DESCRIPTION OF THE INVENTION
Referring now to the drawings wherein like reference numerals designate identical or corresponding parts throughout the several views, FIG. 1 shows a device 10 constructed in accordance with a preferred embodiment of the present invention, attached to a compact tool carrier 11 (This prime mover is often referred to as a “skid loader” when a front end loader bucket is attached to the front thereof) and is being used to lift a log 21 to or from a trailer 20 .
The grapple apparatus 10 is pivotally attached to the boom 12 , which boom 12 is pivotally attached to the compact tool carrier 11 at pivot 13 . A hydraulic cylinder 14 pivotally attached at one end to the compact tool carrier 11 and pivotally attached to the boom 12 pivots the boom 12 up and down as desired. A universal mounting plate or adaptor 17 , as best shown in FIG. 10 , is pivotally connected to the boom 12 at pivot axis 18 .
A hydraulic cylinder 16 is pivotally attached to the boom 12 at one end and is pivotally attached to the universal mounting plate 17 at the opposite end, at pivot axis 19 . The grapple apparatus 10 includes an adapter plate or receiver 23 which mounts securely to the universal mounting plate 17 of the compact tool carrier 11 ( FIG. 10 ). This allows the operator to pivot the grapple apparatus 10 between the positions of it shown in FIGS. 1 and 4 , for example.
The adapter plate 23 is rigidly attached to a housing 24 , which is, in turn rigidly attached to a frame 26 . A grapple sub-frame comprises members 27 and 28 which are rigidly attached together. A grapple pivot pin 29 extends through member 27 and through frame 26 for pivotally attaching the sub-frame 27 / 28 to frame 26 . So pin 29 can be referred to as a grapple pivot pin 29 .
Looking to FIG. 5 it is noted that the member 27 has a plurality of holes 32 therein for selectively receiving a pin 31 that has a handle 33 thereon for selectively locking the pin 31 in place or allowing the pin 31 to be moved upwardly to the position shown in dashed lines in FIG. 5 out of one of the openings 32 . See also FIGS. 7 and 13 and a more detailed description below for the operation of the pin 31 . This permits first pivoting the sub-frame 27 / 28 to the position desired and then locking the sub-frame 27 / 28 in such fixed position with respect to the frame 26 for example in the position shown in FIGS. 1 , 2 , 4 and 5 or alternatively in the position shown in FIGS. 3 , 6 7 and 8 . Of course the sub-frame 27 / 28 can be locked in positions between these two positions just mentioned in the sentence above this one, by placing the pin 29 in one of the other intermediate holes 32 in plate 27 after the sub-frame 27 / 28 is manually pivoted to the position desired.
Looking to FIGS. 5 and 9 , for example, a first grapple member 36 is pivotally attached to the members 28 using a pin 38 inside a spacer 39 . Similarly, a second grapple member 46 is pivotally attached to the members 28 using a pin 48 inside a spacer 49 . A hydraulic cylinder 50 is pivotally operatively attached to a pin 51 on the first grapple 36 and to the spacer 49 around pin 48 of the second grapple 46 . Of course lengthening the hydraulic cylinder 50 causes the first and second grapple members 36 and 46 to close as shown in FIGS. 1-6 and shortening the hydraulic cylinder 50 causes the first and second grapple members 36 and 46 to open to the position as shown in FIGS. 7 and 8 .
In operation, the grapple apparatus 10 of the present invention can be used to grasp an object such as the log 21 in the orientation shown in FIGS. 1 and 2 by first pivoting the sub-frame 27 / 28 to the position shown in FIGS. 1 and 2 , then opening the grapple arms 36 and 46 by using cylinder 50 . Then the compact tool carrier 11 and hydraulic cylinders 14 and 16 are used to move the grapple apparatus to a position over the log 21 . When the grapple arms 36 and 46 are resting on top of the log 21 , then hydraulic cylinder 50 is lengthened to cause the grapple arms 36 and 46 to close around the log 21 as shown in FIG. 1 . Operating the present invention in this way permits the loads, such as the log 21 , to be across the front of the skid loader or other prime mover, which allows the operator to lift heavier loads by keeping the load closer to the center of gravity of the machine. It is also useful for grabbing brush out of a pile of brush.
Also in operation, the grapple apparatus 10 of the present invention can be used to grasp an object, such as the log 21 , in the orientation shown in FIGS. 3 and 6 - 8 by first pivoting the sub-frame 27 / 28 to the position shown in FIGS. 3 and 6 - 8 , then opening the grapple arms 36 and 46 by using hydraulic cylinder 50 . Then the compact tool carrier 11 and hydraulic cylinders 14 and 16 are used to move the grapple apparatus to a position over the log 21 . When the grapple arms 36 and 46 are resting on top of the log 21 , the hydraulic cylinder 50 is lengthened to cause the grapple arms 36 and 46 to close around the log 21 as shown in FIG. 3 . After that, when the grapple device 10 is raised, the end of the log closest to the compact tool carrier 11 will pivot upwardly into contact with the heel 25 , thereby stabilizing the log 21 or other object being grasped. Operating the present invention in this way, by locking the grapple sub-frame 27 / 28 to the frame 24 , permits the loads to be in-line with the machine. This allows a person to move long objects through gates without lifting the load high in the air. It also rigidly secures the load between the grapple arms 36 / 46 and the heel 25 , so that the load, such as log 21 , does not shift during transport.
FIG. 4 shows how the present invention is used to move an object, such as a log 21 . The frame 28 has a tooth 30 rigidly attached to it, which tooth 30 , used in conjunction with the compact tool carrier 11 and its hydraulic cylinders 14 and 16 can be used to move or reorient an object such as the log 21 shown by placing the tooth 30 against the log 21 and them moving the skid loader, for example rearwardly as shown in FIG. 4 , while the tooth 30 is in engagement with the log 21 .
FIG. 11 is a view like FIG. 1 but shows an alternate embodiment that does not have a heel on it like that shown in FIGS. 1-10 . FIG. 12 is a view like FIG. 1 but with another alternate embodiment that does not have a heel or a tooth on it like that shown in FIGS. 1-11 . FIG. 14 is a view like FIG. 1 but with an alternate embodiment that has a heel but not a tooth on it.
