description stringlengths 2.98k 3.35M | abstract stringlengths 94 10.6k | cpc int64 0 8 |
|---|---|---|
This is a continuation-in-part of copending application Ser. No. 002,495, filed on Jan. 12, 1987, now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to fibrous mineral wool products. More particularly, it relates to a method for manufacturing strong, structural panels of mineral fiber having a density of from about 3 to about 10 pounds per cubic foot which may be used as acoustical ceiling tiles, thermal insulating panels, sound absorbing panels, pipe and beam insulation and similar products.
2. Description of the Prior Art
The water felting of dilute aqueous dispersions of mineral wool and lightweight aggregate is known. By such methods, a dilute dispersion of mineral wool, lightweight aggregate, binder and other adjuvants are flowed onto a moving foraminous support wire screen such as that of an Oliver or Fourdrinier mat forming machine for dewatering at line speeds of about 10-50 feet per minute. The dispersion dewaters to form a mat first by gravity means and then by vacuum suction means. The wet mat is dried over a number of hours in convection drying ovens; and the product is cut and optionally top coated to produce lightweight structural panels such as acoustical ceiling tiles. Such methods cannot produce low density structural panels below about 12 pounds per cubic foot density. A "structural" panel, by definition, is capable of supporting its own weight without visible sagging, bending or collapsing when supported only at the edges of the panel, as in a suspended ceiling grid.
It is also known to form stable foams with mineral wool. U.S. Pat. No. 4,447,560 suggests a low density insulation sheet may be made by forming a first slurry of fiber containing synthetic rubber latex solids. A detergent slurry is then formed and the two slurries admixed to about 15% solids consistency, agitated to a stable foam, and oven dried. The extremely time consuming, and energy intensive, drying of the stable foam from 15% solids is a severe economic detriment.
U.S. Pat. No. 4,613,627 discloses a modified wet pulp process for forming an acoustical ceiling tile wherein the binder is foamed separately from the rest of the solid ingredients. The foamed binder is then combined with an admixture of the other solids, and the admixture is cast, screeded, textured, press molded and dried.
The use of foam to prevent stratification of the various particles in a slurry of mineral wool, aggregate and other solids during the water felting of mineral fiber panels is taught by Guyer et al in U.S. Pat. No. 4,062,721. The foam retains the particles in a space matrix but also increases the water drainage time according to Guyer et al who solve that problem by delaying the foaming of the furnish until after gravity drainage has occurred. Guyer et al teach that more water is removed because the foam reduces the gross porosity of the furnish thus making vacuum dewatering more effective. This means that air is not passing through the furnish but pressing down on it and reducing the porosity still further.
Bryant teaches in U.S. Pat. No. 1,841,785 that a tough coherent skin of paper-like consistency may be created on the lower surface of a foamed mass of cellulose fibers and water on a Fourdrinier wire by subjecting the lower surface momentarily to a vacuum without imparting the suction deeply into the mass so that only the lower surface area is compacted. Further dewatering of the foamed mass occurs under a lesser vacuum so that the fibrous body of the mass is not broken down or compacted. The still wet fibrous body is then dried by passing it through an oven into which hot air is blown at levels above and below the fibrous body. The spongy consistency of the body, except for the tough skin, is thus preserved.
European Patent Application No. 148,760 teaches the manufacture of an air permeable sheet of mineral fibers and plastic powders. A dispersion of glass fibers, plastic powder, and a foaming agent is aerated to produce a fine-bubbled foam which is then drained on Fourdrinier wire to form a web of unbonded fibers interspersed with the plastic. The web is transferred carefully from the wire to a mesh belt where a binder is applied to the web and it is dried gently in a drying tunnel whereupon bonding of the mineral fibers takes place. Some loss of the plastic powder occurs.
British Patent Specification No. 1,263,812 teaches a method for forming a fiber-containing polymeric sheet capable of being thermoformed or cold pressed. The method includes feeding a paste of a polymeric powder and binder into a foamed suspension of fibers, dewatering the foamy mixture and drying the resulting sheet on a rotary drum drier. The foam is maintained by the addition of surfactant as needed. The dried sheet has a soft, crumbly texture.
Furthermore it is known that paper webs constituted mainly by noble cellulose fibers and fibrilles may be formed from foams. The basic formation of the cellulose fiber for manufacture of paper gives rise to highly fractured fiber fragments and fibrilles having jagged, fuzzy, microstructured surfaces suitable to trap and aid entanglement of microscopic-sized foam bubbles. This is not true for mineral fibers or mineral aggregate, which have smooth surfaces in comparison to the jagged and fuzzy microstructured surfaces of cellulose fibers.
In U.S. Pat. No. 3,228,825, it is suggested that lightweight foams of attenuated glass fibers might be formed into lightweight fibrous products of less than 5 pounds per cubic foot density. According to this patent, microscopic bubbles are generated in an aqueous suspension of lightweight aggregate and attenuated glass fibers in order to achieve uniform incorporation of both in the fibrous structure. Very highly refined cellulosic fibrilles serve as the binder for the glass fibers. The proposed products would appear to be extremely flexible, incapable of structural panel uses.
It is an object and advantage of the present invention to provide low density structural panels of mineral fiber by a wet felting process without having to dry extremely high amounts of water out of the wet mat over long periods of time.
A further object is to provide panels having excellent strength and integrity at densities less than about 10 pounds per cubic foot.
A still further object and advantage is the provision of a wet felting method for manufacturing low density mineral panels in a facile, rapid manner wherein the mat is dewatered and dried in a few minutes.
The above objects and advantages, and others which will become more apparent from the ensuing description, are based upon the peculiar rheology of a delicate, aqueous froth of unstable and weak bubbles, and further upon high volume, high velocity through-air drying of wet, open porous structures. Basically, in accordance with the present invention, the applicant has now discovered a process for rapidly forming shaped structural panels such as acoustical ceiling tile that combine very low densities with good strengths. A modified wet process is employed wherein a dilute aqueous slurry is foamed to a delicate froth between scrim cover sheets on a moving foraminous support wire screen. The froth dewaters and matures under quiescent conditions and is then rapidly ruptured by high vacuum to form a sufficiently stable porous structure that may be rapidly stripped of remaining water and dried by passing large volumes of heated air through the structure without any substantial collapse of the open porous structure.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic diagram of a frothed mineral panel manufacturing process line in accordance with the present invention.
FIG. 2 is a top view cross section of a portion of the process line particularly showing the frothing head forming box apparatus of FIG. 1.
FIG. 3 is a side view cross section of the same portion of the process line with the forming box apparatus broken away to show the internal walls.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Basically, referring to FIG. 1, a delicate, non-resilient, non-viscous and, therefore, unstable mass of irregularly sized bubbles is generated in a mineral fiber slurry in main mix tank 10. This is in contrast to forming a stable foam wherein bubble size is very small, even microscopic, and is generally very uniform, with each bubble behaving as a stable, rigid sphere when subjected to stresses. In a stable foam, the liquid film of the walls of the resilient, stable spheres exhibit great resistance to deformation and dewatering when acted upon by even large stress forces. The process of the present invention generates rather unstable, transitory bubbles with a foaming aid such as polyvinyl alcohol. The froth as formed has active binder and foaming aid constituents forming a large part of the dissolved solids in the liquid film of the bubbles. The liquid coating the entangled solids of fiber and aggregate has a solids consistency which increases from that of the initial dispersion as the froth dewaters, matures and dries out to exhaustion. The bubbles rapidly dewater as they age and mature under generally quiescent conditions in first flooded section 42 of the foraminous wire 40. The froth dewaters to a point where the solids in the wet mass have increased from about 3 weight % to about 6-10 weight % consistency. It is believed that at this point the fiber and aggregate have become sufficiently entangled and coated by binder as to retain the open, porous structural configuration upon the drying out and collapsing of the bubbles.
Thereafter, the bubbles are collapsed and the wet mass is further stripped of water remaining in the interstitial spaces of entangled fiber by providing a pressure differential equivalent to about 4-20 inches of mercury across the wet mass in section 44. It is preferred to employ brief bursts of high vacuum initially. This breaks the bubble walls and the draining liquid further coats the contact points on the highly voided entangled mass of fiber, aggregate and scrim. This provides further structural integrity to the wet panel. Thereafter, water stripping and drying are enabled via continued vacuum of from about 0.4 to about 4 inches of mercury in sections 46 and 48 while passing high volumes of high velocity heated air through the mass without substantial collapse of the open, highly voided structure. Thereby structural mineral panels having a density of about 3-10, and preferably about 3-6 pounds per cubic feet, with a modulus of rupture of about 60-120 pounds per square inch measured with nonwoven fiber glass scrim cover sheets in place are obtained.
The products made according to the process of the present invention are predominantly fibrous mineral products. The mineral fiber for use in the present invention may be any of the conventional fibers prepared by attenuating a molten stream of basalt, slag, granite or other vitreous mineral constituent. The molten mineral is either drawn linearly through orifices, commonly referred to as textile fibers, or it is recovered tangentially off the face of a spinning cup or rotor, commonly referred to as wool fibers. Ceramic fibers and organic fibers such as polyamide fibers, acrylic fibers, polyester fibers, polyolefin fibers, cellulose fibers and the like may also be used. Expressed in terms of the dry solids content of the final panel product, the fiber constituent is suitably present in an amount of about 10-95% by weight, and preferably about 30-40%.
Another essential ingredient is an inorganic lightweight aggregate of exfoliated or expanded volcanic glass origin. Such aggregate includes the well known expanded perlite, exfoliated vermiculite, exfoliated clays and like products which are available in a variety of mesh sizes. Generally, mesh sizes less than 8 mesh are suitable, although not critical. Generally expanded perlite is preferred for reasons of availability and economy. The amount of lightweight aggregate included may vary from about 20% to about 70% on a dry weight basis in the final product. It is particularly preferred to use expanded perlite having particle sizes from about 12 to about 100 mesh in amounts of about 30-40% for very lightweight structural panels of the invention. The lightweight aggregate is quite friable and some of it will be shattered by the mixing herein contemplated. The panel being formed is provided with a bottom cover sheet, and some of the shards of aggregate and any separated fiber shot will collect on the bottom cover sheet.
It is also preferred that the composition include about 3-25% by weight coarse cellulose fibers to aid flotation and entanglement. Such fibers generally are about 1/16-1/4 inch in length with some fibers being up to about one inch. These are conveniently provided by slushing newspaper or other papers in a "Slush Maker". That is, suitable coarse cellulose fibers may be made by charging about 10-20 pounds of newspapers or other paper stock for every 100 gallons of water in a high intensity, high shear mixer and agitating the mix for a couple of minutes in the mix tank 11. Increasingly stiff panels are made as the proportion of cellulose is increased but for ease of cutting with a knife and to avoid jagged edges the amount is preferably about 3 to 5 weight per cent. This amount also aids in retaining binder in the solids collected on the wire screen. At the 5% level, about half of the latex resin binder is retained. As the amount decreases, the amount of binder retained in panel formation decreases and strength of the panel decreases.
Ordinarily the foregoing fiber ingredients and lightweight aggregate together constitute about two-thirds of the total solids of the final panel product. Preferably, the mineral fiber and the aggregate are included in roughly equal amounts.
Any binder that will generate, by itself or in combination with a foaming aid, rather unstable, transitory, delicate and non-resilient bubbles upon high energy mixing may be used. Cooked starch binders or resin latex binders that are homopolymers or copolymers containing acrylic, acetate, or styrene-butadiene groups, for example, that provide the requisite bubbles may be used. A preferred combination of binder and foaming aid is polyvinyl acetate with polyvinyl alcohol. It is particularly preferred to employ a polyvinyl acetate that is partially hydrolyzed for foaming the mineral wool and lightweight aggregate slurry to a delicate non-resilient froth. Thus polyvinyl acetates which are from about 87% to about 91% hydrolyzed (that is, in which there is about 9% to about 13% residual polyvinyl acetate) and have molecular weights from about 22,000 to about 110,000 appear to be the most effective with a separate polyvinyl acetate binder. Polyvinyl acetates that are hydrolyzed from about 75% up to about 87% and from 91 to about 95% may be used but are not as effective as those within the preferred range.
The amount of binder or binder plus foaming aid is quite variable. Generally about half to three-quarters of the amounts initially added will pass through the wire in the drainage white water. Recycling draining water to the main mixer for dilution slurry formation will keep binder and foaming aid usage at a minimum since only make-up additions for the amounts retained in the panel will be required. The polyvinyl acetate is present in the panel in an amount of about 5-30%, preferably about 10-15%, by weight. Preferred polyvinyl acetates are commercially available as the VINAC or AIRFLEX resins from Air Products Company, X-LINK or RESYN resins from National Starch and Chemicals Corporation, or CASCOREZ resins from Borden Chemical Division of Borden, Inc.
Generally the polyvinyl alcohol will be solubilized to appropriate concentration levels of about 0.1% to about 5% of total solids in a separate vessel for use in the present process such as in the mix tank 16, and amounts will be used as to provide about 0.1-1.0% retained in the panel.
Other frothing aids and binders that exhibit weak foaming characteristics may be used in the present process.
Generally the mat will be formed upon one or more cover sheets which become integral parts of the final panel. Such sheets may be of paper, woven or non-woven glass fiber, and the like. A particularly preferred cover sheet is a nonwoven glass fiber scrim, such as battery type scrim, having a weight of about 0.4-2.5 pounds per hundred square feet.
The following specific examples will further illustrate various specific embodiments of the present invention. Unless specified to the contrary, all amounts are expressed as parts by weight on a total dry solids weight basis. Of course, it is to be understood that these examples are by way of illustration only and are not to be construed as limitations on the present invention.
EXAMPLE 1
In a first evaluation, mineral wool having about 30% by weight loose and adhered shot content was mixed with a solution of 0.01% medium viscosity polyvinyl alcohol (VINOL 523). This level did not produce a stable foam but was sufficient to create a frothing type foaming of delicate, non-resilient, non-viscous and non-uniformly sized bubbles. By circulating the slurry through a centrifugal pump with air injection at the exhaust, the mineral wool was selectively entangled in the bubbles. When agitation was stopped, the fiber floated to the surface exhibiting an about 800% increase in volume of entangled fiber compared to the mass of wool before mixing. No visible shot was observed in the frothed fiber, which was dried to achieve an approximately 500% increase in fiber volume.
EXAMPLE 2
A series of evaluations were conducted with a standard mineral wool furnish for conventional dilute water interfelting and various amounts of polyvinyl alcohol (VINOL 540S). Drainage time increased geometrically with increasing amounts of polyvinyl alcohol. Substituting polyvinyl acetate for the polyvinyl alcohol as the binder over ranges of 1-6% binder and 3-10% total solids, passing the furnish through 30 seconds of high shear mixing to develop bubbles and allowing the froth to age, mature and partially dewater by gravity before drainage resulted in much lower linear rather than geometric drainage time increases.
EXAMPLE 3
Old newspaper stock was fed to water in mix tank 11 and "slushed" by high speed impeller mixing to form an about 5% dispersion of coarse paper fiber that was then fed to main mix tank 10. A solution of 95% hydrolyzed polyvinyl acetate (VINOL 540S) was diluted in mix tank 16 and also fed to main tank 10. In addition, mineral wool, expanded perlite, starch and polyvinyl acetate were added to main mix tank 10 and diluted with water to form an about 3-6% solids dispersion proportioned to 33% expanded perlite, 33% mineral wool, 15-19% coarse paper fiber, 0-11% cooked corn starch, 0-14% polyvinyl acetate and 3% polyvinyl alcohol. After 30 seconds high shear, high speed mixing with impeller 12, which pulled a vortex of air into the area of the impeller, the dispersion was passed by pump 22 to modified head box 30 above a conventional moving foraminous wire screen of a mat forming machine, hereinafter wire 40. The modified head box 30 functioned to allow the developing froth of bubbles to consolidate the solids in the frothing mass and to further entangle the developing froth with the solids of the dispersion. The convoluting channelization through box 30, shown more particularly in FIGS. 2 and 3, enhanced the maturing and aging of the bubbles as they self-dewatered and consolidated solids, with excess water from the dewatering bubbles draining out in the controlled drainage section 42. About half-way through the head box 30 the foaming mass 41 is about 25% air by volume and the liquid is about 5% solids.
A continuous scrim bottom cover sheet 43, such as nonwoven battery scrim having a weight of about 0.8-2 pounds per 100 square feet of scrim, was applied above wire 40 before the frothing mass 41 cascaded out of box 30 onto wire 40. A similar top cover sheet 47 was fed through box 30. Feeding the top cover sheet 47 through box 30 and under smoothing roll 34 provided an intimate contact with the frothing mass 41 and assisted in smoothing out the surfaces of the panel core frothing mass 41.
The frothing mass 41 was deposited above the wire at flooded section 42, wherein the foam begins to age and degrade. At the end of this section, the foam or froth is about 50% air by volume and about 10% solids before being hit with the shock of the first vacuum section 44. At this point the froth disappears. It has been found that brief pulses (0.5-2.0 seconds) of vacuum (about 5-20 inches of mercury or about 70-280 inches of water) more rapidly and thoroughly collapse the bubbles without any substantial collapse of the open porous structured wet mass than would a lower vacuum for longer intervals. After rapid pulse high vacuum shock the mass 41 is about 25% solids with the remainder being water in an open porous structure. Underflow water was continuously withdrawn from flooded section 42 and high vacuum section 44 and pumped to a white water holding tank (not shown) for periodic recycling to main mix tank 10.