FIGS. 7 and 13 show how the pin 31 is biased, by a compression spring 69 , downwardly towards sub-frame 27 / 28 and into the slot 66 therein when the shaft 67 with handle 33 is aligned with the slot 66 . When the shaft 67 is in the long slot 66 the pin can extend into any one of the holes 32 in member 27 , thereby preventing the sub-frame 27 / 28 and the grapple arms 36 and 37 from pivoting about the axis of pin 29 . This allows the grapple sub-frame 27 / 28 to be moved, for example, between the positions shown in FIGS. 2 and 3 and locked into the FIG. 2 or FIG. 3 positions for use as shown in FIGS. 2 and 3 .
FIG. 13 shows a close-up of the lock pin 31 , and supporting tube 65 , with a long slot 66 and a short slot 68 with the spring 69 positioned between the bottom of tube 65 and a shoulder 70 on pin 31 . FIGS. 7 and 13 also illustrate that when the shaft 67 is not in the slot 66 is in the short slot 68 , the pin 31 is held above and out of the holes 32 because shaft 67 rests on the top shoulder of tube 65 at the top of short slot 68 . When the pin 31 is held in this position, the sub-frame 27 / 28 and the sub-frame 27 / 28 and grapple arms 36 and 46 can freely pivot about the axis of pin 29 . Some operators may prefer to use the grapple in this freely pivoting mode at certain times.
Accordingly, it will be appreciated that the preferred embodiments do indeed overcome the deficiencies of the prior art explained above. Obviously many 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.
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A grapple apparatus of a type having arms that pivot about parallel axes of a frame for grasping and releasing objects and wherein the entire grapple, including the grapple arms, pivots about a pivotal axis transverse to such parallel axes, and more particularly to a grapple which is pivotally adjustable about such pivotal axis between a first position and can be locked in at least the first and second positions thereof. A heel is fixed to the frame for supporting an object being grasped by the grapple when the grapple is in the first pivotal position thereof. A tooth is also optionally attached to the frame for permitting manipulation of the position of an object when the grapple itself is not being used.
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BACKGROUND OF THE INVENTION
Field of the Invention
The present invention relates to an apparatus for detection of the occupied or free state of a track section having a transmitter for feeding a transmitted signal in the form of an AC voltage into the rails of the track section and at least one receiver for receiving a received signal which is produced by transmission of the transmitted signal via the rails of the track section.
One such apparatus is known in the form of a track-free signaling device, in the form of a track circuit, for example from the company publication from Siemens AG “FTG S—Gleisfreimeldung mit dem Tonfrequenz-Gleisstromkreis FTG S” [FTG S—Track-free signaling using the FTG S audio-frequency track circuit], Order No. A19100-V100-B607-V2. In this case, a transmitter feeds an AC voltage into the rails of a track section to be monitored. A receiver receives a received signal in the form of the incoming voltage, and evaluates the received signal. Since a short circuit is produced between the rails of the track section by the axles of a rail vehicle which is traveling on the track section, this prevents the transmitted signal from being transmitted to the receiver. This therefore makes it possible to identify that the relevant track section is occupied.
In general, apparatuses for detection of the occupied or free state of a track section of the type mentioned initially are subject, for safety reasons, to the requirement of that, because of the dangers associated with this, an incorrect indication of a free state must not be produced in any circumstances.
Therefore, in order to avoid influences, for example, it is normally forbidden for transmitting and receiving lines of a track circuit to be carried within the same cable. Nevertheless, in principle, situations are feasible in which undesirable influences can occur between a transmitter and receiver, or between the respective lines to the rails.
This relates both to apparatuses having a transmitter and a receiver and, in particular, to those apparatuses which have a plurality of receivers, in general two or three. For example, in the course of monitoring switches or crossings by means of a single track circuit, there is therefore a requirement or a necessity to use a plurality of receivers. This also applies, for example, to the situation in which the transmitted signal is supplied to the track section by means of a so-called center feed, in which case one receiver is connected to each of the two ends of the track section. In apparatuses such as these having a plurality of receivers, disturbing influences can now also occur in particular in the situation in which the electrical lines of a plurality of receivers are carried within the same cable. In a situation such as this, it is necessary to ensure that an incorrect free message relating to a track section is reliably avoided even when a fault occurs, that is to say for example in the event of damage resulting in a short circuit to a cable or to one of the lines carried in the cable. For example, an incorrect free message such as this could occur by a short circuit resulting in the high level of a first received signal of a first receiver being coupled into the line of a second receiver, whose second received signal is at a low level because of occupancy.
BRIEF SUMMARY OF THE INVENTION
The present invention is based on the object of specifying an apparatus of the type mentioned initially in which faults, in particular apparatus-side cable faults, can be identified particularly reliably and at the same time cost-effectively.
According to the invention, this is object is achieved by an apparatus for detection of the occupied or free state of a track section having a transmitter for feeding a transmitted signal in the form of an AC voltage into the rails of the track section and at least one receiver for receiving a received signal which is produced by transmission of the transmitted signal via the rails of the track section, in which case the apparatus is designed to determine the phase shift between the transmitted signal and the received signal.
The apparatus according to the invention is advantageous because determination of the phase shift between the transmitted signal and the received signal allows reliable fault identification, in a simple manner. Therefore, there is a phase shift between the received signal and the transmitted signal, because the transmitted signal, which is fed into the rails of the track section, propagates in the form of the AC voltage. Since the path of the transmitted signal from the transmitter via the rails of the track section to the receiver is predetermined and fixed, the phase shift should no longer change once the apparatus and the track section have been configured. This makes it possible to immediately identify faults or defects in the apparatus on the basis of the phase shift between the transmitted signal and the received signal. By way of example, a phase shift of zero would therefore immediately indicate that the received signal has not been transmitted as intended via the rails of the track section, but, for example, has passed directly from the transmitter to the receiver.
If the apparatus has a plurality of receivers, it is advantageously possible to determine the phase shift between the transmitted signal and each individual one of the received signals.
Furthermore, the apparatus according to the invention is advantageous because the phase shift between the received signal and the transmitted signal can be evaluated independently of the processing and evaluation of the actual free message information. In particular, it is therefore possible to distinguish between a defect, for example in the form of a cable fault, and an occupied message resulting from an influence of axles. In this case, it should be remembered that the phase shift between the transmitted signal and the received signal means that a fault identification parameter is used, which is not used for the purposes of detection of the occupied or free state of the track section.
A further advantage is that, in contrast, to other feasible circuits for monitoring the cables or the lines in the cable or in the cables, scarcely any or no additional circuit parts are advantageously required, as a result of which the apparatus according to the invention can be implemented particularly cost-effectively. Because faults can be identified reliably it is also feasible to dispense with the requirement for transmitting lines and receiving lines to be routed separately, that is to say lines which lead from the track to the transmitter or receiver. A modification such as this, which is in principle made possible by the apparatus according to the invention, would lead to a considerable simplification of the wiring of the railroad monitoring system, in the form of the apparatus for detection of the occupied or free state of the track section.
Furthermore, according to the invention, the object on which the present invention is based is achieved by an apparatus for detection of the occupied or free state of a track section having a transmitter for feeding a transmitted signal in the form of an AC voltage into the rails of the track section and at least one receiver for receiving a received signal which is produced by transmission of the transmitted signal via the rails of the track section, in which, in an apparatus having a first receiver for receiving a first received signal which is produced by transmission of the transmitted signal via the rails of a first part of the track section, and having a second receiver for receiving a second received signal which is produced by transmission of the transmitted signal via the rails of a second part of the track section, the apparatus is designed to determine the phase shift between the first received signal and the second received signal.
In contrast to the first solution according to the invention to the object on which the invention is based, in the case of the second solution according to the invention, because the apparatus has a transmitter and at least two receivers, this advantageously makes it possible, in addition or as an alternative to the first solution according to the invention, to determine the phase shift between the first received signal and the second received signal, instead of comparing the phase shift between the transmitted signal and the respective received signal. This allows particularly efficient and simple fault monitoring of the apparatus, in particular for cable faults.
In this case, both solutions according to the invention are based on the same common idea, that the determination of the phase shift between the signals that are used makes it possible to identify discrepancies and/or disturbances or faults, in particular relating to the propagation path of the signals. The advantages of the further or second apparatus according to the invention therefore correspond substantially to the advantages already mentioned above in conjunction with the first apparatus according to the invention.
At this point, it should be noted in general that, with the two solutions according to the invention, there is no need for the transmitter and the at least one receiver of the apparatus to be arranged directly adjacent to the track. Said components and means for determining the phase shift between the respective signals, that is to say for example an appropriately designed evaluation device, are therefore associated in a preferred manner with the internal system, that is to say installed or accommodated by way of example in a signal box.
The apparatus according to the invention preferably continuously determines the phase shift between the respective signals. This advantageously ensures permanent functional monitoring of the respective apparatus. However, as an alternative to this, it is in principle also possible, for example, for the phase shift between the respective signals to be determined only while carrying out a functional test on the apparatus. A corresponding functional test could therefore be carried out, for example, every minute, every hour, or once a day, depending on the respective requirements.
It should also be noted that the apparatus according to the invention can be used particularly advantageously in conjunction with audio-frequency track circuits since, in this case, the signal which is used to detect the occupied or free state of the track section is already an AC voltage signal. However, in principle, it is also possible for the apparatuses according to the invention to be used in conjunction with those track circuits which operate at a signal frequency below or above the audible tone range, or else based on the direct-current principle. In the latter case, the transmitted signal in the form of the AC voltage is a signal which is superimposed on the direct current used for detection and is used exclusively for functional monitoring of the apparatus by determining the phase shift between this transmitted signal and the received signal, or between two received signals. In a situation such as this, an appropriate transmitted signal in the form of an AC voltage can either be permanently superimposed on the direct current or else can additionally be fed in, for example at predetermined time intervals only for functional testing.
According to one particularly preferred embodiment, the respective apparatus according to the invention is designed to compare the phase shift with at least one reference phase shift. This is advantageous since this allows the phase shift to be evaluated in a particularly simple manner. Thus, for example, before the apparatus is commissioned, the phase shift can be determined between the transmitted signal and the received signal when the apparatus for detection of the occupied or free state of the track section is serviceable, without any faults. This phase shift can then be stored, for example in a memory device for the apparatus, in the form of the reference phase shift, possibly taking account of tolerance values. Therefore, during subsequent operation of the apparatus, a fault can be identified immediately and unambiguously on the basis of a simple comparison of the phase shift with the reference phase shift, which has previously been determined in this way.
Independently of how a fault or a disturbance is identified in a specific case on the basis of the determined phase shift, the relevant, associated track section is preferably immediately signaled, as a precaution, as being occupied when a fault occurs, in order to avoid danger.
As an alternative to determining the reference phase shift before commissioning of the track-free signaling device in the form of the apparatus for detection of the occupied or free state of a track section, it would also be possible to monitor the phase shift between the received signal and the transmitted signal or between the first and the second received signals, for example by permanently comparing the instantaneous phase shift with a reference phase shift in the form of the most recently determined value of the phase shift. This also makes it possible to identify a change in the phase shift immediately and without any time delay.
The apparatuses according to the invention can also be developed in a preferred manner such that they are designed to produce a fault signal, which indicates a disturbance state, on the basis of the comparison between the phase shift and the reference phase shift. The fault signal therefore advantageously makes it possible, for example, to inform an operator in a signal box immediately of the presence of a fault situation.
A fault signal which indicates a disturbance state or fault and has been produced by the apparatus on the basis of the comparison between the phase shift and the reference phase shift can be output in various ways. In principle, it would be feasible, therefore, simply to make an appropriate entry in a log file. In a further particularly preferred embodiment, the respective apparatus according to the invention is designed to output the fault signal in the form of a visual and/or audible warning message. This advantageously means that the operator, that is to say for example the operator in a signal box, can be made aware of this in a particularly reliable manner.
According to one particularly preferred development of the apparatuses according to the invention, the transmitter is designed to feed a transmitted signal, which has been coded by means of modulation, into the rails of the track section, and the apparatus is designed to compare the modulation on the received signal or the modulation on at least one of the received signals with the modulation on the transmitted signal. In general, it is advantageous to use a transmitted signal which is coded by means of modulation, since this improves the insensitivity to disturbing influences. In this case, the association between the two signals is verified in a particularly simple manner by the comparison of the modulations on the received signal and on the transmitted signal. This is done without any need for rigid, fixed predetermined codings, permanently associated with the respective device, for example in the form of bit patterns, for this purpose. This also advantageously avoids the corresponding effort for configuration of the individual apparatuses, thus reducing the production costs of the apparatus. This also simplifies the assembly process, therefore additionally resulting in a time and cost saving. In addition, the configuration of a railroad monitoring system is also simplified, since no associations need be provided between codings or modulations and apparatuses, and there is therefore also no need to store corresponding associations on situation plans and data sheets, and to subsequently observe them. Furthermore, there are advantageously also no restrictions to the number and nature of the modulations used for coding, thus satisfying the precondition to making it possible to preclude multiple use of the same modulations within a system. In this context, the apparatus according to the invention can preferably be designed to produce a transmitted signal which is coded by means of any desired modulation, in particular generated on a random basis. If a discrepancy between the modulations is found when the modulation on the received signal is compared with the modulation on the transmitted signal, the track section associated with the apparatus is preferably immediately signaled as being occupied, in order to prevent danger.