After high vacuum dewatering of the wet panel, comprising bottom sheet 43, top sheet 47 and a core 41 of open, porous entanglement of fiber, aggregate and binder, it was still about 75% by weight moisture. Because of the open porous nature, that water was readily stripped off and the panel dried by rapidly passing large volumes of heated dry air through the panel first in the hooded low vacuum zone 46 and secondly in the drier 48. Conventional convection drying would require at least three hours to remove this moisture. A lessened pressure differential equivalent to about 5-70, and preferably about 5-15 inches of water (about 0.4-1.1 inches of mercury) was maintained across the surface of mass 41 in vacuum sections 46 and 48. In section 48 the vacuum pressure differential was augmented with the very slight positive pressure (about 1 inch or less of water) of dry air flow through enclosure 49 from blower 50 to aid continued stripping of water and to dry the wet mass 41. The blower was operated to provide air through mass 41 at a volume-velocity of about 50-350, and preferably about 300 cubic feet per minute of air per one square foot of mat surface with the air provided at a temperature of about 37°-180° C., preferably about 175° C. The time for a segment of core mass 41 to be stripped of water and dried from 25% solids varied considerably, depending primarily upon the core thickness which varied from about 1/8th inch through 2 inch thicknesses. Generally an about 1/2 inch thick panel was stripped and dried to less than 1% moisture in about 2 minutes, with about 3/4th of that moisture being removed in the first 30 seconds due to the enchanced stripping and drying resulting from the high volume, high velocity heated air flow through the open porous structure. Additional optional drying may be provided as by drier 52, which also further may be located over section 46. The resultant panels showed an open, porous core exhibiting a large number of voids of highly variable and non-uniform, irregular shapes, ranging from about 1/64th inch to about 5/16th inch in size in a typical nominal half-inch panel. Representative panels had a density from 3 to 6 pounds per cubic foot and exhibited modulus of rupture values of 60 to 120 pounds per square inch. Analysis of the panel and of the drainage white water from the flooded section and the various vacuum sections showed about 40-80% of the polyvinyl alcohol and polyvinyl acetate passing into the white water, depending primarily upon the solubilities of the particular alcohols used, the amount of coarse paper fiber, and the temperature of processing. Adding the white water back to main mix tank 10 maintained a low level of binder and frothing aid additions in continuous operation of the process. Exemplary panel formulations, all of which had about 5 pounds per cubic foot density, modulus of rupture of about 60 psi, noise reduction coefficients of greater than 0.75 and panel thicknesses of 0.24-2.0 inches, were:
__________________________________________________________________________COMPONENT (PERCENT) PROPERTY MIN- COARSE POLY- POLY- B-10 THICK- MODULUSPAN- ERAL PER- PAPER CORN VINYL VINYL BATTERY WEIGHT NESS, OF RUP-EL WOOL LITE FIBER STARCH ACETATE ALCOHOL SCRIM (LB/FT.sup.2) INCHES TURE__________________________________________________________________________ (PSI)1 30 30 15 10 -- 1 14 0.1 0.24 602 34 34 18 11 -- 1 2 1.0 2.0 1203 32 32 16 -- 5 1 14 0.1 0.24 604 36 36 19 -- 6 1 2 1.0 2.0 120__________________________________________________________________________ | A method for the manufacture of very low density mineral wool structural panels on a moving foraminous support wire by frothing a dilute aqueous dispersion of mineral wool is disclosed. The forth, a mass of delicate, non-resilient and non-uniform bubbles among the entangled mineral wool fibers readily breaks, is stripped of water and dried without substantial loss of the highly open, porous structural configuration by a first controlled rate of maturation dewatering followed by brief pulses of high vacuum. Then the open structure is rapidly stripped of remaining water and dried by passing high volumes of heated dry air through the structure with continued vacuum. The drainage water may be recycled in the process to maintain a low level of binder and any frothing aid additions. | 3 |
FIELD OF THE INVENTION
This invention relates to an apparatus for a plant for reducing the alcohol content of beverages that operates with a vacuum.
BACKGROUND OF THE INVENTION
German Offenlegungsschrift (Laid-Open Patent) 3,843,516 shows such an apparatus. Such plants operate with a vacuum. In this case the vacuum is produced there by a single vacuum pump 43 (bottom right in FIG. 1) of the German Laid-Open Patent. The vacuum is maintained through duct 42. The vacuum does not remain constantly in existence. This is less because of air leaks but because a beverage, e.g. in the form of wine or beer, is in fact supplied through the duct 11. At least to this extent, in that a supply of liquid takes place here, but also because of thermal expansion and for other reasons, it is not sufficient to produce a vacuum once only. Rather, the vacuum must be continuously maintained. The word "vacuum" is not to be taken literally here, since an absolute vacuum cannot be produced economically. One or more vacuum pumps can be made use of for the production of this vacuum. Water ring vacuum pumps are usually used. However, rotary vane vacuum pumps can be used, or even venturi nozzles, with which a lower degree of pressure reduction can be attained in a cheaper manner than with water ring vacuum pumps.
Wine, cider, home-made wine, perry, etc., have 400 volatile aroma materials. The majority of these wines have H 2 SO 3 (sulfurous acid), which is also necessary and permissible, so that oxidation is prevented.
The vacuum pumps now have the property of drawing off volatile constituents, e.g. via the duct 42 of the state of the art, and to discharge them through their exhaust air pipes or the like into the surroundings. On smelling these exhaust air pipes, they are found to smell of sulfur and/or aroma materials. The loading of the environment is very small. However, the final product lacks these materials. Indeed, during the reduction of the alcohol content, in the ideal case it would be preferred to remove solely the ethyl alcohol and not the aroma materials. A filter would be desired with an infinite edge steepness for very selective filtration. Moreover, the liquid of reduced alcohol content is also to be stable, so that it has a sufficiently long life.
SUMMARY OF THE INVENTION
The object of the invention is to again increase the edge steepness of such a plant, considered overall as a filter.
According to the invention, this is solved by a vacuum pump for maintaining a reduced pressure in at least one portion of the plant, a reduced pressure duct leading to the plant and containing volatile content materials when in operation, an exhaust pipe connected to the vacuum pump, a second duct at the exhaust air pipe leading at least indirectly, to a beverage of reduced alcohol content, and operating liquid for the vacuum pump comprising at least a partial stream of the beverage.
Even the last residue of aroma materials is thereby fed back again. The better the sensory faculties of the consumers, the more sensitively they react to a lack of volatile aroma materials. Many easily volatile aroma materials are already volatilized at 10°-15° C. For example, they include all of the amyl alcohol and all amyl acetate; and furthermore, many ester components and easily volatile alcohols.
Moreover, the H 2 SO 3 splits under the action of heat into H 2 O and SO 2 . If sulfur dioxide SO 2 is now added to the water again, it dissolves again to form sulfurous acid.
Advantageously, the apparatus according to the invention includes one or more of the following features:
The vacuum pump comprises a water ring, or a rotary disk, or a venturi nozzle.
The volatile content materials include aroma materials and SO 2 .
A device leading from the second duct is provided for adding volatile content materials to the beverage. This device includes a gas washer. The gas washer can be counterflow gas washer, or the gas washer can operate according to the condensation principle, or the absorption principle.
The gas washer has an upper supply device for supplying the beverage and a bottom portion, at which the second duct enters the gas washer. The supply device is a fine spray nozzle.
Packed materials are provided in the gas washer for impingement by the beverage during operation of the gas washer.
The device for adding volatile content materials to the beverage is a cold air dryer.
The beverage supplied to the device passes through a cooler.
The operating liquid for the vacuum pump is water suitable for beverages. The water comprises water for brewing and/or the water is demineralized water, or the water is drinking water of permissible quality in connection with the beverage.
DESCRIPTION OF THE DRAWINGS
The invention will now be described with reference to a preferred embodiment example. In the drawings,
FIG. 1 shows a layout diagram, and
FIG. 2 shows a cross-section through a water ring vacuum pump.
FIG. 3 shows a cross section through a rotary disk pump, and
FIG. 4 shows a layout diagram including a venturi nozzle.
DETAILED DESCRIPTION
Starting from German Offenlegungsschrift 3,843,516 as the state of art, the duct 11 shown in FIG. 1 corresponds to the duct 42 in the German document, and a vacuum pump 12 corresponds to the vacuum pump 43 in the German document. The invention can however also be connected to follow an apparatus according to the Ventriterm process and the evaporation process, both of which operate with reduced pressure. The apparatus according to the invention can also be connected to follow an osmosis apparatus or a dialysis apparatus, although these apparatuses primarily do not operate with reduced pressure. Since however large quantities of residual liquid arise, the residual quantities are further thermally reduced in alcohol content in these processes or apparatuses also. The reduction can amount to a few percent. A beverage is classed as dealcoholized in which the alcohol content has been reduced to 0.5 volume %.
The apparatus according to the present invention permits a reduction of 0.06 volume %.
According to the embodiment example, an exhaust air duct 13 leads from the vacuum pump 12 and ends, in fact above a level 16, within an elongate housing 14 which stands perpendicularly. A duct 17 for the dealcoholized product ends above this level 16. According to the quantity for which the plant is designed, the whole volume of the dealcoholized product, or else only a partial volume of it, can flow through the duct 17. The height of the level 16 is sensed by a level sensor 18. The upper end 19 of the exhaust air duct 13 must always lie above the level 16. A packed column 21, which has a very large surface, is provided in the middle to upper region of the housing 14. A spray device 22 is provided above the packed column 21. The dealcoholized liquid is sprayed by means of this device 22, so that it trickles down over the large surface of the packed column 21. The volatile content materials coming from the end 19 below rise upwards and are united with the dealcoholized liquid coming from above.
A duct 23 leaves considerably below the level 16 and pumps dealcoholized liquid to the "water ring" 24 of the vacuum pump 12. The volatile content materials already unite there, at least in part, with the dealcoholized liquid, which in fact is situated above the vacuum pump 12 up to the level 16, so that it has a certain hydrostatic pressure. The hydrostatic pressure of this liquid volume 27 up to the level 16 drives the vacuum pump 12. The operating liquid is the dealcoholized liquid. In the present invention we replace water that is normally used to drive the vacuum pump with the dealcoholized liquid.
A further duct 26 removes, as does the duct 23, dealcoholized liquid from this liquid volume 27. The liquid is pumped via a pump 28 with a duct 29 to the spray device 22. The liquid at this time passes through a cooler (cold air drier) 31, since the absorption ability is greater when the liquid sprayed by the spray device 22 is cool. The level switch 18 is connected via an electrical lead 32 to a magnetic valve 33. If the level 16 rises too much, the magnetic valve is opened and a portion of the dealcoholized liquid flows out of the duct 29 via the duct 34. If the vacuum pump consumes for its water ring 24 as much dealcoholized liquid as is produced, then the whole volume of the dealcoholized product comes out of the duct 34. Otherwise, the duct 34 leads to where the dealcoholized product is collected: in the state of the art, lastly in the supply container 21 in the German document. Thus, the dealcoholized product or liquid (i.e., the beverage of reduced alcohol content) is used as the operating liquid for the vacuum pump. As shown, this dealcoholized liquid pumps the vacuum pump 12. Also, moving through the duct 26, the dealcoholized liquid passes to the pump 28, rises via the duct 29 and is sprayed by the spray device 22. This liquid also operates the vacuum pump 12, via the duct 23.
The vacuum pump 12 is known per se, e.g. from an article by Dipl.-Ing. E. Mohrdieck, or others. The intake pipe 36, at which the duct 11 ends, and the exhaust air pipe 37, from which the duct 13 leaves, are seen in FIG. 2. The duct 23 is connected, in a manner now shown, to the volume of the water ring 24 which, as described above, does not consist of water here, but of dealcoholized liquid. Furthermore the vanes 38 are recognized, and also the rotary shaft 39 driven by a motor.
With foaming beverages such as, e.g., beer, the beverage of reduced alcohol content is not used as the operating liquid for the vacuum pump. Instead, water flows in through the duct 17. In the case of beer, this can be water for brewing. In the case of wine, it can be demineralized water. If mains water is available which corresponds to the pertinent standards for additions to beverages, the mains water can also be used.
This water flows in through the duct 17, passes via the duct 26 to the pump 28, rises via the duct 29 and is sprayed by the spray device 22 into the housing 14 at the top. The vacuum pump 12 is also operated with this "water," to which the gaseous, easily volatile aroma materials are supplied, as usual, via the duct 11. In the case of beer, the sulfur dioxide is omitted. Thus the apparatus remains as in the arrangement of FIG. 1. Only the operation is different. This water of the vacuum pump 12 is exchanged in continuous flow, so that, as described in the first embodiment example, it flows through the plant according to FIG. 1. The quantity of the added "water" here corresponds at least substantially, but preferably exactly, to that quantity in which an alcohol concentrate was removed from the liquid of reduced alcohol content. According to legal requirements, the quantity can however be greater or lesser.
The water ring pump 12 (FIG. 2) and rotary disk pump 12' (FIG. 3) merely are different in the known way of sealing the rotor vanes with respect to the pump chamber. Both known pumps have a rotor with radially protruding vanes.
According to FIG. 2 the vanes 38 are fixedly mounted on the rotary shaft 39. Their radially outward ends dive more or less into a fluid ring of substantial radial thickness, which provides a gas tight sealing.
According to FIG. 3 the vanes 40 are slidably mounted on the rotor 41, so that their outward ends can follow the contour of the chamber in a sealingly manner.
The known "ventury pump" 12" of FIG. 4 needs an auxiliary pump 43 in order to force the "wine" into the venturi nozzle 42. The auxiliary pump 43 is of the same well known type as pump 28 in FIG. 1. | In known beverage dealcoholizing plants, one disadvantage is that volatile content materials always escape, and the end product consequently lacks aroma materials and/or preserving materials that were previously present. This disadvantage is eliminated in that the volatile content materials, previously lost into the surroundings via the vacuum pump, are fed back again into the beverage. A duct at the exhaust air pipe, connected to the vacuum pump and leading to a gas washer, circulates the volatile content materials back into the beverage. | 2 |
BACKGROUND
[0001] Reducing vehicle emissions has been a strong focus for the federal government as catalytic converters were introduced in the early 1970's to insure cleaner exhaust. Levels as high as 20% of global warming gasses are attributed to vehicle emissions according to the United States Environmental Agency (US EPA) and smog in cities is strongly attributed to motor vehicle exhaust. In 2013, a study at the Massachusetts Institute of Technology by *Barret et al. indicated that in the US alone, approximately 50,000 deaths a year can be attributed to exhaust emissions from motor vehicles. A study published by the World Health Organization by Blanco showed that California children living near roadways had an increased risk of cancer due to diesel exhaust fumes. Despite the almost ten time reduction in exhaust pollutant from vehicles (according to the US EPA) from 1967 to 2002 due to tougher emission standards and technology improvements, the number of cars on the roads has increased by approximately the same factor. The elimination of exhaust gases from motor vehicle combustion engines would be a tremendous societal benefit.
[0002] Generally, motor vehicle exhaust from the combustion of gasoline contains water, carbon monoxide, nitrogen oxides, volatile organic compounds, hydrocarbons, airborne particles, sulfur dioxide, and carbon dioxide. These chemicals in combination with atmospheric constituent molecules, heat, moisture, and other chemicals including ammonia, combine to form noxious gasses including ozone, aldehydes, peroxyacyl nitrates, and nitrogen oxides.
[0003] According to the US Department of Transportation, “A typical automobile on the road in 2002 had an average trip length of 4.0 miles, and, with slightly more than 7 trips per day, an average of about 29 vehicle miles traveled per day. On a given weekday, cold starts of a typical vehicle produces 7.7 grams of Volatile Organic Compound (VOC) gases (25 percent of the typical daily emissions), 88 grams of Carbon-monoxide (CO) (26 percent of the typical daily emissions), and 5 grams of Nitrous Oxide (NOx) (19 percent of the typical daily emissions). Running exhaust accounts for another 7.8 grams of VOC, 251 grams of CO, and 20.2 grams of NOx.”
[0004] The U.S. Environmental Protection Agency estimates the average passenger car emissions in the United States for July 2000 is provided in Table 1 below.
[0000]
TABLE 1
Component
Emission Rate
Annual Pollution Emitted
Hydrocarbons
2.80 grams/mile (1.75 g/Km)
7.1
pounds (35.0 kg)
Carbon
20.9 grams/mile (13.06 g/Km)
75
pounds (261 kg)
Monoxide
NO x
1.39 grams/mile (0.87 g/Km)
8.2
pounds (17.3 kg)
Carbon
0.16 pounds per mile
1,450
pounds (5,190 kg)
Dioxide
(258 g/km)
[0005] Extrapolating the above annual figures, these components add up to roughly 500 million vehicles on the road worldwide, and that yields values for total production of exhaust per year as noted in Table 2 below.
[0000]
TABLE 2
Estimated Annual Pollution Emitted By
Component
Vehicles (B = Billion)
Hydrocarbons
1.6 B pounds (0.72 B kg)
Carbon Monoxide
37.5 B pounds (17.0 B kg)
NO x
1.1 B pounds (0.5 B kg)
Carbon Dioxide
725 B pounds (329.5 B kg)
[0006] *Barrett, Fabio; Ashok, Akshay; Waitz, Ian A.; Yim, Steve H. L.; Barrett, Steven R.H. (November 2013). “Air pollution and early deaths in the United States. Part I: Quantifying the impact of major sectors in 2005”. Atmospheric Environment (Elsevier). Volume 79: 198-208. Bibcode:2013AtmEn . . . 79 . . . 198C. doi:10.1016/j.atmosenv.2013.05.081. Retrieved 25 Oct. 2013.
[0007] Collecting exhaust from vehicles is generally a very difficult task. Catalytic converters are effective at combining unburned hydrocarbons and carbon monoxide to produce carbon dioxide (CO2) and water. Diesel exhaust fluid is effective to help contain the exhaust of harmful nitrogen oxides by combining them with urea to form ammonia. Despite these solutions, the exhaust of carbon dioxide, the largest component of exhaust is not reduced.
[0008] The mechanical compression and storage of gasses coming from the exhaust is not practical due to weight and cost factors. In addition, a buildup of back pressure from an exhaust is generally known to stall the combustion process in an engine. In addition, the buildup of pressure can cause leaks within the cabin of the vehicle which can cause suffocation to vehicle passengers.
SUMMARY
[0009] A system and method for the collection of motor vehicle combustion engine exhaust fumes incorporating an active control and sensor system is disclosed. The system and method are capable of detecting the placement of road installed exhaust collection tubing and ports, and moving an exhaust tube to the collection tubing. The tubing system may be installed under or on top of roads, within road barriers, as guard railing, or in other locations along roadways.
[0010] In exemplary embodiments, a robotic exhaust system includes: flexible tubing configured to connect to a tail pipe at a first end and to connect to an exhaust collection tubing interface at a second end; a motor configured to move the flexible tubing; a sensor configured to detect a marker in the road, wherein the marker provides information indicating a position of the exhaust collection tubing interface; and a controller configured to move the second end of the flexible tubing to the position of the exhaust collection tubing interface.
[0011] In exemplary embodiments, a system to collect exhaust gas from a moving vehicle includes: an exhaust collection tubing interface connected to a collection tubing and disposed adjacent a road; a robotic exhaust system comprising flexible tubing configured to connect to a tail pipe at a first end and to connect to the exhaust collection tubing interface at a second end; and a controller configured to move the second end of the flexible tubing to the position of the exhaust collection tubing interface.
[0012] It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory and are intended to provide further explanation of the invention as claimed.
BRIEF DESCRIPTION OF THE FIGURES
[0013] The accompanying drawings, which are included to provide a further understanding of the invention and are incorporated in and constitute a part of this specification, illustrate embodiments of the invention, and together with the description serve to explain the principles of the invention.
[0014] FIG. 1A illustrates an isometric view of a Robotic Exhaust Positioner (REP) attached or affixed to a vehicle for transferring exhaust to a road embedded collection tubing according to exemplary embodiments.
[0015] FIG. 1B illustrates a close up view of the REP and a motion control system according to exemplary embodiments.
[0016] FIG. 2A illustrates an isometric view of a vehicle with two REPs and a tubing collection system integrated within a road side barrier according to exemplary embodiments.
[0017] FIG. 2B illustrates an isometric view of a vehicle with a top mounted exhaust and top mounted REP (such as a tractor trailer) with collection pipes located or disposed higher than or above a height of the vehicle and vehicle exhaust according to exemplary embodiments.
[0018] FIG. 3 illustrates a cross section of a collection pipe, an interface between the REP and the collection tubing according to exemplary embodiments.
[0019] FIG. 4 is a flow chart of a method for collecting vehicle exhaust according to exemplary embodiments.
[0020] Throughout the drawings and the detailed description, unless otherwise described, the same drawing reference numerals will be understood to refer to the same elements, features, and structures. The relative size and depiction of these elements may be exaggerated for clarity, illustration, and convenience.
DESCRIPTION OF EMBODIMENTS
[0021] Exemplary embodiments will now be described more fully hereinafter with reference to the accompanying drawings, in which exemplary embodiments are shown. This disclosure may, however, be embodied in many different forms and should not be construed as limited to the exemplary embodiments set forth therein. Rather, these exemplary embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of this disclosure to those skilled in the art. Various changes, modifications, and equivalents of the systems, apparatuses, and/or methods described herein will likely suggest themselves to those of ordinary skill in the art. Elements, features, and structures are denoted by the same reference numerals throughout the drawings and the detailed description, and the size and proportions of some elements may be exaggerated in the drawings for clarity and convenience.
[0022] Additional features of the invention will be set forth in the description which follows, and in part will be apparent from the description, or may be learned by practice of the invention.
[0023] A system and method for the collection of motor vehicle combustion engine exhaust fumes incorporating an active control and sensor system is disclosed. The system and method are capable of detecting the placement of road installed exhaust collection tubing and ports, and moving an exhaust tube to the collection tubing. The tubing system may be installed under or on top of roads, within road barriers, as guard railing, or in other locations along roadways.
[0024] The tubes may be equipped with valving including one way valving. The tubes may be able to interface in a continuous manner as a vehicle is moving.
[0025] The exhaust collected by the tubing system may be disposed or deposited within an air stream of pumped air. The exhaust may be pumped to a collection system.
[0026] The exhaust may be separated to collect waste products from exhaust, such as, heat energy, sound energy, exhaust gasses, water, and particulate matter.
[0027] The system for the collection of motor vehicle combustion engine exhaust fumes may be integrated in cities and large highway systems. In exemplary embodiments, the system for the collection of motor vehicle combustion engine exhaust fumes may allow for a vehicle to run independently, and may easily disassociate from the collection system.
[0028] In exemplary embodiments, the system enables the collection of vehicle emissions. The system allows for the collection of exhaust from vehicles. The collection of exhaust can be conveyed for centralized separation of particulate matter, carbon dioxide, nitrogen oxides, volatile organic compounds, hydrocarbons, and water.
[0029] In exemplary embodiments, the system enables collecting wasted heat and sound energy. The collected wasted heat and sound energy may be recoverable from the exhaust systems.
[0030] In exemplary embodiments, the system enables adapting to a wide range of vehicles, driving patterns, and roads.
[0031] In exemplary embodiments, the system creates little or no back pressure applied to the combustion process at the tail pipe. In other words, the vehicle exhaust exits the tail pipe of the vehicle into a pressure volume where the pressure is equal to or less than 1 atmosphere, equal to or less than 2 atmospheres, or equal to or less than 5 atmospheres.
[0032] In exemplary embodiments, the collection system may be tamper and vandalism resistant. In exemplary embodiments, the collection system may be as suitable for warm and cold climates, and with various types and levels of precipitation. In exemplary embodiments, the collection system be easily automatable and require little or no human interface.
[0033] In exemplary embodiments, the collection system may be easily turned off and/or de-coupled from the tubing system, when the vehicle is travelling through an area where the tubing system is not available, for example, in rural areas.
[0034] In exemplary embodiments, there is describe a coupled robotic exhaust pipe (REP) as well a system of tubing able to accept, collect and convey the exhaust from the REP. The REP may include flexible tubing, motors, sensors, and valving. The REP may be attached or connected to the motor vehicle at the tail pipe. The REP may be powered by an electric connection to the external tubing system. The REP may be powered by the vehicle's power system or by captured energy from the environment or exhaust waste. The REP may include sensors capable of detecting markers or electronic signals in the roads, road structure, or the collection tubing. The REP may dynamically move to couple with the collection tubing and to adjust for the position of the collection tubing as the vehicle moves.
[0035] In exemplary embodiments, the collection tubing system may be pressurized to create a flow of gas able to transport the collected exhaust away from a vehicle's tail pipe. The collection tubing system may be pressurized in an automated manner to maintain a proper flow. The interface of the REP and the collection tubing may include a passive or a dynamic one way valve system. The tubing system may use venturi air inlets to form a suction to collect exhaust gas from the REP as the vehicle travels in a continuous or intermittent manner. A venture air inlet may include a short tube with a tapering constriction in the middle that causes an increase in the velocity of flow of a fluid and a corresponding decrease in fluid pressure and that is used for creating a suction. The tubing system may be integrated within roadway structures, such as, the road, the underlayment, side barriers or railings, or simply exposed adjacent above, on or besides the road.
[0036] In exemplary embodiments, electronic communication between the REP and the collection tubing can be provided to monitor and devise an efficient collection methodology. In exemplary embodiments, the system can be connected, via the collection tubing, to a gas and/or particulate separation station for enabling the collection and in some cases compression of exhaust gases for transport. The exhaust gases can be compressed to form liquids.
[0037] FIG. 1A illustrates an isometric view of a Robotic Exhaust Positioner (REP) attached or affixed to a vehicle for transferring exhaust to a road embedded collection tubing according to exemplary embodiments. FIG. 1B illustrates a close up view of the REP and a motion control system according to exemplary embodiments.
[0038] In FIG. 1A , a vehicle 1 travelling on a road 2 on a set of tires 3 with a tail pipe 4 may include a Robotic Emission Positioner (REP) 5 . The REP 5 is further detailed with respect to FIG. 1B below. The REP may form a dynamically moving exhaust tube that can interface with an exhaust collection tube. The REP 5 is connected, attached or affixed to the tail pipe 7 near a tail pipe outlet 18 . The REP 5 can include a motor system 118 for moving a flexible joint and tubing 11 in order to position an extension 9 of the REP 5 at an interface 20 of collection tube 8 . The motor system 118 can include a servo or stepper motor. The motor system 118 may dynamically move extenders 19 . The motor system 118 can move the extension 9 based on commands from a control system, where the control system receives input from sensors 200 embedded in the REP 5 . In exemplary embodiments, the control system may receive input by on sensing the road 10 .
[0039] FIG. 2A illustrates an isometric view of a vehicle with two REPs and a tubing collection system integrated within a road side barrier according to exemplary embodiments.
[0040] In FIG. 2A , a vehicle 1 , 30 is disposed to travel on a road 2 on a set of tires 3 fitted with an REP 5 as well as a secondary REP 31 . The REP 5 interfaces with a collection tube 8 located or disposed within or along a road side wall 32 . The road side wall 32 may be formed from materials such as concrete or steel. A pump 50 in the collection tubing system may be adjusted by a controller 33 . The pump 40 may force air down or through the collection tube 8 past one or more one way valves 34 . A section 700 forming the side wall 32 may fit additional road side sections (not shown) in a modular fashion so as to form a chain of sections to collect exhaust from a vehicle. Multiple vehicles can connect, attach or be affixed to the collection tubing system at the same time.
[0041] FIG. 2B illustrates an isometric view of a vehicle with a top mounted exhaust and top mounted REP (such as a tractor trailer) with collection pipes located or disposed higher than or above a height of the vehicle and vehicle exhaust according to exemplary embodiments.
[0042] In FIG. 2B , a large vehicle, such as, a tractor trailer 91 , may include a vertically oriented tail pipe outlet 50 connected to a REP 5 . The REP 5 may move to dynamically position itself and mate or couple with the collection tube 8 at interface 20 . To ameliorate environmental conditions, such as, snow and ice 41 , the collection tube 8 may be disposed to protect the interface 20 , so that exposure to the elements is minimized for the interface 20 .
[0043] FIG. 3 illustrates a cross section of a collection pipe, an interface between the REP and the collection tubing according to exemplary embodiments.
[0044] In FIG. 3 , a cross sectional view of the REP 5 , the collection tube 8 and an interface system 60 is illustrated. Exhaust tail pipe 4 , 501 may emit exhaust 66 through one way valves 65 . Exhaust tail pipe 4 , 501 may connect, couple or attach at interface 20 with the collection tube 8 . The physical connection may be spaced by a gap, or may be a solid connection or flexible connection, such as, an air bladder, a bellows, or the like, so as to create a seal between the REP 5 and the collection tube 8 . An air flow 62 may be created within the collection tube 8 by pump 50 . The air flow 62 may form a pressure 61 (P 0 ) and exit pressure 63 (P 1 ). The pressure 61 (P 0 ) and exit pressure 63 (P 1 ) may be adjusted to optimize the collection or vacuum pressure required to pull, extract, or outflow exhaust from a tail pipe of a vehicle. The one-way valve 64 may be actuated mechanically or electromechanically. For example, a mechanical actuation force may include the exhaust generating an exhaust pressure at the one-way value and the exhaust pressure pushing one a one-way flap, a door or the like at the outlet of 5 to dispose the exhaust into the collection tube 8 .
[0045] FIG. 4 is a flow chart of a method for collecting vehicle exhaust according to exemplary embodiments.
[0046] FIG. 4 illustrates a process or method 600 for collecting exhaust from the collection and interface system 60 commencing with an internal combustion engine 101 in operation 101 delivering an exhaust in operation 102 . The exhaust may be delivered to a funneling device, such as, a robotic exhaust positioner (REP). in exemplary embodiments, the REP is getting input or control from electronic detection of markers at operation 103 . In exemplary embodiments, the REP may control or drive motors so as to position the exhaust at the point of collecting publicly 111 in operation 104 . In exemplary embodiments, the REP may activate when a proximity to a collection and interface system 60 is detected in operation 106 . The proximity activation may occur along with initiating or activating valving procedures in operation 107 . The proximity activation may occur along with initiating or activating a pump driving protocol 112 and 109 . In exemplary embodiments, a vandalism control may shut the system down in operation 107 so as to prevent the contamination of the collection and interface system 60 .
[0047] In exemplary embodiments, operation 113 may provide for collecting solar or renewable energy or heat collection from heat collector 110 . The energy may be used using it to drive the electronics or mechanics of the REP in operation 114 . In exemplary embodiments, the energy for any of the aforementioned collection processes of 600 (for example 111 ) may be provided by other power sources, such as, vehicle power. The process of further separating the collected exhaust 115 may include using gas separation 116 , carbon dioxide sequestration 119 , liquid separation and storage 117 , dust and other solid particulate separation 118 (through for example filtering), or the like.
[0048] The examples presented herein are intended to illustrate potential and specific implementations. It can be appreciated that the examples are intended primarily for purposes of illustration for those skilled in the art. The diagrams depicted herein are provided by way of example. There can be variations to these diagrams or the operations described herein without departing from the spirit of the invention. For instance, in certain cases, method steps or operations can be performed in differing order, or operations can be added, deleted or modified. | A robotic exhaust system to connect to a vehicle, a system to collect exhaust gas from a moving vehicle, and a method thereof is described. The robotic exhaust system includes: flexible tubing configured to connect to a tail pipe at a first end and to connect to an exhaust collection tubing interface at a second end; a motor configured to move the flexible tubing; a sensor configured to detect a marker in the road, wherein the marker provides information indicating a position of the exhaust collection tubing interface; and a controller configured to move the second end of the flexible tubing to the position of the exhaust collection tubing interface. | 4 |
BACKGROUND OF THE INVENTION
[0001] The present invention relates to a clutch for washing machine and method for using same.
[0002] Vertical axis washers include a perforated spinner basket having an agitator therein. These washers have an agitation mode which causes the agitator to reciprocate back and forth in opposite rotational directions. These washers also include a spin cycle wherein the spinner basket is rotated at high speeds to cause the materials therein to be spun out by centrifugal force.
[0003] When a vertical axis washer goes into the spin portion of its cycle, the spinner basket full of wet clothes is far too heavy for the drive motor to ramp up to speed quickly. Prior art methods for handling this ramping up involve the use of a loose or slipping belt between the motor and the spinner basket. This allows the motor to ramp up to full speed and slowly bring the spinner basket full of clothes up to speed.
[0004] Other methods for handling this problem include slip clutches having an outer housing that is belted to the spinner basket and an inner hub that is keyed to the motor with weights that are centrifugally applied to the outer hub to accelerate the spinner gradually. These clutches include a center hub that is ramped on one side to give it a positive drive in that direction for agitation and a radial side for a slip-clutch feature in the opposite direction for spinning.
[0005] Therefore a primary object of the present invention is the provision of an improved clutch for washing machine and method for using same.
[0006] A further object of the present invention is the provision of an improved clutch which has no springs or weights.
[0007] A further object of the present invention is the provision of a clutch for a washing machine having a metal plate that flexes outwardly in response to centrifugal force and engages an annular hub.
[0008] A further object of the present invention is the provision of an improved clutch which gradually engages two rotating members to permit a gradual ramp up to full speed for the spinner basket.
[0009] A further object of the spinner basket is the provision of an improved clutch and method for using same, which is economical to manufacture, durable in use, and efficient in operation.
BRIEF SUMMARY OF THE INVENTION
[0010] The foregoing objects may be achieved by a washing appliance clutch for transferring rotational power from a motor to a driven basket for rotating the driven basket about a drive axis. The washing appliance clutch comprises a drive member adapted to be driven by the motor for rotation about the drive axis. An intermediate plate is engaged by the drive member for rotation with the drive member about the drive axis. The intermediate plate includes an outer peripheral edge and a hub surrounds the outer peripheral edge of the intermediate plate in close spaced relation thereto. The outer peripheral edge of the intermediate plate is capable of flexing in response to centrifugal force during the rotation of the intermediate plate from a retracted position free from engagement with the hub to an expanded position engaging the hub and rotating the hub about the drive axis.
[0011] According to a further feature of the invention the intermediate plate includes a plurality of cutout portions that create a plurality of weakened points in the intermediate plate. The weakened points in the intermediate plate permit flexing of the intermediate plate in response to centrifugal force during rotation.
[0012] According to another feature of the present invention the intermediate plate includes a first group of cutout portions that comprise slots extending from the outer peripheral edge inwardly towards the drive axis.
[0013] According to another feature of the invention a second group of cutout portions are located completely inwardly from the peripheral edge of the intermediate plate.
[0014] According to a further feature of the invention the drive member includes a first cam surface and the intermediate plate includes a first cam follower surface engaging the first cam surface of the drive member. The motor includes an agitate mode in which it drives the drive member continuously in a first rotational direction. The motor also includes a spin mode in which it drives the drive member continuously in a second rotational direction opposite from the first rotational direction.
[0015] The first cam surface and the first cam follower surface cooperate to cause the outer peripheral edge of the intermediate plate to move from the retracted to the expanded position during rotation of the drive member in the second direction.
[0016] According to another feature of the invention the outer peripheral edge of the intermediate plate flexes from the retracted to the expanded position solely in response to centrifugal force during rotation of the intermediate plate when the motor is in the spin mode.
[0017] According to another feature of the invention a high friction material is positioned between the outer peripheral edge of the intermediate plate and the hub for facilitating frictional engagement between the hub and the outer peripheral edge of the intermediate plate.
[0018] The foregoing objects may also be achieved by the method of the present invention. The method includes connecting the motor to a drive member. The drive member is then placed in driving connection with an intermediate plate so that the rotation of the drive member will cause rotation of the intermediate plate. The intermediate plate includes an expandable outer peripheral edge. The method further includes surrounding the peripheral edge of the intermediate plate with an annular hub connected to the washing appliance basket. The motor is activated to rotate the drive member and cause rotation of the intermediate plate whereby the outer peripheral edge of the intermediate plate will flex in response to centrifugal force from a retracted position spaced in an inner radial direction from the annular hub to an expanded position frictionally engaging and rotating the hub.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] [0019]FIG. 1 is a schematic drawing showing the clutch in section taken along line 1 - 1 of FIG. 2 and showing the clutch connected to a washing basket and agitator.
[0020] [0020]FIG. 2 is a sectional view taken along line 2 - 2 of FIG. 1.
[0021] [0021]FIG. 3 is an exploded perspective view of the clutch mechanism of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0022] The numeral 10 generally designates the clutch of the present invention. The clutch shown drivingly connected to a spinner basket 12 for rotating the spinner basket 12 . Alternatively the clutch is capable of driving an agitator 14 within the spinner basket 12 . The agitator 14 includes agitator fins or paddles 16 and an agitator base 18 .
[0023] A transmission 20 includes an agitator drive shaft 22 and a spinner drive shaft 24 . The transmission 20 includes an input shaft 26 having a pulley 28 thereon. The rotation of the pulley 28 in a first rotational direction will cause the transmission 20 to alternatively rotate the agitator 14 in first and second opposite rotational directions so as to create an agitation action within the spinner basket 12 . This alternative agitating motion is transferred from the transmission 20 through the shaft 22 to the agitator 14 .
[0024] When the pulley 28 is rotated in an opposite second direction the transmission 20 transfers rotational movement through the spinner drive shaft 24 to the spinner basket 12 and causes rotation of the spinner basket 12 only in the second direction. This rotation is usually at high speeds so as to centrifugally spin the washing fluid out of the fabrics that are within the spinner basket 12 .
[0025] Connected to the pulley 28 is a drive belt 30 which is also trained around a pulley 32 fixed to a clutch hub 34 for rotation in unison therewith. The clutch hub 34 includes a circular end wall 36 and an angular flange 38 .
[0026] Inside the clutch hub 34 is a circular intermediate plate 40 having a central cutout portion 42 shown in FIG. 3.
[0027] The cutout portion 42 includes four cutout spokes 44 and four arcuate T-slots 46 at the outer ends of the cutout spokes 44 . The arcuate T-slots 46 are very close to the outer peripheral edge 82 of the intermediate plate 40 . This close proximity creates four outer weak spots 48 that are capable of flexing in response to centrifugal force resulting from rotation of the intermediate plate 40 . Each of the cutout spokes 44 in the intermediate plate 40 include an orthogonal side 50 and an angled side or cam surface 52 . The four orthogonal sides 50 are perpendicular to one another and form a generally rectangle shape. The four angled sides 52 are angled with respect to the orthogonal sides at an angle of approximately 30°. However, the angle may be varied without detracting from the invention.
[0028] Extending inwardly from the outer peripheral edge 82 of the intermediate plate 40 are four outside T-slots 54 each of which comprise a T-leg 56 and a T-cross 58 . As can be seen in FIG. 2 the T-leg 56 is at a slight angle with respect to the T-cross 58 . This angle may be varied without detracting form the invention. The T-crosses 58 are very close to the orthogonal sides 50 of the central cutout 42 , and because of this close proximity they create inner weak spots 60 which are capable of flexing in response to centrifugal force of the intermediate plate 40 when it rotates.