The apparatuses according to the invention can also be developed in a preferred manner by designing the respective apparatus to transmit data signals via the rails of the track section to a rail vehicle which is occupying the track section. This is advantageous because this additionally allows the apparatus to be used for information transmission to a rail vehicle. By way of example, this also assists applications in the field of line train control. An appropriately developed apparatus can advantageously be used in such a way that the transmitter and receiver are linked to the respective trackside feed points, for example in the form of so-called track connection housings, such that either a transmitted signal from a transmitter can be selectively fed into the feed points, or a received signal can be read or received for a receiver. Such switching, which is known per se, is advantageous since data signals can be transmitted to a rail vehicle only for as long as the transmitter is located in front of the rail vehicle in the direction of travel. This is because shorting of the rails by the axles of the rail vehicle otherwise also prevents the transmission of data signals to a receiving device, which is normally arranged in the front area of a rail vehicle. In this context, it should be noted that the apparatuses according to the invention can also advantageously be used to determine in the same manner the phase shift between the transmitted signal and the received signal, or between the two received signals, independently of the direction of travel and the position of the rail vehicle in the track section.
Furthermore, the present invention relates to a method for operation of an apparatus for detection of the occupied or free state of a track section, in which a transmitted signal in the form of an AC voltage is fed into the rails of the track section, and a received signal which is produced by transmission of the transmitted signal via the rails of the track section is received.
With regard to the method, the present invention is based on the object of specifying a method for operation of an apparatus for detection of the occupied or free state of a track section, which allows faults, in particular apparatus-side cable faults, to be identified particularly reliably and at the same time cost-effectively.
According to the invention, this object is achieved by a method for operation of an apparatus for detection of the occupied or free state of a track section, wherein a transmitted signal in the form of an AC voltage is fed into the rails of the track section, and a received signal which is produced by transmission of the transmitted signal via the rails of the track section is received, and the phase shift between the received signal and the transmitted signal is determined.
Furthermore, the object on which the method according to the invention is based is also achieved, according to the invention, by a method for operation of an apparatus for detection of the occupied or free state of a track section, wherein a transmitted signal in the form of an AC voltage is fed into the rails of the track section, a first received signal which is produced by transmission of the transmitted signal via the rails of a first part of the track section is received, and a second received signal which is produced by transmission of the transmitted signal via the rails of a second part of the track section is received, and the phase shift between the first received signal and the second received signal is determined.
The advantages of the methods according to the invention correspond essentially to those of the apparatuses according to the invention, as a result of which reference is in this context made to the corresponding statements above. This also applies with regard to the developments of the methods according to the invention as mentioned in the following text, with respect to which reference is likewise made in a corresponding manner to the corresponding statements in conjunction with the respective preferred developments of the apparatuses according to the invention.
The methods according to the invention are preferably designed such that the phase shift is compared with at least one reference phase shift.
According to a further particularly preferred embodiment, the methods according to the invention are designed such that a fault signal, which indicates a disturbance state, is produced on the basis of the comparison between the phase shift and the reference phase shift.
The methods according to the invention can preferably also be carried out in such a way that the fault signal is output in the form of a visual and/or audible warning message.
The method according to the invention is advantageously designed such that a transmitted signal, which has been coded by means of modulation, is fed into the rails of the track section, and the modulation on the received signal or the modulation on at least one of the received signals is compared with the modulation on the transmitted signal.
According to a further particularly preferred development of the method according to the invention, data signals are transmitted via the rails of the track section to a rail vehicle which is occupying the track section.
The invention will be explained in more detail in the following text with reference to exemplary embodiments. In this case, in the figures:
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING
FIG. 1 shows a schematic sketch of an arrangement having a track section and first exemplary embodiment of the apparatus according to the invention with a transmitter and a receiver,
FIG. 2 shows a schematic sketch of an arrangement having a center-fed track section and a second exemplary embodiment of the apparatus according to the invention with a transmitter and two receivers,
FIG. 3 shows a schematic sketch of an arrangement having a track section in the form of a switch and a third exemplary embodiment of the apparatus according to the invention with a transmitter and two receivers, and
FIG. 4 uses a schematic illustration in the form of a graph with a transmitted signal and two received signals, in order to illustrate one exemplary embodiment of the method according to the invention.
DESCRIPTION OF THE INVENTION
For clarity reasons, the same reference symbols are used for the same components or components having the same effect in the figures.
FIG. 1 shows a schematic sketch of an arrangement having a track section and a first exemplary embodiment of the apparatus according to the invention with a transmitter and a receiver. The illustration shows an apparatus V for detection of the occupied or free state of a track section G. The apparatus V has a transmitter S for feeding a transmitted signal SIG S in the form of an AC voltage into the rails F of the track section G. Furthermore, the apparatus V has a receiver E for receiving a received signal SIG E which is produced by transmission of the transmitted signal SIG S via the rails F of the track section G.
As shown in the illustration in FIG. 1 , an AC voltage at the frequency f 1 is fed into the track section G. In order to make it possible to reliably distinguish between the respective signals, the adjacent track sections are operated with an AC voltage at a different frequency f 5 or f 3 . The following text assumes that the arrangement shown in the figure is an audio-frequency track circuit having a plurality of frequencies, in which an AC voltage in the form of a transmitted signal SIG S in the audio-frequency range is fed into the rails F of the track section G.
By way of example, the apparatus V can be arranged in a signal box of a railroad system, or a railroad monitoring system. This offers the advantage that particularly high reliability is achieved since mechanical stresses and climatic influences have less effect on the electronic components of the apparatus V than would be the case if these components were accommodated close to the track. Furthermore, this results in further advantages relating to the availability and maintenance of the apparatus V, that is to say, in particular of the transmitter S and of the receiver E. A corresponding separation between the internal system, which is associated with the apparatus V, and the external system, which is part of the track section G, is indicated by means of the horizontal dashed-dotted line in FIG. 1 .
Corresponding to the illustration in FIG. 1 , track connecting housings GAG 1 , GAG 2 are arranged on the track side and are used to introduce the transmitted signal SIG S , which is fed in or provided by the transmitter S, and to read the received signal SIG E , which is transmitted to the receiver E, into and respectively out of the rails F. Normally, the track connecting housings GAG 1 , GAG 2 in this case do not contain any active electronic components, but essentially only a resonant circuit for frequency-selective amplification of the signals which are fed in and out at a predetermined useful frequency, that is to say at the frequency f 1 in the case of the track section G illustrated in FIG. 1 .
In order to allow monitoring to be carried for disturbances and faults, in particular with respect to the cables and lines from the transmitter S to the track connecting housing GAG 1 and from the track connecting housing GAG 2 to the receiver E, the apparatus V also has an evaluation device AE, which is used to determine the phase shift between the transmitted signal SIG S , which is transmitted by the transmitter S, and the received signal SIG E , which is received by the receiver E. For this purpose, the evaluation device AE receives the transmitted signal SIG S from the transmitter S and the received signal SIG E from the receiver E and determines the phase shift, preferably based on safe signaling technology, between the two signals SIG S , SIG E . In this case, the apparatus V or the evaluation device AE is designed to compare the determined phase shift with at least one reference phase shift. The reference phase shift is preferably that value of the phase shift between the transmitted signal SIG S and the received signal as measured when there are no faults in the system.
Disturbances, for example resulting from crosstalk between the signals in adjacent track circuits, for example as a result of damage to an electrical line, can now advantageously be reliably detected from the comparison of the phase shift with the reference phase shift. When a corresponding fault is identified, the evaluation device AE in the apparatus V signals as a precaution that the track section G is occupied, and produces a fault signal which indicates the relevant disturbance state. For this purpose, the fault signal may, for example, be output in the form of a visual and/or audible warning message. In this case, a reliable distinction can be advantageously drawn between a disturbance, that is to say a cable fault, and a regular free or occupied message. Furthermore, determination of the phase shift and the comparison with the reference phase shift can advantageously be implemented with comparatively little complexity such that no or scarcely any additional circuit components are required, thus achieving a cost saving in comparison to other feasible solutions.
It should be stressed that the illustration in FIG. 1 is only a schematic illustration. For example, in practice, further components may be provided or required, which are not illustrated in FIG. 1 for clarity reasons. Thus for example, it is feasible for the apparatus V to additionally be designed to transmit data signals via the rails F of the track section G to a rail vehicle which is occupying the track section G. In this case, the transmitter S of the apparatus V advantageously has an external drive, by means of which the data signals can be supplied to the transmitter S.
FIG. 2 shows a schematic sketch of an arrangement having a center-fed track section and a second exemplary embodiment of the apparatus according to the invention with a transmitter and two receivers. In contrast to the illustration in FIG. 1 , FIG. 2 therefore shows an arrangement with two receivers E 1 , E 2 . In this case, the respective received signal SIG E1 or SIG E2 is supplied to the receivers E 1 , E 2 via the track connecting housings GAG 1 , GAG 3 . The first receiver E 1 is used to receive the first received signal SIG E1 which is produced by transmission of the transmitted signal SIG S via the rails F of the first part of the track section G, with the first part of the track section being formed by the track section between the track connecting housings GAG 1 and GAG 2 . In a corresponding manner, the second receiver E 2 is used to receive the second received signal SIG E2 which is produced by transmission of the transmitted signal SIG S via the rails F of a second part of the track section G, which is formed by the track section between the track connecting housings GAG 2 and GAG 3 .
The arrangement illustrated in FIG. 2 can on the one hand be used to monitor the serviceability of the apparatus V in the form of the track-free signaling device, by determining the phase shift between the transmitted signal SIG S of the transmitter S and the first received signal SIG E1 of the receiver E 1 , and the phase shift between the transmitted signal SIG S and the second received signal SIG E2 of the second receiver E 2 .
In addition or as an alternative to this, it is, however, also possible to determine the phase shift between the first received signal SIG E1 of the receiver E 1 and the second received signal SIG E2 of the second receiver E 2 . The phase shift determined in this way also allows reliable identification of disturbances, in particular in the form of cable faults. This is particularly important in the case of an arrangement having one transmitter S and a plurality of receivers E 1 , E 2 , since, particularly in the situation in which the lines of a plurality of receivers E 1 , E 2 are carried within one cable, disturbances can be caused by crosstalk or coupling in of a received signal into the line of another receiver. Disturbances and faults such as these are reliably identified by means of the evaluation device AE of the apparatus V, by the comparison of the phase between the transmitted signal SIG S and the respective received signals SIG E1 , SIG E2 , or between the received signals SIG E1 , SIG E2 , as a result of which faults or disturbances can also be excluded in the case of lines for a plurality of receivers E 1 , E 2 which are carried in the same cable.
If the apparatus were to have more than two, that is to say by way of example three, receivers, then the phase shifts between the transmitted signal SIG S and the individual received signals could be determined analogously to the procedure described above, or else the phase shift of a combination or a plurality of combinations of the signals received by the receivers could be determined.
FIG. 3 shows a schematic sketch of an arrangement having a track section in the form of a switch and a third exemplary embodiment of the apparatus according to the invention with one transmitter and two receivers. In a similar manner to the illustration in FIG. 2 , this relates to an arrangement having an apparatus V with a transmitter S and two receivers E 1 , E 2 . In the illustrated case, this is a switch circuit, which is used for complete monitoring of a switch W.
Analogously to the procedure described in conjunction with FIG. 2 , it is also possible in an arrangement such as this to reliably ensure, by determining the phase shift between the transmitted signal SIG S of the transmitter S and the respective received signals SIG E1 , SIG E2 of the receivers E 1 , E 2 , or by determining the phase shift between the received signals SIG E1 , SIG E2 of the first receiver E 1 and the second receiver E 2 , that the received signals SIG E1 , SIG E2 received by the respective receivers E 1 , E 2 are also actually the respective uncorrupted received signal SIG E1 or SIG E2 as received or read out at the intended point on the track section G.
FIG. 4 uses a schematic illustration in the form of a graph with a transmitted signal and two received signals to illustrate one exemplary embodiment of the method according to the invention. The illustration in this case shows the amplitude A as a function of time t for a transmitted signal SIG S , a first received signal SIG E1 and a second received signal SIG E2 . As shown in the illustration in FIG. 4 , the illustrated signals SIG S , SIG E1 , SIG E2 differ not only in terms of their amplitude A, but in particular also in terms of their phase.