[0029] A drive member 62 fits within the cutout 42 and includes a square hub 64 having four spokes 66 extending outwardly from its four corners. Each spoke includes an orthogonal surface 68 and an angled or cam follower surface 70 . The drive member 62 is mounted for rotation on an output shaft 74 extending from a motor 72 . The motor 72 is reversible and is capable of driving the drive member 62 either in a clockwise or a counter clockwise direction. Shaft 74 is attached to the drive member 62 by means of a nut 76 . Extending around the outer peripheral edge 82 of the intermediate plate 40 is a frictional ring 78 , and extending around the interior of the annular flange 38 of hub 34 is a similar friction ring 80 . While two friction rings 78 , 80 are shown in the drawings, it is possible to have just one friction ring, either mounted on the outer edge of the intermediate plate 40 or alternatively a single friction ring mounted on the inside surface of the annular flange 38 of hub 34 .
[0030] In operation the motor 72 is actuated to drive the drive member 68 in an agitation mode. As viewed in FIG. 2 this agitation mode would rotate the drive member 62 in a clockwise direction. This causes the orthogonal surface 68 of the drive member 62 to cam against the orthogonal side 50 of the intermediate plate 40 . The camming action results in the intermediate plate 40 being deflected radially outwardly so that its outer peripheral edge 82 forces the frictional rings 78 , 80 into contact with one another. The outer weak points 48 and the inner weak points 60 flex in order to permit this outward radial expansion. The rotational movement is then transferred because of the frictional engagement between the two frictional rings 78 , 80 to the hub 34 and then through belt 30 to the transmission 20 . The transmission responds to this driving movement by rotating the agitator 14 alternatively first in one direction and then in the opposite direction.
[0031] When the spin cycle is reached in the cycle of the washing machine, the motor 72 is reversed to rotate the drive member in a counter clockwise direction as viewed in FIG. 2. Initially the rotation of the intermediate member 40 does not result in expansion, but as the rotational velocity increases, centrifugal force causes the intermediate member 40 to bend at the weak points 48 , 60 and expand radially outwardly. Ultimately the frictional members 78 , 80 come into contact with one another and they initially slip slightly. This permits some slippage between the rings 78 , 80 as the ramp up speed is achieved thereby causing a gradual shift of driving force to the transmission 20 and ultimately to the spinner basket 12 . This gradual application of force is important because of the heavy load of wet fabrics that is often contained within the washing basket 12 . As the rotational speed of drive member 62 increases the expansion of the intermediate plate 62 also increases until there is tight frictional engagement between the rings 78 , 80 thereby completing the driving and spinning action to the spinner basket 12 .
[0032] The clutch shown in the drawings includes no springs or weights to be held in place to control the rate of acceleration. Instead the gradual engagement of the clutch occurs as the centrifugal force increases during the increasing of rotation of the drive member 62 .
[0033] While orthogonal surfaces 50 , 68 are shown to be straight, it is also possible to curve one or both of those surfaces to ensure a positive drive condition.
[0034] In the drawings and specification there has been set forth a preferred embodiment of the invention, and although specific terms are employed, these are used in a generic and descriptive sense only and not for purposes of limitation. Changes in the form and the proportion of parts as well as in the substitution of equivalents are contemplated as circumstances may suggest or render expedient without departing from the spirit or scope of the invention as further defined in the following claims. | A clutch for washing machine includes a rotating hub driven by a motor. The hub engages a ratable intermediate plate which is mounted in spaced relationship inside an annular hub. As the rotational speed of the intermediate plate increases it expands radially outwardly and engages the hub to complete the clutch engagement. | 3 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation application Ser. No. 12/292,328, entitled “Mortgage Foreclosure Insurance Product and Method for Hedging and Calculating Premiums,” filed on Nov. 17, 2008 by Wallace Benward and Branden Dwayne Rife, which is incorporated herein by reference in its entirety.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present subject matter relates to a financial product such as a foreclosure insurance policy, and a method and means for producing such a product, including producing a value on which policy premiums are based.
[0004] 2. Related Art
[0005] Currently, the only form of commonly utilized mortgage insurance that exists with respect to home mortgage payments is Private Mortgage Insurance (PMI). PMI is designed to protect the lender in case of a mortgage default. PMI is typically required by a lender for those individuals who qualify for a home loan, but are unable to provide a down payment of 20% or more towards the amount of the home's purchase price. The lender will either require the homeowner to purchase PMI directly from a PMI insurer, or it will charge a higher interest rate on the loan and purchase a PMI product against the loan to hedge and protect itself Either way, if the prospective homeowner is not able to produce a down payment of 20% or more, they will bear the financial burden in one form or another to protect the lender.
[0006] Moreover, if the homeowner lives in a state that allows the lender to seek financial recourse against the borrower for losses and costs associated with the foreclosure and subsequent resale of their home (potentially at a price lower than their existing loan balance), they become faced with an even greater financial burden, the likes of which they most likely would not be able to endure. Furthermore, when a homeowner refinances their mortgage loan, the new loan is automatically deemed to have recourse no matter what state they reside in. This allows lenders to sue the homeowner for a variety of losses. Unfortunately, most homeowners are unaware of the consequences they face should they fall into foreclosure.
[0007] A problem for homeowners is that PMI protects only the lender. United States Patent Application Publication No. 20050108064 provides for a financial arrangement in which a homeowner's down payment is structured in a manner to avoid the requirement for PMI. The specification points out that consumers do not attach a high value to Private Mortgage Insurance. Private Mortgage Insurance protects the mortgage holder. Consumers do not see how they benefit by paying for insurance to protect another party. While this publication discloses an arrangement to avoid the need for PMI, a vehicle for protection of the homeowner is not provided.
[0008] PMI insurance companies use a revenue model in which their income or loss is based on a method that is often analogized to casino gaming. Insurance companies use actuarial data to calculate the likelihood of the occurrence of losses against which they are ensuring. With regard to PMI, statistical data used by actuaries may include likelihood of occurrences such as unemployment of a mortgagor, and drop in home values due to any number of factors. The premium charged will yield a predicted profit to the insurance company if a predicted level of loss in incurred. The insurance company is betting that its prediction is correct.
[0009] The prior art has also sought to add functionality to insurance beyond that of ensuring for a specific risk. A conventional policy may be modified to provide an acceptable economic outcome in the event of old currents of a predetermined set of circumstances. For example, U.S. Pat. No. 7,392,202 discloses methods and systems for providing an insurance policy with an inflation protection option. The disclosed method requires tracking economic circumstances and making additional purchases to correct for selected economic circumstances. The additional functionality requires the use of transactions initiated at a later time, and is not built into the initial structure of a product.
SUMMARY
[0010] The present subject matter is directed to an insurance policy and insurance method to protect homeowners from foreclosure and to the production of such a policy. A financial insurance product and a method, means, and a computer program are provided. The policy will financially assure a homeowner for a specified period of time to prevent the foreclosure of the policy holder's home. An insurance company or financial institution agrees to pay on behalf of an insured, the fixed monthly mortgage of the policy holder for a determined period of time based upon occurrence of a triggering event. Examples of a triggering event include a home loan being placed into default and/or being categorized in foreclosure. The subject matter also includes methods of calculating premiums for said policy as well as methods to mitigate risk associated with writing the policy via financial instruments that will effectively hedge its risk.
[0011] Briefly stated, in accordance with the present subject matter, a method and means to produce a value of a premium for a financial product, which method may incorporate a method to hedge that product's risk, are provided. In one form, a computer program is provided which uses financial data that has been entered into an insurer's database to produce the value for the premium of an insurance product. The insurance product will pay the monthly mortgage of the homeowner in the event of default on the homeowner's mortgage loan or if the underlying mortgaged property is at risk of being categorized in foreclosure. The value of the policy premium is based on a predetermined set of parameters. Parameters may include the homeowner's monthly mortgage payment, asset valuation, the terms and conditions of the associated mortgage loan, e.g. whether the loan is a first mortgage, and borrower creditworthiness. The foreclosure insurance policy is packaged to allow for the sale, hedging, or reinsurance by the insuring entity. In the preferred form, the hedging vehicle performs in response to the market including the mortgaged property.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] The accompanying drawings illustrate the various features and aspects of the invention and together with the description, explain the advantages and principles of the invention.
[0013] FIG. 1 is a flowchart illustrating the steps performed in order to create an insurance policy;
[0014] FIG. 2 is a block diagram of a data processing system suitable for use with the present subject matter;
[0015] FIG. 3 is a chart of database fields and input information used within the insurance premium calculation and policy creation;
[0016] FIG. 4 consists of FIGS. 4A and 4B , which illustrate the input parameters and calculation of insurance premium and its profitability metrics for insurance policies covering mortgage payments in a first and in a second price range respectively;
[0017] FIG. 5 consists of FIGS. 5A , 5 B, 5 C, and 5 D, which illustrate the input parameters and calculations in a hedging process by which an insurer reduces risk through the use of first and second hedging vehicles respectively;
[0018] FIG. 6 is a flowchart describing the process that transpires after a Mortgage Foreclosure Insurance policy has been executed between the parties; and
[0019] FIG. 7 consists of FIGS. 7A and 7B , which respectively illustrate hedging through the use of a derivative and through the use of a derivative of a derivative.
DETAILED DESCRIPTION
[0020] In accordance with the present subject matter, a financial insurance product and method and means for producing and hedging a product are provided. The financial insurance product affords financial assurance to a homeowner for a specified period of time to forestall the foreclosure of his or her home. The present subject matter enables production of a value for an insurance premium. This value is related to the hazard being insured. The generation of the value employs risk mitigation through the use of a hedging vehicle. A hedge may comprise futures, options, or other instruments, e.g., housing futures for a given geographical area traded on the Chicago Mercantile Exchange.
[0021] The present subject matter comprises a form of individual policy having premiums that can either be set at a fixed price, or calculated by multiplying the homeowner's monthly mortgage payment by a percentage rate to be determined by the insurer. The percentage rate could be based upon any individual or combination of factors, which may include conventional parameters in addition to the risk mitigation parameters. These parameters may include marketability in the opinion of the insurer, risk/reward tolerance, projected default ratios (percentage of policies that will have claims made against them), required reserve ratios (the amount of reserve capital to be held at all times as a percentage of total liabilities), the borrower's FICO® score or other form of credit scoring technique, the underlying or existing mortgage loan terms and structure, the respective Loan To Value (LTV) ratio (the amount the loan represents as a percentage of the total value of the home), the geographic projection of a housing market's affordability ratios and/or its respective net present value and future value. The insurance company is not required to rely solely on “playing probabilities” as to the number of losses to be incurred and the cost of the losses.
[0022] Since the insurer can mitigate risk, insurance becomes more accessible to homeowners. Said another way, a single policy or a group of policies will contain the ability to be hedged. By combining an insurance policy or group of policies with a hedging vehicle, e.g., a derivative product whose price fluctuates based upon an underlying index, market data or an observable input from which the derivative's value is determined, the insurer can mitigate financial exposure by associating an expected number of claims and their dollar equivalent with the appreciating or depreciating valuation of housing within any given geographic region.
[0023] Examples of such derivatives are futures contracts that trade on the Chicago Mercantile Exchange based upon the value of the S&P Case-Schiller Home Price Indices®. Additional examples of indices, market data, and observable inputs that currently have derivative contracts associated with their value and can be used to mitigate the inherent risk of the foreclosure insurance policy are The Markit Group's ABX Indices, The Radar Logic Residential Property Index™ and OFHEO's HPI (Office of Federal Housing Enterprise Oversight's Housing Price Index). The index utilized may be an index for a geographical area in which the insured property is located.
[0024] The insurer can enter into contracts for exchange-traded or private over-the-counter futures. Alternatively, the insurer can enter into option contracts with institutions that have created or trade derivative products. Typically the respective derivative's valuation and prices are derived from economic statistics issued by United States Government agencies or by private entities that create and maintain statistics for use in the computing of economic activity. The insurer can use, for example, futures contracts, or derivative option contracts whose valuation is derived based upon the underlying futures or derivative's contract price. The option contracts can be in the form of puts, calls, or any strategy that employs a combination of the two either individually or combined.
[0025] The insurer can also enter into forward conversion contracts with any institution for the previously stated risk mitigation objectives either by encompassing the aforementioned techniques and strategies within a forward conversion contract, or by entering into a custom and proprietarily developed forward conversion contract or swap contract.
[0026] These techniques and strategies can be implemented for a single policy or implemented by combining numerous individual policies to form a group of policies and or entered into as separate tranche transactions with the purpose of mitigating losses associated with any potential policy claims from policies that are comprised of similar amounts of financial risk and or structure of risk tolerance. Similar to futures and futures options contract strategies, risk can also be mitigated by purchasing re-insurance on an individual mortgage foreclosure insurance policy, a pool of mortgage foreclosure insurance policies, or a tranche of mortgage foreclosure insurance policies. Reinsurance transactions for an individual policy, a group of policies, or a tranche of policies can be entered into as separate transactions notwithstanding any additional hedging techniques or strategies that are employed with the purpose of mitigating losses associated with any potential policy claim or claims.
[0027] If a triggering event occurs, the policy holder will file a claim on the policy. Examples of triggering events include the mortgage loan being placed into default or being categorized as being delinquent or in foreclosure The definition of a triggering event could also be written to include a status where events leading up to the foreclosure process have occurred. Following the claim notification, the insurer will contact the lender and or loan servicer and verify the validity of the claim either via written, verbal, or electronic correspondence. Once the claim has been deemed valid, the insurer will begin payment to the lender or servicer under the terms and conditions of the respective policy.
[0028] In the instance that no triggering event occurs, the policy will renew with all terms and conditions contained within the previous policy unless terminated by either the insurer or the insured.
[0029] FIG. 1 is a flowchart illustrating a context for the present subject matter. In a process 100 to initiate coverage, a homeowner applies for insurance at block 110 . At block 120 , the homeowner provides information to the insurer regarding selected parameters, which are discussed further with respect to FIG. 2 . At block 130 , the insurer verifies all personal and financial information provided by the homeowner.
[0030] At block 140 , the insurer determines annual and/or monthly premiums. The premium has a structure comprising a first component related to a rate category and a second component based on a hedge selected for it mitigating risk of loss with respect to the insured interest premium is based on a number of components. A first component may be based on commonly used standard actuarial formulas as well as any subjective or other criteria that are included in the insurer's business model. Conventional parameters include credit worthiness of the borrower, percentage of loan to equity in the subject house, and a number of other factors. The rate is also a function of factors calculated in accordance with the present subject matter (further discussed with respect to FIG. 4 ). For purposes of the present description, selecting a combination of conventional parameters on which the premium will be based is referred to as determining a rate category. Assigning a value on which the component of premium due to this first factor is referred to for purposes of the present description as determining a premium component for the rate category.
[0031] A second component of the rate is based on risk mitigation achieved through hedging the insured interest. The hedging process is described in detail below. For purposes of the present description, selecting a hedging procedure, i.e., selecting the various parameters discussed with respect to FIGS. 4 and 5 , and determining costs in connection therewith is referred to as determining a hedging cost. Assigning a value on which the component of premium due to this second factor is referred to for purposes of the present description as determining a hedging premium component. The insurer will determines the premium by combining the cost components due to risk along with other price components, e.g., profit and overhead. This determination of the premium is referred to as establishing an insurance premium based upon a predetermined relationship between the cost level and the premium. The relationships are embodied in rules, as further described below.
[0032] At block 150 , the insurer writes the foreclosure insurance policy. At block 160 , both parties agree to the terms and conditions set forth within the policy. Once the parties agree on the terms, the foreclosure insurance policy is executed and issued at block 170 .
[0033] FIG. 2 illustrates a block diagram of data processing system 200 in which methods and systems consistent with the present invention may be implemented. The data processing system 200 includes a display device 202 , an input device 204 , and a cursor control device 206 which each interact with a computer 208 . The data processing system 200 further comprises a communications network 220 and a network server 222 .
[0034] The computer 208 also comprises a bus 214 or other electronic communication mechanism used for transmitting data within and between computer systems and peripherals, a central processing unit 216 , a random access memory 210 , long-term storage devices 212 , and a network communication device 218 . The computer 208 in the present illustration communicates within and between device display 202 , input device 204 , and cursor control device 206 takes place via the bus 214 . Within the computer 208 , bus 214 acts as the electronic communication mechanism that allows simultaneous communication between random access memory 210 , long-term storage device 212 , and central processing unit 216 . Communication between the computer 208 and network server 220 takes place via network communication device 218 , which uses a communication network 222 . Communication network 222 can be in the form of any current or future networking systems such as a local area network, a wide area network, a virtual private network, or a direct closed network.
[0035] The computer 208 and apparatus interacting therewith can respond to commands of a machine-readable medium. A machine-readable medium includes any mechanism that provides (i.e., stores and/or transmits) information in a form readable by a machine (e.g., a computer). For example, a machine-readable medium includes read-only memory (ROM); random access memory (RAM); magnetic disk storage media; optical storage media; flash memory devices; electrical, optical, acoustical or other form of propagated signals (e.g., carrier waves, infrared signals, digital signals, etc.) etc. The particular architecture illustrated of the data processing system 200 is illustrative of the functions performed, and many alternatives may be provided.
[0036] FIG. 3 is a chart 300 comprising database fields. The database fields comprise the information used to produce a value on which an insurance premium is based and information utilized for administration of policies. The set of parameters used in FIG. 3 is illustrative. Fewer or additional parameters could be utilized.
[0037] FIG. 3 may be viewed in a number of ways. FIG. 3 is illustrative of one form of data structure for the long-term storage device 212 ( FIG. 2 ). FIG. 3 also represents a graphical user interface provided on the display device 202 . Additionally, FIG. 3 represents a portion of the software architecture for operating a system in accordance with the present subject matter.
[0038] Chart 300 includes input fields for information such as mortgagor name, property address, and select mortgage loan information. In the present illustration, fields 302 - 312 contain information identifying the homeowner and the home. Field 302 includes the name of the homeowner. Fields 304 and 306 are used for first and second address lines. The name fields 308 , 310 and 312 respectively record city, state, and zip code. If desired, a legal description of the property as recorded in County Clerk title records could also be included.
[0039] Fields 314 - 316 contain information relating to current financial information regarding the home. Fields 314 and 316 illustrate an original mortgage amount and a current value of remaining balance respectively. Fields 318 and 320 respectively contain information on the type of loan, e.g., fixed or adjustable, and interest-rate respectively. Field 322 is used to indicate whether there is an outstanding value. In field 324 , an estimated property value is illustrated, while field 326 illustrates the ratio of the loan balance to the property value, i.e., the mortgage amount plus the amount secured by a property interest in the house, expressed as a percentage.