The illustrated signals SIG S , SIG E1 , SIG E2 can therefore be either used as the basis for determining the phase shift PH S,E1 between the transmitted signal SIG S and the first received signal SIG E1 , the phase shift PH S,E2 between the transmitted signal SIG S and the second received signal SIG E2 , and/or the phase shift PH S,E2 between the first received signal SIG E1 and the second received signal SIG E2 . Evaluation of the phase shifts PH S,E1 , PH S,E2 , PH E1,E2 , for example by comparison with a respective corresponding reference phase shift, makes it possible to check the signal path of the respective received signals SIG E1 or SIG E2 , or both received signals SIG E1 , SIG E2 . In this case, in particular, faults relating to the cables or lines between the track and the respective receiver can be identified in a corresponding manner to the above statements, thus advantageously, in particular, avoiding an incorrect free message, that is say an incorrect indication that the track section is free.
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A device detects an occupied state or a free state of a track section and has a transmitter for feeding a transmission signal in the form of an alternating voltage into the running rails of the track section and at least one receiver for receiving a reception signal which is brought about by a transmission of the transmission signal via the running rails of the track section. In order to be able to detect faults in the device, in particular cable faults, particularly reliably and at the same time cost-effectively, the device accordingly is configured to determine a phase shift between the transmission signal and the reception signal. A method for operating such a device is further disclosed.
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BACKGROUND OF THE INVENTION
The invention relates to an injection device for fluid, in particular to an injection device for injecting fluid into an exhaust tract of an internal combustion engine.
The demands on the exhaust-gas quality of internal combustion engines, in particular of internal combustion engines for driving motor vehicles, have become ever higher in recent years. In the case of diesel engines in particular, NO x emissions constitute a problem, which is counteracted by means of so-called SCR catalytic converters. In an SCR catalytic converter, environmentally harmful NO x is converted into N 2 and H 2 O by means of NH 3 , which is supplied to the catalytic converter generally in the form of an aqueous urea solution.
In order to supply the urea solution to the exhaust gases of the internal combustion engine, a dosing system is required which conventionally comprises an electrically operated pump and an electrically activated dosing valve. Such known dosing systems are complex and expensive in terms of manufacture, assembly and maintenance.
EP 1 878 920 A1 discloses a liquid pump having an inlet, an outlet, a pump chamber for receiving the liquid, and an actuator which is movable between a first position and a second position and which is designed to pump liquid out of the pump chamber and into the outlet. The inlet and the outlet are fluidically connected to a supply passage when the actuator is in the first position. The supply passage runs around the actuator in order to permit a transfer of heat from the actuator to the liquid.
US 2007/0295003 A1 describes a high-pressure dosing pump which is intended for providing a reducing agent to an exhaust-gas reduction system. The high-pressure dosing pump has an electromagnet for driving a piston which is movably mounted in an inner bore of a valve housing of the pump. The inner bore has a pressure chamber with a one-way inlet valve and a one-way outlet valve. Movement of the piston causes reducing agent at high pressure to be supplied to an injection nozzle. The injection nozzle is arranged at a location which permits a maximum reduction of undesired pollutants in the exhaust gases.
SUMMARY OF THE INVENTION
It is an object of the invention to provide an improved dosing system which permits an effective injection of fluid and which is inexpensive to manufacture, assemble and maintain.
The object is achieved by means of an injection device according to the invention for a dosing system, as claimed in independent patent claim 1 . The dependent patent claims describe advantageous embodiments of an injection device according to the invention.
An injection device according to the invention which is designed in particular for injecting fluid into an exhaust tract of an internal combustion engine comprises a valve unit which has a valve needle (nozzle needle), a control chamber and an injection chamber with at least one injection opening. The injection device is designed such that the valve needle can be moved between an open position, in which the valve needle permits a fluid flow through the injection opening, and a closed position, in which the valve needle closes the injection opening, by a pressure difference between the injection chamber and the control chamber.
There is additionally integrated into the injection device a pump unit which is designed to suck fluid out of a fluid supply and discharge said fluid at elevated pressure, that is to say at a pressure higher than the pressure in the fluid supply, to the valve unit. When the valve unit is open, fluid is thus discharged out of the injection device at a pressure higher than the pressure in the fluid supply.
In one embodiment, the valve unit and the pump unit are arranged in a common housing. This permits a particularly compact construction of the injection device. The line paths between the pressure-generating pump unit and the valve unit in which the fluid is under elevated pressure during operation are shorter than in a conventional construction with an external pump unit, and run entirely within the injection device. The risk of an uncontrolled escape of fluid from the injection device (leakage) is reduced, and the hydraulic stability of the system is improved.
An injection unit according to the invention permits a fast release of pressure from the valve needle during the opening process, such that short switching times and a broad range of possible injection quantities can be realized.
A reduced structural size of the injection device permits a high degree of variability during assembly, for example on an exhaust tract, and increases the freedom for the configuration of the fluid tank; in particular, a reduced structural size of the injection device makes it possible to enlarge the usable volume of the fluid tank.
The required injection pressure is, according to the invention, generated in the injection device itself. A (high-pressure) feed line in which the fluid is at elevated pressure and which must therefore be of particularly stable form, and which is nevertheless susceptible to failure and leakage, can be dispensed with. This increases the operational reliability of the injection system.
An injection device according to the invention has a low voltage and power requirement during operation, and permits a standardized design for multiple applications.
In one embodiment, the valve unit has a control chamber which is delimited by an end of the valve needle, wherein the volume of the control chamber can be varied by movement of the valve needle, or the valve needle can be moved by variation of the pressure in the control chamber. Such an arrangement makes it possible for the valve needle to be actuated by variation of the fluid pressure in the control chamber. It is possible to dispense with a mechanical actuator for activating the valve needle. This simplifies the construction of the injection device, and in particular of the valve unit.
In one embodiment, the control chamber is hydraulically connected to a supply line through which fluid can be supplied to the injection device during operation. The same pressure thus prevails in the control chamber as in the supply line, and the valve needle is pushed by the fluid pressure in the control chamber into a closed position in which it prevents a fluid flow out of the injection device. During operation, the valve unit is reliably closed by the fluid pressure, without the need for an additional actuator.
In one embodiment, the pump unit has a piston chamber and a piston which is movable within the piston chamber. Here, the piston is arranged and designed such that the volume of the piston chamber and the pressure in the piston chamber can be varied by movement of the piston. As a result of such a combination of a piston chamber and a movable piston, a reliable and effective pump unit is provided which is suitable for increasing the pressure of the fluid to be injected.
In one embodiment, the piston chamber is hydraulically connected to the fluid supply by a one-way valve which is formed for example as a non-return ball valve. The one-way valve prevents fluid from flowing out of the piston chamber back into the supply line, and the elevated pressure built up by movement of the piston in the piston chamber thereby being dissipated as a result of a fluid flow out of the piston chamber into the supply line.
In one embodiment, the piston and the valve needle are movable along a common axis. An injection device in which the piston and the valve needle are movable along a common axis can be of particularly simple, space-saving and inexpensive construction. In particular, such an injection device can be constructed in the longitudinal direction of a cylindrical housing, wherein the piston and the valve needle are of cylindrical form and are movable parallel to the axis of the cylinder. A cylindrical injection device of said type is particularly durable and is simple and inexpensive to manufacture.
In one embodiment, the piston can be moved by energization of an electromagnet arranged in the injection device. An electromagnet provides a simple, inexpensive and reliable actuator for moving the piston. The actuator may alternatively be formed as a piezo actuator.
In one embodiment, the piston is supported by an elastic piston-spring element which pushes the piston in the direction of an initial position. An elastic piston-spring element of said type makes it possible to ensure that, when the electromagnet is deactivated, the piston is moved reliably into an initial position.
In one embodiment, the valve needle is supported on a housing of the injection device by an elastic valve needle spring element in such a way that, when the electromagnet is deactivated, that is to say deenergized, the elastic spring element forces the valve needle into the closed position, and the valve unit is reliably closed when the electromagnet is deactivated.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be explained in more detail below on the basis of the appended figures, in which:
FIG. 1 shows a first sectional view of an exemplary embodiment of an injection device according to the invention during the suction process;
FIG. 2 shows a second sectional view of the injection device according to the invention during an injection process; and
FIG. 3 shows an enlarged schematic detail of an injection device according to the invention; in particular an upper region of the piston with an armature and a surrounding electromagnet.
DETAILED DESCRIPTION
In the following description of the figures, statements such as “top” and “bottom” are used for better explanation of the exemplary embodiments of the invention shown in the figures, without restricting the invention to the exemplary embodiments shown or to a particular orientation and/or installation position.
FIG. 1 shows a first sectional view of an injection device 2 according to the invention during a suction process.
An injection device 2 according to the invention has a for example cylindrical nozzle body 4 , along the longitudinal axis A of which there is formed a for example substantially cylindrically shaped injection chamber 38 . At that face end of the injection chamber 38 which is illustrated at the bottom in FIG. 1 there is formed an injection opening 8 through which fluid emerges from the injection chamber 38 during an injection process. A lower region, which adjoins the injection opening 8 , of the injection chamber 38 has a smaller cross section in a plane perpendicular to the longitudinal axis A of the nozzle body 4 than an upper region, which is at a greater distance from the injection opening 8 , of the injection chamber 38 .
In the injection chamber 38 there is arranged a substantially cylindrical valve needle 6 , the longitudinal axis of which is aligned along the longitudinal axis A of the nozzle body 4 . The valve needle 6 is of stepped form with a conical lower region 6 a and a plurality of cylindrical regions 6 b , 6 c , 6 d , 6 e , wherein the cylindrical regions 6 b , 6 c , 6 d , 6 e have, in a plane perpendicular to the longitudinal axis A of the valve needle 6 , a cross section which is larger the greater the distance thereof from the lower, conical region 6 a.
The valve needle 6 is movable along its longitudinal axis A between a closed position, in which the lower end 6 a of the valve needle 6 rests on the valve seat 8 a and closes off the injection opening 8 in a substantially fluid-tight manner, and an open position, in which the valve needle 6 opens up the injection opening 8 .
Around the circumference of an upper region, which is remote from the injection opening 8 , of the valve needle 6 there is arranged a cylindrical control chamber sleeve 16 . Within the control chamber sleeve 16 there is formed, above the upper face end 6 b of the valve needle 6 , a control chamber 36 whose volume can be varied by movement of the valve needle 6 in a direction parallel to the longitudinal axis A thereof. Conversely, the valve needle 6 can be moved parallel to its longitudinal axis A by variation of the difference between the pressure in the injection chamber 38 and the pressure in the control chamber 36 .
The control chamber 36 is delimited on the upper side, which is remote from the valve needle 6 , by a control plate 18 . The control plate 18 is fixed to the nozzle body 4 by securing pins (poka-yoke pins) 46 (not visible in FIG. 1 ) and by a nozzle clamping nut 10 which surrounds the nozzle body 4 and the control plate 18 .
In a central region 6 e of the valve needle 6 as viewed in the longitudinal direction, a support ring 12 is formed around the circumference of the valve needle 6 . Between the support ring 12 and the control chamber sleeve 16 , a cylindrical valve needle spring element 14 is arranged around the circumference of the valve needle 6 , which valve needle spring element is supported with its two faces at one side on the control chamber sleeve 16 and at the other side on the support ring 12 . The valve needle spring element 14 pushes the valve needle 6 elastically into the lower closed position, in which the valve needle 6 closes off the injection opening 8 in a substantially fluid-tight manner.
In the control plate 18 there is formed a fluid duct 33 with a one-way valve 20 designed for example as a ball valve or non-return valve. When the one-way valve 20 is open, the control chamber 36 is hydraulically connected via the fluid duct 33 to a piston chamber 34 which is formed above the one-way valve 20 in the control plate 18 .
The volume of the piston chamber 34 is delimited, on a side facing away from the one-way valve 20 , by a movable piston 28 which is arranged above the piston chamber 34 and which is supported elastically on the control plate 18 by a piston spring element 40 . The volume of the piston chamber 34 can be varied by movement of the piston 28 in a direction parallel to the longitudinal axis A.
A setting disk 22 is arranged between a lower face end, which faces toward the valve needle 6 , of the elastic piston spring element 40 and the control plate 18 . The stroke of the piston 28 can be set through selection of the thickness of the setting disk 22 .
Around the circumference of the piston 28 there are formed a metallic inner pole 24 and a coil 30 , which together form an electromagnet which is suitable for moving the piston 28 . At an upper region of the piston 28 remote from the control plate 18 , an armature 26 is formed around the circumference of the piston 28 . The armature 26 is magnetically attracted by the inner pole 24 when an electrical current flows through the coil 30 .
During a suction process (“suction stroke”) as shown in FIG. 1 , with the coil 30 deactivated, that is to say when no electrical current flows through the coil 30 , the piston 28 moves away from the control plate 18 parallel to the longitudinal axis A under the action of the force exerted by the elastic piston spring element 40 , such that the spacing between the piston 28 and the control plate 18 increases. The volume of the piston chamber 34 is increased and fluid from the supply 32 flows through the control chamber 36 , the fluid duct 33 and the open one-way valve 20 into the piston chamber 34 .