[0040] Fields 328 - 336 contain information about the homeowner. Fields 328 , 330 , and 332 respectively represent annual household income, liquid net worth, and total net worth. Fields 334 and 336 respectively represent credit score and adjusted credit score. The most common credit score used is a proprietary computational score generated by this Fair Isaac Corporation known as FICO®. The adjusted credit score is a score that the homeowner would have but for the factor which is excluded from the calculation for purposes of the adjustment. For example, in a market with a historically high level of foreclosures, the inventors herein contemplate that credit score and rating agencies will create an additional credit score that reflects the credit worthiness of a borrower if he or she had not gone into foreclosure.
[0041] Fields 338 - 342 contain information about the current mortgage. Fields 338 , 340 , and 342 respectively represent the name of the lender, identification of the mortgage loan, and the monthly mortgage payment. Field 340 represents the loan identification number that is assigned to all mortgage loans outstanding for purposes of organization, tracking, payment association, deed ownership, and reconciliation. Field 342 represents the data base field containing the mortgagor's monthly mortgage payment.
[0042] FIG. 4 , consisting of FIGS. 4A and 4B , illustrates one exemplary method 400 of producing a value for the monthly premium of a Mortgage Foreclosure Insurance product. Additionally, profitability metrics may be generated. It is common practice for an insurance company to establish different tiers of rates for different ranges of pay-off benefits. FIG. 4A corresponds to a first tier premium level for a policy providing payment coverage of $1-$1600. FIG. 4B corresponds to a first tier premium level for a policy providing payment coverage of $1601-$2500. Additional or alternative ranges may be established.
[0043] In FIG. 4A , field 402 specifies a range for a tier. Fields 404 and 406 will identify the benefits under the insurance policy, namely the monthly mortgage payment which is insured and the number of months of payments that can be made under the policy respectively. Field 408 identifies the total liability of mortgage payments insured by the insurer. Premium information is specified in the fields 410 - 416 . Fields 410 and 412 represent the price for coverage as a percent of monthly mortgage payment and as a dollar value respectively. Fields 414 and 416 respectively illustrate monthly and annual premiums.
[0044] Fields 418 through 442 provide information to the insurance company indicative of profitability metric for one illustrative scenario. Fields 418 , 420 , and 422 respectively represent a particular number of policies that are in effect in one tier, the average monthly premium per policy and the total monthly revenue for that tier of policies. Fields 424 and 426 respectively represent annualized revenue in that tier and profit ratio. Fields 428 , 430 and 432 respectively represent a projected default rate, the numerical value of that percentage based on the information in field 418 , and the number of payments for which the insurer will be liable. This data allows the insurer to analyze the-magnitude of risks.
[0045] FIG. 5 is a chart illustrating parameters utilized in creating a foreclosure insurance policy in accordance with the present subject matter. The policy embodies a hedging process by which an insurer reduces risk and in which the insurer may relate the premium to market values having an association with the value of the mortgaged property. FIG. 5 consists of FIGS. 5A , 5 B, 5 C, and 5 D which illustrate the input parameters and calculations in a hedging process by which an insurer reduces risk through the use of first and second hedging vehicles respectively. FIG. 5 is illustrative of a graphical user interface on the display device 202 ( FIG. 2 ), data structure within the long-term storage device 212 , and a program for execution on a processor.
[0046] The operations described below may be performed on the computer 208 ( FIG. 2 ) in response to a machine-readable medium provided in accordance with the present subject matter. The factors and terms utilized in the calculations below may be accessed from their respective locations in the long-term storage device 212 . These calculations may be performed in the central processing unit 216 .
[0047] In the present illustration, a single policy or group of policies as illustrated in FIGS. 4A and 4B are being hedged. FIG. 5A illustrates the use of a derivative, for example a futures contract as a hedging vehicle for an individual mortgage policy. Identification information is provided in Fields 501 , 502 , and 503 , which respectively indicate an insurance policy number, identity of the mortgage loan to which the insurance applies, and whether the homeowner is carrying PMI for benefit of the lender. Field 504 represents the amount needed to be hedge by the insurer. This value is obtained from field 408 in FIG. 4A or 4 B respectively.
[0048] Fields 505 through 518 relate to the hedging vehicle used in conjunction with the foreclosure insurance policy. Fields 505 and 506 respectively identify a futures contract symbol and the name of the index corresponding to that symbol. A number of hedging vehicles are available. In the present illustration, the symbol of the particular futures contract utilized is NYMX10. This illustrated symbol is the identifier of the S&P Case Schiller Housing Index futures contract for the New York City metropolitan area. This illustrated index future contract is traded on the Chicago Mercantile Exchange. This is a vehicle best suited for hedging a policy on a house in the New York City metropolitan area. The Chicago Mercantile Exchange maintains futures contracts for many metropolitan areas in the United States. However, it is not necessary that the hedging vehicle be a futures contract. Broker-dealers may create their own derivative contracts or forward conversion contracts that may be utilized for identical purposes.
[0049] Field 507 indicates whether the position taken is long or short. In the present illustration, a short position is taken. A short position is best explained as the sale of a “borrowed” security, commodity, currency, or derivative with the expectation that the asset that was sold short will fall in value. The asset must eventually be returned to whom it was “borrowed” from by buying it back on the open market. If the asset is purchased on the open market at a price that is lower than the price it was sold short at, a profit is made. Fields 508 and 509 indicate the number of contracts which have been bought or sold short and their expiration date respectively. The futures contracts on the Chicago Mercantile Exchange always expire on the third Friday of their designated expiration month. Fields 510 and 511 respectively indicate dollar per index point and the average cost basis per contract. Multiplying the value is in fields 508 , 510 and 511 yields a total value of the effective dollar hedge, noted in field 512 . Field 513 represents the margin requirement per futures contract as dictated by the Chicago Mercantile Exchange. Field 514 represents the total initial cost of entering into the hedging position and is calculated by multiplying field 513 by field 508 . Field 515 is used to indicate the percentage of the risk which has been hedged. This percentage is determined by dividing the value in field 512 by the value in field 504 . The current value of the respective underlying index is shown in field 516 .
[0050] The current financial position for this hedge may be found by determining a current market value, as by viewing a “ticker” or “symbol” listing price of the current market or marketable price of the illustrated futures contract utilized, to be shown in field 516 , and comparing the current market value to the cost basis. The cost basis may be seen in field 514 . The cost basis is usually the purchase price paid by the insurer or a value arrived at through standard accounting procedures for property acquired other than by a cash purchase. Hedge profit or loss is entered in field 539 . The current market value of the position to be listed in field 517 is determined by multiplying the values in fields 508 , 510 and 516 . The value in field 518 represents the total profit or loss value for the hedge and is determined by subtracting field 517 from field 512 .
[0051] FIG. 5B illustrates the use of a derivative of a derivative, for example a futures options contract, as a hedging vehicle for a single mortgage policy. Fields 519 and 520 respectively identify serial numbers of a foreclosure insurance policy and corresponding mortgage loan. These identification numbers could be used in addition to or in the alternative to names. For administrative purposes, Fields 521 and 522 may be provided respectively indicating the monthly mortgage payment coverage and whether the mortgage has PMI coverage.
[0052] Fields 523 and 524 contain the symbol and name of a futures option contract respectively. Fields 525 , 526 , 527 , and 528 respectively represent the position taken, i.e., long or short, the nature of the option, i.e., put or call, the number of contracts, and the strike date. The strike price is listed in field 529 , and the delta of the option is listed in field 530 . The delta of an option is defined as the rate of change of the option price with respect to the change in price of the underlying asset from which its value is determined. For example, an option with a 0.65 delta will increase or decrease in value by 65% of the change in value of the underlying index. Therefore every $1 change in value of the underlying index equates to the option increasing or decreasing in value by 0.65 cents. Dollars per index point are listed in field 531 , while cost basis per option contract is contained in field 532 . Fields 534 and 535 respectively represent an index price at the original transaction date and a current index price.
[0053] The total cost of the hedge is shown in field 533 . In field 536 , the total dollar value that has been hedged as a result of the purchase of the contracts at their calculated delta is listed. This effective hedge is compared to the value in field 521 and is expressed as a percentage seen in field 537 . Current financial position for this hedge may be found by first determining a current market value, as by viewing a “ticker” or “symbol” listing of the current market or marketable price of the illustrated futures option contract utilized, to be listed in field 538 . The current value is then compared to the basis, i.e., the purchase price paid by the insurer or a value arrived at through standard accounting procedures for property acquired other than by a cash purchase. Hedge profit or loss is entered in field 539 . The options have not been exercised at this point, and the value in field 539 may be referred to as “paper profit” or “paper loss.” In order to determine a current profit or loss value, the value in field 532 is subtracted from the value in field 538 . The resulting difference is then multiplied by the product obtained by multiplying the values in fields 527 and 531 .
[0054] FIG. 5C illustrates the use of a pooled mortgage hedge or a securitized mortgage bond hedge with futures contracts as a hedging vehicle. Fields 540 , 541 and 542 respectively refer to identification numbers of a mortgage pool, a bond CUSIP (a unique identifier assigned to a bond at the time it is issued) and a foreclosure insurance pool. These identification numbers could be used in addition to or in the alternative to names. Field 543 lists the pooled foreclosure insurance liability risk.
[0055] Fields 544 and 545 contain the symbol and name of a futures contract respectively. Fields 546 , 547 , 548 respectively represent the position taken, i.e., long or short, the number of contracts utilized for the hedge, and the futures contract expiration date. Dollars per index point are listed in field 549 , while the average cost basis per futures contract is contained in field 550 . Field 551 represents the effective dollar amount of the hedge. The value in field 551 is obtained by multiplying the values in the fields 547 , 549 , and 550 .
[0056] Margin requirements per contract and total initial hedging costs are seen in fields 552 and 553 . The percent of liability the hedge is represented in field 554 . This value is obtained by dividing the value in field 551 by the value and field 543 . Current financial position for this hedge may be found by first determining a current index price, as by viewing a “ticker” or “symbol” listing price of a current-market or marketable price of the illustrated futures contract utilized, to be shown in the field 555 and comparing the current market value to the initial hedging cost shown in field 553 . The current market value of the position shown in field 556 is determined by multiplying the values in fields 547 , 555 and 549 . In order to determine a current profit or loss value for the hedge, the value in field 556 is subtracted from the value in field 551 . Hedge profit (a positive result) or loss (a negative result) is entered in field 557 .
[0057] FIG. 5D illustrates the use of a pooled mortgage hedge or a securitized mortgage bond hedge with futures options as a hedging vehicle. Fields 558 , 559 , and 560 respectively refer to identification numbers of a mortgage pool, bond CUSIP (a unique identifier assigned to a bond at the time it is issued) and a foreclosure insurance pool. These identification numbers could be used in addition to or in the alternative to names. Field 561 lists the pooled foreclosure insurance liability risk.
[0058] Fields 562 and 563 contain the symbol and name of a future options contract respectively. Fields 564 , 565 , 566 , and 567 respectively represent the position taken, i.e., long or short, the type of option, i.e., a put or call, the number of contracts utilized for the hedge, and the futures contract expiration date. The option contract's strike price is listed in field 568 , and the delta at the initial transaction date is listed in field 569 . Dollars per index point are listed in field 570 , while average cost basis per option contract is contained in field 571 . The total cost of the hedge is shown in field 572 .
[0059] The index price at the initial transaction date and a current index price are listed in fields 573 and 574 respectively. In field 575 , the effective dollar amount of the hedge is presented. The percent of liability hedged is represented in field 576 . This value is obtained by dividing the value in field 575 by the value and field 561 . Current financial position may be found by first determining the current market value or marketable price of the illustrated futures option contract utilized, as by viewing a “ticker” or “symbol” listing price to be shown in the field 577 , and comparing the current market value to the average cost basis. In order to determine a current profit or loss value, the value in field 577 is subtracted from the value in field 571 . The resulting difference is then multiplied by the product obtained by multiplying the values in fields- 566 and 570 . Hedge profit (a positive result) or loss (a negative result) is entered in field 578 .
[0060] FIG. 6 is a flowchart describing a process 600 that transpires after a Mortgage Foreclosure Insurance policy has been executed between the parties at block 602 . The insurance coverage, once in effect, will cover the homeowner should a triggering event occur. A triggering event is defined in the policy. In one illustrative scenario, a triggering event is a homeowner's going into default according to the terms of their mortgage.
[0061] The occurrence of a triggering event is detected at block 604 . Should no triggering event occur, the process proceeds to block 606 at which the policy would renew unless terminated by the mortgagor or the insurer. Should a triggering event occur, the process proceeds to block 608 , at which a policyholder contacts the insurer. At block 610 , the insurer performs its procedure to validate the claim. Once the claim is validated, the insurer executes the agreed-upon performance at block 612 . The agreed-upon performance may, for example, comprise the insurer's paying the homeowner's monthly mortgage for a specified period of time.
[0062] At block 614 , it is determined whether the benefits payable under the policy have been exhausted. If so, coverage ends at block 614 . If the policy has remaining benefits, monitoring continues at block 604 . Another triggering event would be sensed at block 604 to start the process once again.
[0063] FIG. 7A is a flowchart illustrating the use of futures to hedge against the losses in the interest insured by the insurance company. This interest may be embodied in a pooled mortgage or securitized bond. FIG. 7B is a flowchart illustrating the use of a futures derivative to hedge against losses in short interest. In the illustration in FIG. 7B , the further derivative comprises a futures option. Other derivatives could be utilized. It is preferred that the derivative be related to the value of the housing market including the insured property. Where a subsequent calculation is not dependent on a previous calculation, the order of steps in FIGS. 7A and 7B may be altered.
[0064] The operations described below may be performed on the computer 208 ( FIG. 2 ) in response to a machine-readable medium provided in accordance with the present subject matter. The Factors and terms utilized in the calculations below may be accessed from their respective locations in the long-term storage device 212 . These calculations may be performed in the central processing unit 216 .
[0065] The calculation of the values associated with hedging the insured interest with futures contracts is illustrated in FIG. 7A . At block 700 , the pooled liability risk amount is accessed. In one embodiment, the value is accessed from the memory location represented by field 434 in FIG. 4A . Next, at block 702 , the number of futures contracts needed to hedge effectively is derived. This is derived by dividing the value at block 700 by dollars per index point times the cost per contract. At block 704 the number of contracts times the dollars per index point times the average cost basis per contract are multiplied together to produce a value of the effective monetary hedge. The total initial hedging cost is calculated at block 706 by multiplying the number of futures contracts by the margin requirement per contract. At block 708 , the percent of liability hedged is calculated. This is done by accessing the memory location represented by block 704 and dividing it by the pooled foreclosure insurance liability risk used in the calculation at block 700 . At block 710 , the current market value of the hedge is calculated. This is equal to the current contract price times the dollars per index point times the number of contracts. At block 712 , the hedge profit or loss from a short position is determined by subtracting the current market value calculated at block 710 from the effective dollar hedge calculated at block 704 .
[0066] The calculation of the values associated with hedging the insured interest with futures options is illustrated in FIG. 7B . At block 714 , the pooled liability risk amount is accessed. In one embodiment, the value is accessed from the memory location represented by field 434 in FIG. 4A . Next, at block 716 , the number of option contracts needed to effectively hedge is derived. This quotient is derived by dividing the value at block 714 by the product obtained by multiplying the dollars per index point times the option contract strike price times the Delta at the initial transaction date. The total initial hedging cost is calculated at block 718 by multiplying the cost basis per option contract times the dollars per index point times the total number of option contracts. At block 720 , in order to calculate the effective and monetary hedge value, the number of option contracts times the dollars per index point times the option contract strike price times the Delta is calculated. At block 722 , the percent of liability hedged is calculated. This is done by accessing the memory location represented by block 720 and dividing it by the pooled liability risk located in block 714 . At block 724 , the current market value of the hedge is calculated. This equals the current option contract price times the dollars per index point times the number of option contracts. At block 726 , the hedge profit or loss resulting from a short position is determined by subtracting block 724 from block 718 .
[0067] The financial product provided is a unit of coverage which the insurer may hedge in a dynamic matter. The hedging vehicle may be modified either occasionally or frequently for optimization of risk mitigation. The product is dynamically adjusted in relation to current real estate values. The financial product according to the present subject matter is not related solely to periodically updated actuarial factors. Rather it is current and dynamic.
[0068] This subject matter will serve a critical role in allowing individual homeowners to protect themselves against any unforeseen economic and financial hardship they may encounter while owning a home. This product is designed to provide peace of mind during financial distress and transition by allowing the homeowner to obtain other means in order to satisfy their financial obligation to their mortgage lender. Homeowners can avoid home foreclosures and the resulting adverse financial consequences. A homeowner can use the precious time allotted to them by their policy to renegotiate a new loan with their lender, sell their home, or obtain other financial arrangements.
[0069] While the foregoing written description of the subject matter enables one of ordinary skill to make and use what is considered presently to be the best mode thereof, those of ordinary skill will understand and appreciate the existence of variations, combinations, and equivalents of the specific embodiment, method, and examples herein. The subject matter should therefore not be limited by the above described embodiment, method, and examples, but by all embodiments and methods within the scope and spirit of the subject matter as claimed. | A method, non-transitory machine-readable medium, and financial product provide borrower foreclosure insurance for insured interests in real property, each classified in a rate category. A processor is controlled to calculate a premium for at least some of the real property interests with a rule utilizing the data indicative of the rate category and storing the calculation. The processor receives data indicative of a cost of a hedge vehicle respectively associated with each real property interest. A hedge vehicle is selected based on an index for real property in a preselected geographical area. A monetary level to hedge is selected, and a hedge vehicle or vehicles are selected. A number of hedge contracts of at least one type to achieve hedging of the monetary level is calculated on the processor. | 6 |
FIELD OF THE INVENTION
The present invention relates to novel formulations for oral administration comprising lipid-regulating agents.
BACKGROUND OF THE INVENTION
2-[4-(4-chlorobenzoyl)phenoxy]-2-methyl-propanoic acid, 1-methylethylester, also known as fenofibrate, is representative of a broad class of compounds having pharmaceutical utility as lipid regulating agents. More specifically, this compound is part of a lipid-regulating agent class of compounds commonly known as fibrates, and is disclosed in U.S. Pat. No. 4,058,552.
Fenofibrate has been prepared in several different formulations, c.f., U.S. Pat. Nos. 4,800,079 and 4,895,726. 4,895,726 discloses a co-micronized formulation of fenofibrate and a solid surfactant.
U.S. Pat. No. 4,961,890 discloses a process for preparing a controlled release formulation containing fenofibrate in an intermediate layer in the form of crystalline microparticles included within pores of an inert matrix. The formulation is prepared by a process involving the sequential steps of dampening said inert core with a solution based on said binder, then projecting said fenofibrate microparticles in a single layer onto said dampened core, and thereafter drying, before said solution based on said binder dissolves said fenofibrate microparticles, and repeating said three steps in sequence until said intermediate layer is formed.
European Patent Application No. EP0793958A2 discloses a process for producing a fenofibrate solid dosage form utilizing fenofibrate, a surface active agent and polyvinyl pyrrolidone in which the fenofibrate particles are mixed with a polyvinyl pyrrolidone solution. The thus obtained mixture is granulated with an aqueous solution of one or more surface active agents, and the granulate thus produced is dried.
PCT Publication No. WO 82/01649 discloses a fenofibrate formulation having granules that are comprised of a neutral core that is a mixture of saccharose and starch. The neutral core is covered with a first layer of fenofibrate, admixed with an excipient and with a second microporous outer layer of an edible polymer.
U.S. Pat. No. 5,645,856 describes the use of a carrier for hydrophobic drugs, including fenofibrate, and pharmaceutical compositions based thereon. The carrier comprises a digestible oil and a pharmaceutically-acceptable surfactant component for dispersing the oil in vivo upon administration of the carrier, which comprises a hydrophilic surfactant, said surfactant component being such as not to substantially inhibit the in vivo lipolysis of the digestible oil.
Gemfibrozil is another member of the fibrate class of lipid-regulating agents. U.S. Pat. No. 4,927,639 discloses a disintegratable formulation of gemfibrozil providing both immediate and sustained release, comprising a tablet compressed from a mixture of a first and second granulation, and a disintegration excipient operable to effect partial or complete disintegration in the stomach. The first granulation comprises finely divided particles of pure gemfibrozil granulated with at least one cellulose derivative, and the second granulation comprises finely divided particles of pure gemfibrozil granulated with a pharmaceutically-acceptable water soluble or insoluble polymer which are then uniformly coated with a pharmaceutically-acceptable (meth)acylate copolymer prior to admixture with the first granulation. The first and second granulations are present in the final composition in a ratio of from about 10:1 to about 1:10.
U.S. Pat. No. 4,925,676 discloses a disintegratable gemfibrozil tablet providing both immediate and enteric release, which is compressed from a mixture of a first granulation of gemfibrozil with at least one acid-disintegratable binder, and a second granulation formed from the first granulation, but regranulated or coated with an alkali-disintegratable formulation of at least one substantially alkali-soluble and substantially acid-insoluble polymer.
Another class of lipid-regulating agents are commonly known as statins, of which pravastatin and atorvastatin are members. U.S. Pat. Nos. 5,030,447 and 5,180,589 describe stable pharmaceutical compositions, which when dispersed in water have a pH of at least 9, and include a medicament which is sensitive to a low pH environment, such as prevastatin, one or more fillers such as lactose and/or microcrystalline cellulose, one or more binders, such as microcrystalline cellulose (dry binder) or polyvinyl pyrrolidone (wet binder), one or more disintegrating agents such as croscarmellose sodium, one or more lubricants such as magnesium stearate and one or more basifying agents such as magnesium oxide.
It is an object of the present invention to provide formulations for oral administration comprising lipid-regulating agents having enhanced bioavailability when compared to commercially available formulations.
SUMMARY OF THE INVENTION
The present invention is directed to a formulation comprising a lipid-regulating agent, and further comprising at least one monoglyceride as the primary solvent medium for said agent. One or more emulsifiers may be added to the formulation.
The formulation may be administered directly, diluted into an appropriate vehicle for administration, encapsulated into soft or hard gelatin shells or capsules for administration, or administered by other means obvious to those skilled in the art.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a graph showing the plasma concentration in fasted dogs of the formulation of Example 1 and a reference composition.
DETAILED DESCRIPTION OF THE INVENTION
The bulk lipid-regulating agent can be prepared by any available method, as for example the compound fenofibrate may be prepared by the procedure disclosed in U.S. Pat. No. 4,058,552 or the procedure disclosed in U.S. Pat. No. 4,739,101, both herein incorporated by reference.
Representative monoglycerides include, but are not limited to, glyceryl oleate (Capmul GMO-K™, Abitec), glyceryl caprylate/caprate (Capmul MCM, Abitec), glyceryl caprylate (Capmul MCMC8, Abitec), and glyceryl caprate (Capmul MCMC10, Abitec). A preferred monoglyceride is glyceryl oleate.
Suitable emulsifiers include pharmaceutically-acceptable surfactants such as, for example, TPGS (d-alpha Tocopheryl Polyethylene Glycol 1000 Succinate), phospholipids, polyoxyethylene sorbitan fatty acid derivatives, castor oil or hydrogenated castor oil ethoxylates, polyglycerol esters of fatty acids, fatty acid ethoxylates, alcohol ethoxylates, polyoxyethylene-polyoxypropylene co-polymers and block co-polymers. Preferred emulsifiers include castor oil or hydrogenated castor oil ethoxylates. A more preferred emulsifier is Cremophor EL™, a polyoxyl 35 castor oil, available from BASF.
Other optional ingredients which may be included in the compositions of the present invention are those which are conventionally used in oil-based drug delivery systems, e.g. antioxidants such as, for example, tocopherol, ascorbyl palmitate, ascorbic acid, butylated hydroxytoluene, butylated hydroxyanisole, propyl gallate, etc.; pH stabilisers such as, for example, citric acid, tartaric acid, fumaric acid, acetic acid, glycine, arginine, lysine, potassium hydrogen phosphate, etc.; thickeners/suspending agents such as, for example, hydrogenated vegetable oils, beeswax, colloidal silicone dioxide, gums, celluloses, silicates, bentonite, etc.; flavoring agents such as cherry, lemon, aniseed flavors, etc.; sweeteners such as aspartame, saccharin, cyclamates, etc.; and co-solvents such as, for example, ethanol, propylene glycol, dimethyl isosorbide, etc.
The solution comprising the lipid-regulating agent is prepared by dissolving said agent in the monoglyceride with adequate mixing at a temperature sufficient to liquefy the monoglyceride. If an emulsifier is used, it is added to the monoglyceride with mixing prior to addition of the lipid-regulating agent.
The resulting premix liquid comprising the lipid-regulating agent may be dosed directly for oral administration, diluted into an appropriate vehicle for oral administration, filled into soft or hard gelatin capsules for oral administration, or delivered by some other means obvious to those skilled in the art. The premix liquid can be used to improve the oral bioavailability, and/or increase the solubility of said agent.
The invention will be understood more clearly from the following non-limiting representative examples.
EXAMPLE 1
Capmul GMO-K (Abitec) (8.0 gm) was heated to approximately 40 C until it was liquefied and added to a scintillation vial. Ethanol USP, 200 proof (1.3 gm) was added to the vial, heated to 50-60 C in a water bath and mixed until it was uniform. Fenofibrate (0.7 gm) was then added to the vial and mixed until it was completely dissolved. 957 mg. of the premix (containing 67 mg. fenofibrate) was added to each of six soft gelatin capsules using a syringe. The capsules were heat-sealed and stored.
EXAMPLE 2
Capsules prepared by the process described in Example 1 and from a commercial fenofibrate composition, Lipanthyl 67M (Groupe Fournier) (reference) were administered to a group of six fasted dogs at a dose of 67 mg/dog (one capsule per dog). The plasma concentrations of fenofibric acid were determined by HPLC. Concentrations were normalized to a 6.7 mg/kg dose in each dog. FIG. 1 presents the resulting data in graph form. | The present invention is directed to a formulation comprising a lipid-regulating agent dissolved in at least one monoglyceride as the primary solvent medium for said agent. One or more emulsifiers may be added to the formulation. | 0 |
RELATED APPLICATION
[0001] This application claims the benefit of U.S. Provisional Application No. 62/032,319, filed Aug. 1, 2014, which is incorporated herein by reference in its entirety.
FIELD OF THE DISCLOSURE
[0002] The present invention relates to torsional vibration dampers for vehicle engines and, more particularly, to a two-part hub for such torsional vibration dampers.
BACKGROUND
[0003] A crankshaft drives the front end assembly drive (FEAD) system of an engine. The crankshaft is turned by the firing of pistons, which exerts a rhythmic torque on the crankshaft, rather than being continuous. This constant application and release of torque causes vacillations, which can stress the crankshaft to the point of failure. Stated another way, the crankshaft is like a plain torsion-bar, which has a mass and a torsional spring rate, that causes the crankshaft to have its own torsional resonant frequency. The torque peaks and valleys, plus the inertia load from the acceleration of the reciprocating components, cause the crankshaft itself to deflect (rotationally) forward and backward while it is operating. When those pulses are near the crankshaft resonant frequency, they cause the crank to vibrate uncontrollably and eventually break. Accordingly, a torsional vibration damper (sometimes referred to as a crankshaft damper) is mounted on the crankshaft to solve this problem by counteracting torque to the crank, negating the torque twisting amplitude placed upon the crankshaft by periodic firing impulses, and to transfer rotational motion into the FEAD system, typically by driving an endless power transmission belt.
[0004] Torsional vibration damper hubs are expected to be as light, strong, and cost effective as possible. The traditional means of producing a hub in the United States has been through casting the hub with either Nodular or Gray Cast Iron and then machining it to its final shape. However, this method of production has to keep a keen eye of the castability of the material (i.e. filling the mold, and not causing voids etc.) which then leads to a structure that is usually heavier than necessary.
[0005] There are other means of production employed elsewhere in the world that yield much lighter and cheaper designs such as stamping and/or forming the hub. However, these methods do not allow for the incorporation of a seal nose because the material used in these processes is soft and does not provide sufficient abrasive/wear resistance needed because of the wear experienced by the seal nose. Some European designs have incorporated a two-piece construction (one of a formed soft steel for the main body of the hub and the other of a hardened or tough steel for the seal nose area) that are welded together to provide axial and angular integrity to the structure. Welding requires specialized capital investment in equipment and is esthetically unappealing, which makes welded two-part hub constructions more difficult to sell in the U.S. market.
SUMMARY
[0006] The limitations disclosed in the background section are overcome in the disclosed two-part hub for torsional vibration dampers by eliminating the need for welding the two-part construction together. Nodular Iron (D4512 or equivalent) and Gray Cast Iron (G3500 or equivalent) have been used at the seal nose interface and have proven to have sufficient surface wear toughness to receive an engine seal without causing oil leaks. These tougher, wear resistant irons are used to make a seal nose that is mated, without welding, to a primary hub component that is made of soft(er) steel, in particular, by using a mechanical engagement that allows for both axial and angular integrity of the joint.
[0007] In one aspect, two-part hubs are disclosed that include a main body and a seal nose mechanically engaged to one another. The main body has a plate having a front face and a back face, an annular core extending axially outward from the back face of the plate and defining an innermost, outer radial surface and a first bore through the main body, and an outermost, radial, elastomer-receiving surface spaced apart from the innermost outer radial surface by the plate. The seal nose is mated to the innermost, outer radial surface of the annular core and is mechanically engaged with the main body for rotation together without a welded joint. The main body comprises a first material and the seal nose comprises a second material that are different from one another, in particular the first material is softer than the second material, or. stated another way, the second material is more abrasion resistant than the first material. The seal nose has a front face seated in contact with the plate and a shoulder proximate, but spaced a distance apart from, a terminus of the annular core, and the seal nose defines a second bore that, collectively, with the first bore of the annular core defines a crankshaft-receiving bore.
[0008] In one embodiment, the innermost, outer radial surface of the main body includes threads, and the seal nose has threads threadingly engaging the threads of the innermost, outer radial surface of the main body. A keyway is formed within at least the first bore of the annular core, which broaches the threads of the seal nose, thereby locking the threads of the annular core and the threads of the seal nose together.
[0009] In another embodiment, the seal nose is press-fittingly engaged with the innermost, outer radial surface of the annular core, and one or more pins extend axially into a front face of the seal nose, and connect the seal nose to the main body for rotation together.
[0010] In either embodiment, a geometric lock, comprising a hole defined by either or both of the seal nose or the annular core and a pin received in the hole, mechanically engages the main body to the seal nose.
[0011] In another aspect, torsional vibration dampers are disclosed that include one of the two-part hubs described herein, an elastomeric damper member disposed in contact with an outermost, radial, elastomeric-receiving surface of the hub, and an inertia member seated against the elastomeric damper member thereby operably coupling the inertia member to the hub for rotation therewith. In one embodiment, the elastomeric member is an annular ring of elastomeric material seated against the outermost, radial elastomer-receiving surface of the main body of the hub, and the inertia member is an annular ring seated against the elastomeric member, both of which are concentric about an axis of rotation of the hub.
[0012] In another aspect, any of the torsional vibration dampers disclosed herein may be mounted to the crankshaft as part of a front end accessory drive system.
[0013] In another aspect, methods of manufacturing the two-part hub are disclosed. The methods include providing a main body portion comprised of a first material, having a front face and a back face, and having an annular core extending axially outward from the back face and defining a first bore therethrough, providing a seal nose defining a second bore and comprised of a second material that is more abrasive resistant than the first material, mating the seal nose to the annular core of the main body with the first bore and the second bore aligned to collectively define a crankshaft-receiving bore, mechanically engaging the seal nose with the main body for rotation together without a welded joint, and machining the crankshaft-receiving bore to meet selected axial and radial run-outs.
[0014] In one embodiment, mating the seal nose to the annular core comprises threading the seal nose to the annular core of the main body, and the method further comprises, subsequently, forming a generally axially-oriented keyway recessed in the crankshaft-receiving bore to a depth that broaches the threads of the seal nose thereby locking threads of the annular core and threads of the seal nose together. In this embodiment, mating the seal nose to the annular core includes threading the seal nose to the annular core until a front face of the seal nose is seated against the plate, and if the seal nose includes a shoulder in the second bore, the shoulder is spaced apart from a back face of the annular core by a distance when the front face of the seal nose is seated against the plate.
[0015] The methods may include forming the main body by stamping the first material to include the annular core defining an innermost, outer radial surface of the hub and an outermost, radial elastomer-receiving surface spaced apart from the innermost outer radial surface by a plate, and forming the seal nose by machining it from a piece of abrasion resistant material. In one embodiment, the seal nose comprises nodular iron or grey cast iron, and the main body comprises a low carbon steel.
[0016] In another embodiment, in a front face of the seal nose, the seal nose comprises a plurality of axially extending receptacles or a plurality of protruding pins. In this embodiment, mating the seal nose to the annular core includes press-fitting the seal nose to the annular core while aligning the receptacles or protruding pins with openings defined in the plate of the main body. When the seal nose includes the plurality of axially extending receptacles aligned with openings defined in the plate, the method further comprises inserting a pin through each opening in the plate into a receptacle in the seal nose, thereby engaging the seal nose with the main body for rotation together without a welded joint.
BRIEF DESCRIPTION OF DRAWINGS
[0017] Many aspects of the disclosure can be better understood with reference to the following drawings. The components in the drawings are not necessarily to scale, emphasis instead being placed upon clearly illustrating the principles of the present disclosure. Moreover, in the drawings, like reference numerals designate corresponding parts throughout the several views.
[0018] FIG. 1 is a perspective view of components in a front end accessory drive.
[0019] FIG. 2 is a side perspective, partial cut-away view of a two-part hub for a torsional vibration damper at a first stage of manufacture.
[0020] FIG. 3 is a side perspective, partial cut-away view of the two-part hub in FIG. 2 after a second stage of manufacture.
[0021] FIG. 4 is a side perspective, partial cut-away view of a completed two-part hub after a third stage of manufacture.
[0022] FIG. 5 is a longitudinal cross-sectional, perspective view of a second embodiment of a two-part hub for a torsional vibration damper.
[0023] FIG. 6 is a side, perspective view of a torsional vibration damper having the two-part hub of FIG. 4 .
DETAILED DESCRIPTION
[0024] Reference is now made in detail to the description of the embodiments as illustrated in the drawings. While several embodiments are described in connection with these drawings, there is no intent to limit the disclosure to the embodiment or embodiments disclosed herein. On the contrary, the intent is to cover all alternatives, modifications, and equivalents.
[0025] Referring now to FIG. 1 , an example of one embodiment of a FEAD system 18 is shown, merely for illustration purposes, that includes an integrated housing 15 , having a front surface 30 and a rear surface 27 . The rear surface 27 of the integrated housing 15 is preferably mounted to an engine. The FEAD system 18 may be utilized with any engine, including vehicle, marine and stationary engines. The shape and configuration of the integrated housing 15 depends upon the vehicle engine to which it is to be mounted. Accordingly, the integrated housing 15 and more specifically the FEAD system 18 may vary along with the location of engine drive accessories 9 and still achieve the objects of the present invention. It should be understood that the location and number of engine drive accessories 9 may be varied. For example, a vacuum pump, a fuel injection pump, an oil pump, a water pump, a power steering pump, an air conditioning pump, and a cam drive are examples of other engine drive accessories 9 that may be mounted on the integrated housing 15 , for incorporation into the FEAD system 18 . The engine drive accessories 9 are preferably mounted to the integrated housing 15 by bolts or the like at locations along the surface that are tool accessible for easy mounting and also service accessible. In FIG. 1 , the integrated housing 15 has a plurality of engine drive accessories 9 including an alternator 12 and a belt tensioner 21 .
[0026] The engine drive accessories 9 are driven by at least one endless drive belt 6 , which may be a flat belt, a rounded belt, a V-belt, a multi-groove belt, a ribbed belt, etc., or a combination of the aforementioned belts, being single or double sided. The endless drive belt 6 may be a serpentine belt, and is wound around the engine drive accessories 9 , the alternator 12 and the torsional vibration damper 3 , which is connected to the nose 10 of the crankshaft 8 . The crankshaft drives the torsional vibration damper 3 and thereby drives the endless drive belt 6 , which in turn drives the remaining engine drive accessories 9 and the alternator 12 . The belt tensioner 21 automatically adjusts the tension of the endless drive belt 9 to keep it tight during operation and also prevent wear.
[0027] The improvement to the FEAD system 18 herein is a torsional vibration damper having a two-part hub as shown in FIGS. 2-4 or in FIG. 5 , which is made without welding and provides an abrasion/wear resistant seal nose 104 as a portion thereof. In the assembled view of FIG. 4 , the hub 100 includes a main body 102 and a seal nose 104 threadingly mated thereto. The seal nose 104 has a front face 122 , a back face 128 , and threads 120 that terminate at a terminus 126 proximate a shoulder 128 . The main body 102 includes a plate 109 , an annular core 101 extending axially, outward from the plate 109 , in particular, from a back face of the plate 109 , and defining an innermost, outer radial surface 106 ( FIG. 2 ), and an outermost radial surface 108 spaced apart from the innermost, outer radial surface 106 by the plate 109 . The annular core 101 includes threads 110 as part of the innermost, outer radial surface 106 and defines a bore 112 through the hub 100 for receiving a shaft. The seal nose 104 has threads 120 threadingly mated to the threads 110 of the annular core 101 .