As a result of interaction of the fluid pressure in the control chamber 36 connected to the supply 32 and the elastic force of the valve needle spring element 14 , the valve needle 6 is forced into the lower closed position, in which the lower end 6 a of the valve needle 6 closes the injection opening 8 in a fluid-tight manner and no fluid can flow out of the injection chamber 38 through the injection opening 8 .
FIG. 2 shows a section through the injection device 2 according to the invention, as shown in FIG. 1 , in a plane rotated through 90° about the longitudinal axis A of the injection device 2 .
The components already shown in FIG. 1 are denoted by the same reference numerals, and will not be described in detail again.
In the second section plane shown in FIG. 2 , the supply 32 is not visible. Instead, in this plane, it is possible to see a connecting duct 48 which is formed in the control plate 18 and which hydraulically connects the piston chamber 34 to the injection chamber 38 . The connecting duct 48 is formed such that a fluid flow between the piston chamber 34 and the injection chamber 38 is possible regardless of whether the one-way valve 20 is open or closed.
The securing pins 46 already mentioned in conjunction with FIG. 1 , by means of which the control plate 18 is fixed to the nozzle body 4 , can also be seen in FIG. 2 .
To initiate an injection process, an electrical voltage is applied to the coil 30 such that an electrical current flows through the coil 30 . The armature 26 is attracted in the direction of the inner pole 24 by the magnetic field generated by the current flow in the coil, and the piston 28 which is connected to the armature 26 moves in the direction of the control plate 18 (“pressure or injection stroke”).
As a result of the movement of the piston 28 in the direction of the control plate 18 , the volume of the piston chamber 34 is reduced, and the fluid pressure in the piston chamber 34 is increased. The one-way valve 20 closes and prevents a return of fluid from the piston chamber 34 into the supply 32 . Fluid flows out of the piston chamber 34 into the injection chamber 38 through the connecting duct 48 and also increases the fluid pressure in said injection chamber.
When a certain critical value of the fluid pressure in the injection chamber 38 is exceeded, the fluid pressure in the control chamber 36 and the force of the valve needle spring element 14 are no longer sufficient to hold the valve needle 6 in the closed position counter to the pressure of the fluid which has flowed into the injection chamber 38 , which fluid acts on the regions 6 a , 6 c , 6 d , 6 e of the valve needle 6 and in particular exerts a force, which is directed toward the control chamber 36 , on the transitions between the regions 6 a , 6 c , 6 d and 6 e . The valve needle 6 moves from the closed position into an open position counter to the fluid pressure in the control chamber 36 , and the lower region 6 a of the valve needle 6 moves away from the valve seat 8 a and opens up the injection opening 8 .
Fluid which is displaced out of the control chamber 36 by the opening movement of the valve needle 6 flows back into the supply 32 , such that the fluid pressure in the control chamber 36 does not increase significantly. As a result, the valve needle 6 rises out of its seat 8 a , and opens up the injection opening 8 , particularly quickly.
Fluid at elevated pressure flows out of the injection chamber 38 through the open injection opening 8 (injection process) until the fluid pressure in the injection chamber 38 has fallen to such an extent that it is no longer capable of holding the valve needle 6 in an open position counter to the combination of the fluid pressure in the control chamber 36 and the force of the valve needle spring element 14 . The valve needle 6 moves back into the lower, closed position again under the action of the fluid pressure in the control chamber 36 and the force of the valve needle spring element 14 , in which lower, closed position the lower end 6 a of the valve needle 6 is pressed against the valve seat 8 a and closes off the injection opening 8 .
By deactivation of the current flow through the coil 30 , the electromagnet is deactivated and the piston 28 moves back, under the influence of the piston spring element 40 , in a direction in which the distance from the piston 28 to the control plate 18 and the volume of the piston chamber 34 increase (“suction stroke”, see FIG. 1 ). The one-way valve 20 opens and fluid flows out of the supply 32 into the piston chamber 34 .
By application of an electrical voltage to the coil 30 again, a further injection process as has been described above can now be initiated.
Below, possible dimensions of the pressure unit and in particular of the coil 30 of the electromagnet in order to generate a predefined injection pressure will be described, by way of an example, with reference to FIG. 3 :
In the case of a pressure of 7 bar in the fluid supply 32 , it is sought for example to generate an injection pressure of 9.5 bar, such that an additional pressure of 2.5 bar must be generated by the pressure unit.
For an assumed diameter D K of the piston 28 of 9 mm, that is to say a size of the circular face A of the piston of A K =19.63 mm 2 , a force to be exerted on the piston 28 can be calculated as
F K =Δp*A K =2.5 bar*19.63 mm 2 =4.9 N:
Said force F is to be imparted as a magnetic force which is exerted on the armature 26 by the coil 28 :
Fm=B 2 *AA/ 8π.
For an assumed magnetic field strength of B=1.8 T generated by the coil 28 , the required area of the armature A A can be calculated as:
A A =8π* F m /B 2 ≈4.5 mm 2 .
Assuming that the effective area of the armature 26 pressed onto the piston 28 has an inner diameter of d A =7 mm, a required outer diameter D A of the armature 26 can be calculated as:
DA 2 =AA/ 4π+ dA 2
D A ≈7.5 mm.
For an assumed magnetomotive force θ of 150 Aw and an assumed maximum current through the coil 28 of i max =2.2 A, the number of windings of the coil 28 can be calculated as
N=θ/i max ≈68.
If a wire with a diameter d D of 0.45 mm is used for the coil 28 and the coil 28 is wound in 6 layers each with approximately 12 windings, then for an inner diameter d Sp of the coil 28 of approx. 5.5 mm, the resulting wire length is approximately 2.5 mm.
A wire conventionally used for such coils has, at this length, and at a temperature of 20° C., an electrical resistance of approximately 5.5Ω. For a supply voltage of 16 V, it can thus be calculated that a current i of
i =U/R≈ 2.9 A
must flow through the coil 30 in order to generate the desired injection pressure of 9.5 bar.
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The invention relates to an injection device, in particular for injecting fluid into an exhaust tract of an internal combustion engine, having a valve unit which comprises a valve needle, an injection chamber having at least one injection opening, and a control chamber, wherein the injection device is designed so that a pressure differential between the injection chamber and the control chamber brings about a displacement of the valve needle between an open position in which the valve needle releases a fluid flow through the injection opening, and a closed position in which the valve needle closes off the injection opening. The injection device also has a pump unit integrated in the injection device. The pump unit is designed so as to draw in fluid from the fluid inlet during operation and to provide said fluid to the valve unit under increased pressure.
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