[0028] As labeled in FIGS. 2 and 3 , the plate 109 has a front face FF designated by an arrow in the figures, and an opposing face, the back face BF, as shown by the second arrow in the figures. The plate 109 may define one or more apertures 130 and/or a recesses 132 . The apertures 130 may each be arcuate since these may receive a portion of an elastomeric member (not shown), which is typically an annular member. While the plate 109 is illustrated as having a recess 132 , the plate 109 could instead have one or more protrusions for mating with an elastomeric member. Any one or more of the apertures 130 may be positioned to receive a fastener to hold components of the torsional vibration damper together or to reduce the amount of material needed in the hub 100 to reduce weight and/or cost. Plate 109 should not be construed as requiring a flat, one-planar construction. It may have such a construction, but it may be irregular shaped as seen in the figures. In FIGS. 2 and 3 , the plate 109 portion of the main body 102 has a stair-step configuration when viewed from either the front face FF or the back face BF.
[0029] As seen in FIGS. 2-4 , the nose seal 104 is a femalely-threaded component and the annular core 101 is a malely-threaded component. The threads 110 , 120 thereof are threadingly mated into a fully assembled position ( FIG. 4 ) where the seal nose 104 has its front face 122 seated in contact with the plate 109 . Further, the fully assembled position has a shoulder 124 of the seal nose 104 , which is proximate the terminus 126 of its threads, spaced apart from a back face 113 of the annular core 101 by a distance, thereby defining a gap 130 as shown in FIG. 4 . Accordingly, the shoulder 124 is not seated against the annular core 101 . This configuration provides for contact between only one face of each of the nose seal 104 and the main body 102 to provide proper axial alignment of these two components with respect to one another. The advantage of this construction is axial integrity of the joint formed by threadingly mating the components together. Moreover, once a crank-bolt secures the hub to a crankshaft, the seal nose 104 and the main body 102 cannot be axially separated from one another.
[0030] Still referring to FIG. 4 , a keyway 114 is formed through the bore 112 of the annular core 101 into the threads 120 of the seal nose 104 thereby locking the threads 110 of the annular core 101 and the threads 1120 of the seal nose 104 together, which also provides axial integrity to the joint. The formation of the keyway 114 causes some of the first material, since it is a softer material than the second material, to fill any spaces between the threads 110 , 120 at the site of the keyway 114 thereby locking the threads together and providing angular integrity to the joint. The keyway 114 is also beneficial to prevent angular deflection of the joint by receiving a shaft in the bore 112 that has a matching key that is received in the keyway 114 .
[0031] In one embodiment, the threads 110 and/or 120 may include a coating that enhances the rigidity and/or seal of the joint. In one embodiment, Loctite® threadlocker may be used to coat the threads.
[0032] The main body 102 includes a first material that is abrasion/wear resistant. The seal nose 104 includes a second material that is different from the first material and is more abrasive resistant than the first material. Accordingly, the first material is softer than the second material. In one embodiment, the seal nose 104 includes nodular iron (grade D4512 or equivalent, also known as ductile iron). In another embodiment, the seal nose 104 includes gray cast iron (grade G3500 or equivalent). The main body 102 may include a low carbon steel. In one embodiment, the main body includes a DD13 grade low carbon steel or its equivalent. Other suitable materials for the main body include iron, steel, aluminum, other suitable metals, plastics, or a combination thereof as long as it is different, softer, and/or cheaper from the material included in the seal nose 104 .
[0033] The hub 100 may be manufactured as illustrated by the sequence of FIGS. 2-4 . In FIG. 3 , a main body 102 comprised of a first material and having an annular core 101 defining a bore 112 therethrough for mounting the hub 100 to a shaft (not shown) and having threads 110 on a surface of the annular core 101 is provided along with a seal nose 104 having threads 120 and including a second material that is more abrasive resistant than the first material. Then, as illustrated in FIG. 4 , the seal nose 104 was threadingly mated to the annular core 101 by mating the threads 110 , 120 . And thereafter, a keyway 114 is formed through the bore 112 into the threads 120 of the seal nose 104 thereby locking the threads 110 of the annular core 101 and the threads 120 of the seal nose 104 together. The formation of the keyway 114 causes some of the first material, since it is a softer material than the second material, to fill any spaces between the threads 110 , 120 at the site of the keyway 114 thereby locking the threads together and providing angular integrity to the joint. The keyway 114 typically extends the full axial length of the bore 112 .
[0034] The method for manufacturing the hub 100 may also include providing the main body 102 as described above, but without the threads as shown in FIG. 2 . In this manner the main body 102 may be a stamped piece and the method may include stamping a first material into the shape of the main body 102 and thereafter forming threads 110 as shown in FIG. 3 . Threads 110 may be formed on the innermost, outer radial surface 106 of the annular core 101 by tapping, machining, or other known or hereinafter developed techniques.
[0035] In other embodiments, the main body 102 may be cast, spun, forged, or molded using known or hereinafter developed techniques with or without the threads 110 . Threads 110 may be formed by tapping, machining, or other known or hereinafter developed techniques.
[0036] The method of manufacturing the hub 100 may include forming the seal nose 104 by machining it from a piece of abrasion resistant material such as nodular iron or grey cast iron, including tapping or machining the threads 120 thereof.
[0037] In the method, threading the seal nose 104 to the annular core 101 includes threadingly mating the seal nose 104 to the main body 102 until the front face 122 of the seal nose 104 contacts the plate 109 . The front face 122 of the seal nose 104 once in contact with the plate 109 places its shoulder 124 ( FIGS. 2 and 3 ), which is proximate the terminus 126 of its threads 120 , spaced apart from a back face 113 of the annular core 101 by a distance thereby defining gap 130 ( FIG. 4 ).
[0038] After the seal nose 104 is threadingly mated to the annular core 101 , the method may include honing the bore 112 of the annular core 101 for a press-fit to a selected shaft.
[0039] In another embodiment, the threads 110 of the annular core 101 and the threads 120 of the seal nose 104 are self-locking, thereby providing axial rigidity to the threadingly mated connection therebetween. In this embodiment, the formation of keyway 114 is not necessary and may be omitted. Without the keyway, another mechanism should be introduced to provide angular rigidity to the joint (i.e., prevent angular motion between the seal nose 104 and the main body 102 ). One such mechanism is a geometric lock. In one embodiment, a geometric lock includes a generally D-shaped hole defined by either the nose seal 104 or the annular core 101 of the main body 102 , or both and a generally D-shaped shaft received in the generally D-shaped hole(s), which may be an independent shaft or may extend from either component. In another embodiment, the geometric lock may be a plurality of pins extending axially through the plate of the hub into the nose as illustrated and explained in more detail with respect to FIG. 5 .
[0040] With reference to FIG. 6 , the method of manufacturing includes disposing an elastomer ring 302 circumferentially about the damper assembly-receiving surface 108 of the main body 102 to be concentric with the axis of rotation A of the hub 100 and disposing an inertia ring 304 circumferentially about the elastomer ring 302 to be concentric with the axis of rotation A to form a torsional vibration damper 300 . In one embodiment, the inertia ring 304 is positioned first relative to the hub 100 and the elastomer ring 302 is press fit into a gap between the inertia ring 304 and the damper assembly-receiving surface 108 of the main body 100 . The inertia ring 304 may include an outer radial belt-engaging surface 306 .
[0041] Referring now to FIG. 5 , a second embodiment of a two-part hub 200 is shown. The two-part hub 200 includes a main body 202 and a seal nose 204 press-fittingly mated thereto. The main body 202 include a plate 209 , an annular core 203 extending from the plate 209 and defining an innermost, outer radial surface 206 , and a damper assembly-receiving surface 208 spaced apart from the innermost, outer radial surface 206 by the plate 209 . The annular core 203 defines a bore 212 through the hub 200 . The plate 209 may define one or more apertures 230 positioned to receive a fastener to hold components of the torsional vibration damper together or to reduce the amount of material needed in the hub 100 to reduce weight and/or cost. Plate 209 should not be construed as requiring a flat, one-planar construction. It may have such a construction, but it may be irregular shaped as seen in the figures. In FIGS. 2-4 and FIG. 5 , the plate 209 portion of the main body 202 has a stair-step configuration when viewed from either the front face FF or the back face BF. The front face of the plate 209 at the annular core 203 has an annular recess 244 formed therein to receive the head of a crank-bolt or a washer positioned on the crank-bolt adjacent to the head thereof. Positioned within the annular recess 244 at positions that align with the front face 222 of the seal nose 204 , in particular, each aligned with a receptacle 242 in the seal nose 204 , are a plurality of holes 246 extending through the plate 209 .
[0042] The seal nose 204 has a front face 222 , a back face 228 , and an inner bore 225 shaped with at least a portion 227 thereof dimensioned to be press-fit to the innermost, outer radial surface 206 defined by the annular core 203 of the main body 202 . The front face 222 of the seal nose 204 includes a plurality of receptacles 242 extending axially into the seal nose 204 that are each shaped to receive a pin 240 . In one embodiment, each pin 240 is press-fit into a receptacle 242 through a hole 246 through the plate 209 of the main body 202 at a position that align with the receptacle 242 in the seal nose. The press-fit does not have to overly tight because once a crank-bolt (not shown) secures the hub 200 to a crankshaft (not shown), the head of the bolt or a washer and head of the bolt holds the pins 240 in position during operation of the FEAD system. In another embodiment, the front face 222 of the seal nose 204 includes a plurality of pins protruding axially therefrom, which are received in the holes 246 in the plate 209 when the seal nose 204 is press-fit to the annular core 204 . In both embodiments, the pins 240 lock the main body 202 and seal nose 204 together without welding, but also provide axial rigidity to the hub 200 at reduced expense because the main body 202 can be made of a cheaper, even softer material by a cheaper method of manufacture than the nose seal 204 , as explained above with respect to the embodiment in FIGS. 2-4 . The same materials and methods of manufacture for the main body 202 and the seal nose 204 discussed above apply here. The seal nose 204 includes a second material that is different from the first material that the main body 202 is made of and is more abrasive resistant than the first material.
[0043] In one embodiment, the hub 200 may be manufactured by stamping a first material into the shape of the main body 202 with or without the holes 240 . If the holes 240 are not formed in the stamping process, they are formed thereafter by any suitable method, such as drilling, etching, punching, etc. The manufacturing process further includes forming the seal nose 204 by casting it from a second material, such as a nodular iron or grey cast iron, that is more abrasion resistant than the first material. The casting may include the formation of the receptacles 242 in the front face 222 of the seal nose or a step of machining the receptacles 242 therein may be completed after the casting is complete. Once both the main body 202 and the seal nose 204 are provided, manufacturing includes press-fitting the seal nose 204 to the annular core 203 of the main body 202 , inserting pins 240 , one each, into a receptacle 242 in the front face 222 of the seal nose through the holes 246 in the plate 209 of the main body 202 , machining the annular recess 244 into the plate 209 , machining the back face of the seal nose 204 and the bore B of the hub 200 defined collectively by the bores 212 , 225 of the main body 202 and seal nose 204 to meet axial and radial run-out specifications.
[0044] Also, the method of manufacturing includes disposing an elastomer ring (not shown) circumferentially about the damper assembly-receiving surface 208 of the main body 202 to be concentric with the axis of rotation of the hub 200 and disposing an inertia ring (not shown) circumferentially about the elastomer ring to be concentric with the axis of rotation to form a torsional vibration damper. In one embodiment, the inertia ring is positioned first relative to the hub and the elastomer ring is press fit into a gap between the inertia ring and a damper assembly-receiving surface 208 .
[0045] Once the hub 200 is assembled per the manufacturing method discussed above, it can be mounted onto the crankshaft. In this embodiment, the hub is slip fit onto the crankshaft and no keyway and key mechanism is needed between the crankshaft and the hub to provide axial rigidity to the hub. Instead the pins 240 provide the axial rigidity, and as explained above, the crank bolt or crank bolt and washer hold the pins in place axially once the hub 200 is bolted to the crankshaft.
[0046] Although the invention is shown and described with respect to certain embodiments, it is obvious that modifications will occur to those skilled in the art upon reading and understanding the specification, and the present invention includes all such modifications. | Two-part hubs for torsional vibration dampers are disclosed that have a main body made of a softer material than a seal nose and do not require a welded joint to join them together. The main body has a plate defining a front face and a back face, an annular core extending axially outward from the back face of the plate and defining an innermost, outer radial surface and a first bore through the main body, and an outermost, radial, elastomer-receiving surface spaced apart from the innermost outer radial surface by the plate. The seal nose is mated to the innermost, outer radial surface of the annular core and mechanically engaged with the main body for rotation together. Torsional vibration dampers that include the two-part hubs are also disclosed, as well as a front end accessory drive including the same, and methods of manufacturing the two-part hubs. | 5 |
This is a continuation application of U.S. patent application Ser. No. 08/786,440, filed Dec. 17, 1996, now U.S. Pat. No. 5,778,858.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to split engines, in which the average number of cylinders supplied with fuel is selected in accordance with different operating conditions. More specifically, the present invention relates to a fuel injected engine where specific injectors are deactivated to permit the engine to run on less than all its cylinders in a balanced manner.
2. Description of the Related Art
It is well known in the art that their are numerous benefits to operating an engine with less than a full complement of cylinders under certain loads and running conditions. Thus, it is possible to increase fuel economy and decrease exhaust emissions and engine wear by running an engine on a reduced number of cylinders when operating a vehicle under light loads. However, prior art techniques for implementing a split engine apparatus have had numerous drawbacks, hindering the commercial use of split engine technology. Typically, in an eight cylinder engine using current split engine technology, four cylinder mode operation is achieved by simply deactivating four cylinders, while six cylinder mode operation is achieved by deactivating two cylinders. This elementary implementation of split engine technology results in an engine that operates roughly, in an unbalanced manner, when operating with less than a full complement of cylinders. Another limitation to traditional split engine technology is that when an engine is operated with less than its full complement of cylinders, the same cylinders are repeatedly idled. This results in uneven wear of the cylinders and related hardware.
A further drawback to traditional split engine implementations is that a new split engine control unit is required to replace the non-split engine controller. This limitation requires that the split engine controller be installed by the car manufacturing as a "stock" controller, due to the extent of re-wiring and mechanical installation needed for the split engine controller. Thus, it would be expensive and impractical for a car owner to upgrade her car engine to split engine operation.
Yet another limitation to traditional split engine implementations is that the cylinder itself is deactivated so that no air flows through the deactivated cylinders. This results in higher percentage concentrations of pollutants in the engine exhaust than would be present if air continued to flow through the deactivated cylinder.
Therefore it would be desirable to have a split engine system which operated smoothly with less than a full complement of cylinders and which switched operating modes.
SUMMARY OF THE INVENTION
The present invention provides a split engine controller which advantageously can be inserted into a standard engine system in a motor vehicle without extensive rewiring of the engine system. Furthermore, the present invention provides a system and method for a split engine, where, in a given engine cycle, a fraction of the engine injectors are idled and a fraction of the engine injectors are activated. Advantageously, different injectors are idled every engine cycle, providing for the even wear of the engine cylinders. Furthermore, the injectors are activated in a pattern which ensures the engine operates in a balanced manner. Additionally, the cylinders whose associated injectors are idled act as air pumps, reducing the percentage concentration of pollutants in the engine exhaust.
Furthermore, the present invention provides a method and system for operating an engine at 66.67% of full power by sequentially idling every third cylinder. Thus, when full engine power is not required, such as when the vehicle is cruising, the engine can be operated in 66.67% power mode, advantageously reducing fuel consumption and pollution emissions. Additionally, the firing sequence of the injectors is chosen to insure the balanced operation of the engine. Furthermore, cam pulses are used to synchronize the operation of the engine controller to the engine revolutions.
Another aspect of the present invention is a method and system for operating an engine at 50% of full power by alternately enabling a first half of the cylinders and a second half of the cylinders. Thus, when little engine power is required, such as when the vehicle is at idle, the engine operates in the 50% power mode, advantageously further reducing fuel consumption and pollution emissions.
Yet another aspect of the present invention is a method and system for operating an engine at 75% of full power by alternately enabling a first half of the cylinders, then all of the cylinders, and then a second half of the cylinders. Thus, when a significant percentage of the total available engine power is required, the engine operates in the 75% power mode, while advantageously resting alternate halves of the cylinders one third of the time.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram illustrating the interconnections of a prior art engine controller and fuel injectors.
FIG. 2 is a block diagram of a preferred embodiment of the present invention and the surrounding environment;
FIG. 3 is a more detailed block diagram of the sensor processing circuitry block illustrated in FIG. 2;
FIG. 4 is a detailed block diagram of the logic control circuitry and injector driver circuitry of the preferred embodiment illustrated in FIG. 2;
FIG. 5 illustrates the four cylinder operating mode of the preferred embodiment;
FIG. 6 illustrates the 66.67% operating mode of the preferred embodiment;
FIG. 7A is a timing diagram illustrating the eight cylinder and 66.67% operating modes of the preferred embodiment;
FIG. 7B is a timing diagram illustrating the 50% and 75% operating modes of the preferred embodiment;
FIG. 8 illustrates the group assignments of the injectors and cylinders in the preferred embodiment; and
FIG. 9 illustrates the 75% operating mode of the preferred embodiment.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 is a block diagram illustrating a standard, prior art, engine control system in a motor vehicle, such as, by way of example, a 1993 Ford Crown Victoria with a 4.6 liter V8 engine. A standard engine controller 100 is connected to fuel injectors 140. Engine sensor lines 116, 118, 120, 122, 124, 126, 128 pass through a power-train module connector (PCM) 130 and are connected to the standard engine controller 100 over respective signal lines 104, 106, 108, 110, 112, 114 115. The standard engine controller 100 is not capable of operating the engine in a split engine mode. The engine controller 100 monitors a number of operating condition sensors and engine-related sensors over the sensor lines 116, 118, 120, 122, 124, 126, 128 such as, respectively, an engine coolant temperature sensor (ECT), a throttle position sensor (TP), a vehicle speed sensor (VSS), a cam sensor (CAMS), a right hand oxygen sensor (RH20M), a left hand oxygen sensor (LH20M), and a manifold air flow sensor (MAF). The sensor signals lines are connected the corresponding engine controller inputs ECT, TP, VSS, CAMS, RH20M, LH20M, MAF. In response to the sensor readings, the engine controller 100 outputs eight injector enable signals INJ(8 . . . 1) over signal lines 102. For a given operating condition, each of the enable signals are timed to appropriately enable current to flow through a selected pair of fuel injector coils 140. Each engine cylinder has one fuel injector.
FIG. 2 is a block diagram illustrating a preferred embodiment of the present invention. In the preferred embodiment, the engine is upgraded to split engine functionality by the expedient of unplugging the PCM connector 130 and its mate, and then plugging a split engine controller 200 into the PCM connector 130 and the mating connector. Hence, the engine can be easily upgraded by a consumer after the vehicle has been manufactured. This method of upgrading overcomes the limitations of past split engine implementations, which either required the engine controller 100 to be specifically designed by the manufacturer to enable split engine functionality or required significant rewiring of the vehicle. In another embodiment of the present invention, the split engine controller 200 is installed in the vehcile as standard equipment.
With reference to FIGS. 2 and, the split engine controller 200 taps off the sensor lines 116, 118, 120, 122, 124, 126, 128. Thus, both the engine controller 100 and the split engine controller 200 monitor the ECT, TP, VSS, CAMS RH20M, LH20M, and MAF sensors. However, for reasons that will be detailed below, the signals from the oxygen sensors RH20M, LH20M are intercepted by the split engine controller 200, and the split engine controller 200 in turn provides the standard engine controller 100 either the original oxygen sensor signals or simulated oxygen sensor signals on the signal lines 112, 114.
The split engine controller 200 includes sensor processing circuitry 202, logic control circuitry 204, injector driver circuitry 206 and idle air control (IAC) driver circuitry 208. The sensor processing circuitry 202 performs processing on the outputs of the sensors ECT, TP, VSS, CAMS RH20M, LH20M, MAF and derives a variety of performance and operational information. In response to the sensor signals, the sensor processing circuitry 202 generates the following outputs which are indicative of the operating environment of the engine and which are used by the split engine controller 200 to determine which mode to operate the engine in: a low temperature output LOW -- TEMP, a fixed-throttle output FXD -- TP, a half-throttle output HT, a full-throttle output FT, a power-required output PWR -- REQ, a CAM -- PULSE output, an IDLE output, and a VGTR40 output. These outputs are connected to the logic control circuitry 204 via respective signal lines 220, 222, 224, 226, 228, 230, 232, 236. The logic control circuitry 204 contains both combinatorial logic and state machines. In response to the signals generated from the sensor processing circuitry 202 the logic control circuitry 204 determines if the vehicle should be operated in a 50% power (4 cylinder) mode, a 66.67% power mode, a 75% (6 cylinder) more, or a 100% power (8 cylinder) mode. The logic control circuitry 204 further generates injector enables A, B, C, D and an idle air control enable IAC. The operation of the logic control circuitry 204 will be explained in greater detail below. The injector enables A, B, C, D are connected to the injector driver circuitry 206. The injector driver circuitry 206 is connected to the PCM connector 130 by the signal bus 120. The idle air control enable IAC is connected from the logic control circuit 204 to an idle air control driver 208 by a signal line 210. An output IACS of the idle air control driver 208 is connected to an engine idle air control solenoid.
FIG. 3 is a detailed block diagram of a preferred embodiment of the sensor processing circuitry 202 illustrated in FIG. 2. A voltage regulator circuit 300 receives +12 VDC and +5 VDC on the voltage regulator's inputs 12ECC and 5PF respectively from the PCM connector 130. The voltage regulator circuit 300 filters and regulates the +12 VDC and +5 VDC input power and provides the resulting regulated and filtered power on the outputs +12VF, +5L, +5VREF to other portions of the split engine controller 200.
A CAM processing circuit 390 processes the cam pulses from the CAM sensor received on the line 110 and generates processed cam pulses on the output CAM -- PULSE. One pulse is generated every two engine revolutions. The output CAM -- PULSE is connected to a CLK-CAMPULSE input of an injector controller PAL 420 by the signal line 230, as illustrated in FIG. 4.
A temperature sensor processing circuit 320 receives on an input ECT a temperature sensor voltage representing the engine coolant temperature on the signal line 104 from the engine coolant temperature sensor. The temperature sensor processing circuit 300 inspects the voltage level of the signal 104 to determine if the engine coolant temperature is within the normal range for a warmed-up engine. If the engine coolant temperature sensor voltage indicates that the engine is cold, the temperature sensor processing circuit 320 responds by asserting a logic `1` on the output LOW -- TEMP. The output LOW -- TEMP is connected to the logic control circuit 204 by the signal line 220. As will be explained in detail below, if the temperature processing circuit 320 indicates that the coolant temperature is cold, the logic control circuit 204 responds by disabling the split engine function, instead operating the engine in a non-split engine mode. A manually operated disable switch 326 is located in the vehicle's passenger compartment. An operator may disable the split engine function by closing the disable switch 326. The temperature sensing circuit 320 responds by asserting a `1` on the LOW -- TEMP output, which will again cause the logic control circuit 204 to operate the engine in a non-split engine mode.
A throttle sensor processing circuit 330 receives on an input TP a throttle position sensor voltage representing the throttle position on the signal line 106 from the throttle position sensor. The throttle position sensor processing circuit 330 inspects the voltage level on the signal line 106 and makes several determinations. First, the throttle sensor processing circuit 330 measures the rate of change of the voltage from the throttle position sensor. If the rate of change of the throttle position sensor voltage is less than a predetermined rate, indicating that the operator desires to accelerate slowly, or not at all, then the throttle position sensor processing circuit 330 asserts a logic `1` on the output FXD -- TP, which is connected to the logic control circuit 204 by the signal line 222. Otherwise, a logic `0` is asserted on the FXD -- TP output.
The throttle position sensor processing circuit 330 also determines if the throttle sensor voltage indicates the throttle is approximately at half-throttle or at approximately at full-throttle. If the throttle sensor voltage indicates that the throttle is at half-throttle, then the throttle position sensor processing circuit 330 asserts a logic `1` on the output HT which is connected to the logic control circuit 204 by the signal line 224. Otherwise a logic `0` is asserted on the output HT. If the throttle sensor voltage indicates that the throttle is at full-throttle, then the throttle position sensor processing circuit 330 asserts a logic `1` on the output FT which is connected to the logic control circuit 204 by a signal line 226. Otherwise a logic `0` is asserted on the output FT.
Furthermore, the throttle position sensor processing circuit 330 also determines if the throttle sensor voltage indicates the throttle is at an idle position. If the throttle sensor voltage indicates that the throttle is at idle, then the throttle position sensor processing circuit 330 asserts a logic `1` on the output IDLE. Otherwise a logic `0` is asserted on the IDLE output. The output IDLE is connected by the signal line 232 to an input DISABLE of an airflow comparison circuit 350 which measures throttle position versus airflow. The output IDLE is also connected to an input of the logic control circuit 204, as illustrated in FIG. 4. The throttle position sensor processing circuit 330 provides a buffered throttle position output BTP which is connected to a buffered throttle input BTPI of the airflow comparison circuit 350 by the signal line 334.
The airflow comparison circuit 350 compares the throttle position voltage received on the input BTPI, indicating throttle position, against a manifold airflow voltage, received on an input MAF, indicating the airflow through the engine intake manifold. The result of this comparison is provided on the output PWR -- REQ, which in turn is connected to the logic control circuit 204 by the signal line 228. If the airflow comparison circuit 350 determines there is not sufficient airflow relative to the throttle position, indicating that the engine is under a heavy load, the circuit 350 asserts a logic `1` at the output PWR -- REQ. Otherwise, a logic `0` is asserted at the output PWR -- REQ. If, however, the throttle position is at idle, the throttle sensor voltage and the manifold sensor voltage may to too low for the circuit 350 to accurately compare the two. Thus, the throttle position sensor processing circuit 330 asserts a logic `1` at the output IDLE, disabling the circuit 350 and forcing the output PWR -- REQ to be at a logic `0`.
A vehicle speed sensor processing circuit 382 receives on an input VSS a pulse train representing the vehicle speed on the signal line 108 from the vehicle speed sensor. The vehicle speed sensor processing circuit 382 inspects the frequency of the signal from the vehicle speed sensor to determine if the vehicle speed is greater than 40 miles an hour (MPH). If the vehicle speed sensor pulse train indicates the vehcile is travelling at a speed greater than 40 MPH, the vehicle speed sensor processing circuit 382 responds by asserting a logic `1` on the output VGTR40. The output VGTR40 is connected to the logic control circuit 204 by the signal line 234. As will be explained in detail below, the VGTR40 output is used by the split engine controller 200 to determine in which split engine mode to operate the engine.
An oxygen sensor circuit 380 receives an indication from the logic control circuit 204 from an output FOURCO, on the signal line 234, that the engine is operating in the four cylinder mode. Additionally, the oxygen sensor circuit 380 receives left and right oxygen sensor signals on respective signal lines 126, 124. When the engine is being operated in the four cylinder mode the unused cylinders advantageously act as air pumps, increasing the percentage of oxygen in the engine exhaust gases, thus reducing NOX emissions. The oxygen sensors indicates this increase in oxygen levels. However, if the oxygen sensor signals indicating this increase in oxygen levels were sent to the standard engine controller 100, the engine controller 100 would incorrectly conclude that a malfunction was occurring and thus the engine controller 100 would respond inappropriately. In order to overcome this problem, when the logic control circuit 204 indicates the engine is operating in the four cylinder mode, the oxygen sensor circuit 380 responds by decoupling the oxygen sensor signals from the standard engine controller 100. The oxygen sensor circuit 380 then sends simulated sensor readings over the signal lines 112, 114 to the engine controller 100 by outputing voltage levels that are in the normal range for the engine when operating in standard 8 cylinder mode. This causes the engine controller 100 to operate in appropriate fashion even when the split engine controller 200 has placed the engine in the four cylinder mode.
FIG. 4, and the PAL equations in Appendix A and in Appendix B, illustrate the logic control circuit 204 and the injector driver circuitry 206 of a preferred embodiment of the present invention. The logic control circuit 204 includes an engine control (EC) programmable array logic (PAL) device 410 and an oscillator 440, while the injector drive circuitry 206 includes the injector controller (IC) PAL 420 and injector drivers 430. An output PW of the oscillator 440 is connected to an input PW of the EC PAL 410. The EC PAL 410 has four outputs A, B, C, D which are connected, respectively to inputs GRPA, GRPB, GRPC, GRPD of the IC PAL 420. The output IAC of the EC PAL 410 is connected to the IAC driver 208, while an output FOURCO is connected to a clock input CLK of the EC PAL 410 and to the sensor processing circuitry 202. For purposes of the following description and with reference to FIG. 8, the engine injectors are assigned to four groups A, B, C, D. Group A includes injectors 4 and 7. Group B includes injectors 3 and 5. Group C includes injectors 1 and 6. Group D includes injectors 2 and 8. Each group has a term and an output associated with it in the PAL equations for the EC PAL 410. Thus, Group A is associated with term and output "A", Group B is associated with term and output "B", Group C is associated with term and output "C", and Group D is associated with term and output "D."
Eight Cylinder Mode
The operation of the present invention will now be described when operating in eight cylinder mode. With reference to the PAL equations for the EC PAL 410 for the preferred embodiment of the present invention in Appendix A, if the inputs IDLE, PWR -- REQ, FT, HT, FXT -- TP, LOW -- TEMP satisfy the equation:
(LOW.sub.-- TEMP+/IDLE)·(IDLE+LOW.sub.-- TEMP+/FXD.sub.-- TP+FT+HT+PWR.sub.-- REQ)=1 (1)
then the terms and outputs "A", "B", "C", "D" are set to a logic `0`. Equation 1 defines the operating conditions which will cause the split engine controller 200 to operate the engine in a non-split engine mode, with all the engine cylinders activated. The full complement of engine cylinders may be activated either because the full power of the engine is required, such as when the throttle is positioned at full throttle or half-throttle, or because the engine is cold and needs to warm-up quickly. As will be described below, when all the outputs "A", "B", "C", "D" are set to a logic `0`, all cylinders are operated. However, it will be apparent to one skilled in the art, that other equations, using different terms or sensor inputs, may be used in determining when to operate the engine in the eight cylinder mode.
With reference to the PAL equations for the IC PAL 420 in Appendix B, and the timing diagram illustrated in FIG. 7A, if the outputs A, B, C, D of the EC PAL 410 are set to a logic `0`, and therefore the inputs GRPA, GRPB, GRPC, GRPD of the IC PAL 420 are set to a logic `0`, then the IC PAL 420 terms INJ -- 1, INJ -- 2, INJ -- 3, INJ -- 4, INJ -- 5, INJ -- 6, INJ -- 7, INJ -- 8 are set to a logic `1`. Each term INJ -- 1, INJ -- 2, INJ -- 3, INJ -- 4, INJ -- 5, INJ -- 6, INJ -- 7, INJ -- 8 is associated with a respective output /INJ -- 1, /INJ -- 2, /INJ -- 3, /INJ -- 4, /INJ -- 5, /INJ -- 6, /INJ -- 7, /INJ -- 8 having a logic state that is the complement of its associated term. Each output /INJ -- 1, /INJ -- 2, /INJ -- 3, /INJ -- 4, /INJ -- 5, /INJ -- 6, /INJ -- 7, /INJ -- 8 is connected to a respective one of the injector drivers 430. Each of the injector drivers 430 is in turn connected to one of the fuel injectors 140. When any term INJ -- 1, INJ -- 2, INJ -- 3, INJ -- 4, INJ -- 5, INJ -- 6, INJ -- 7, INJ -- 8 is set to a logic `1`, and thus the respective output /INJ -- 1, /INJ -- 2, /INJ -- 3, /INJ -- 4, /INJ -- 5, /INJ -- 6, /INJ -- 7, /INJ -- 8 is set to a logic `0`, the associated injector 140 are activated. Thus, as all the terms INJ -- 1, INJ -- 2, INJ -- 3, INJ -- 4, INJ -- 5, INJ -- 6, INJ -- 7, INJ -- 8 are set to a logic `1`, all eight injectors are activated, placing the engine in eight cylinder, non-split engine, mode.
Four Cylinder 50% Power Mode
The operation of the present invention will now be described when operating in the four cylinder mode. When the engine is operating in the four cylinder mode (i.e. the output FOURCO of the EC PAL 410 is set active high), then for a given time period, which, in the preferred embodiment is the period of an engine cycle of two revolutions, only four of the eight injectors 140 are enabled. As defined by the equations for the EC PAL 410 in Appendix A, the output FOURCO is set to an active high, logic `1` when both the input LOW -- TEMP is at a logic `0`, indicating the engine is not cold, and the input IDLE is at a logic `1` indicating the engine is idling. Thus, the split engine controller 200 will place the engine in the four cylinder mode when the engine has warmed-up and the engine does not need the power or torque available when operating on all eight cylinders. With reference to the PAL equations for the EC PAL 410 in Appendix A, the PAL equations for the IC PAL 420 in Appendix B, and the waveforms in FIG. 7B, the EC PAL 410 and the IC PAL 420 operate as follows.
When one of the terms A, B, C, D and associated output is set to a logic `0`, the injectors 140 associated with their respective term and output are enabled. Thus, as can be seen from the definition of the terms A, B, C, D, and from FIGS. 5 and 7, when the term FOURCO transitions from a low to an active high, as occurs when the split engine controller 200 transitions from an eight cylinder mode to a four cylinder mode, then the terms A, B, C, D are set to an active high `1`. The EC PAL 410 outputs A, B, C, D are connected respectively to inputs GRPA, GRPB, GRPC, GRPD of the IC PAL 420. As can be seen from the PAL equations in Appendix B for the IC PAL 420, the inputs GRPA, GRPB, GRPC, GRPD respectively have terms GRPA, GRPB, GRPC, GRPD associated with them. The IC PAL 420 is clocked by the processed cam pulses from the cam processing circuitry 390. One cam pulse is generated for every two engine revolutions. One engine cycle is equal to two engine revolutions. Thus, the cam pulses are used to synchronize the operation of the IC PAL 420, and the engine controller 200 as a whole, to the engine revolutions.
Referring to Appendix B, the term FOURCLYMODE is set high when either the terms A, C are both a `1` and when the terms B, D are both a `1`. Thus, when the term FOURCO is a `1`, the term FOURCLYMODE is a `1`. The term FIRE -- 1764, as defined in Appendix B, is used to toggle between a first set of four cylinders and a second set of four cylinders every two engine revolutions. The term FIRE -- 1764 is a registered term, clocked by the cam pulse every two engine revolutions. Thus, when the term FOURCLYMODE is a `1` the term FIRE -- 1764 will change logic states every two engine revolutions. On a first engine cycle, if the term FIRE -- 1764 is at a logic `1` state, and the term FOURCLYMODE is likewise at a logic `1` state, then the terms INJ -- 1, INJ -- 4, INJ -- 6, INJ -- 7 are set high and the terms INJ -- 2, INJ -- 3, INJ -- 5, INJ -- 8 are set low. Thus, Group A and Group C injectors are activated. At the next cam pulse, the term FIRE -- 1764 transitions from a logic `1` to a logic `0`. When the term FIRE -- 1764 is at a logic `0` state, and the term FOURCLYMODE is at a logic `1` state, then the terms INJ -- 2, INJ -- 3, INJ -- 5, INJ -- 8 are set high and the terms INJ -- 1, INJ -- 4, INJ -- 6, INJ -- 7 are set low. Thus, when the engine controller 200 operates the engine is the four cylinder mode a different set of fuel injectors and related cylinder will be used every two engine revolutions. This ensures that the cylinders wear evenly in a balanced manner. However, it will be apparent to one skilled in the art, that other equations, using different terms or sensor inputs, may be used in determining when to operate the engine in the four cylinder mode. Furthermore, in other embodiments of the present invention, the four cylinder mode is not used at all.
In an alternate embodiment, the split engine controller, while in the four cylinder mode, will activate alternate sets of four cylinders every time the engine controller transitions from the eight cylinder mode to the four cylinder mode, rather than every two engine revolutions.
FIG. 5 illustrates the fuel injector activation of a typical V8 engine in the four cylinder mode, with only four injectors activated per engine cycle. The sequence of the injector 140 activation has been chosen for the following reason. The 4.6 liter V8 engine in the 1993 Ford Crown Victoria with the standard engine controller 100, operating in non-split engine mode, fires the injectors 140 in the following order: 1, 3, 7, 2, 6, 5, 4, 8. The aforementioned order causes the ignition of the cylinders to be evenly spaced in time, ensuring that operation of the cylinders is balanced. In a four cycle engine, such as that found in typical automobiles, it takes two revolutions of the engine to fire all the injectors. The four cylinder mode firing sequence, illustrated in FIG. 5, advantageously also causes the ignition of the cylinders to be evenly spaced in time, even though only four injectors are activated every engine cycle. The firing sequence when the term FIRE -- 1764=`1` is 1, 7, 6, 4, and the firing sequence when the term FIRE -- 1764=`0` is 3, 2, 5, 8. The firing sequence is the same as for the standard eight cylinder mode, except when the term FIRE -- 1764=`1` one subset of four injectors is not activated while when the term FIRE -- 1764=`0` the second subset of four injectors is not activated. The split engine controller 200 utilizes the cam pulses to synchronize the operation of the IC PAL 420, and hence the alternating activation of the first subset of injectors and the second subset of injectors, with the rotation of the engine. Thus, the firing pattern has been advantageously selected and synchronized to provide for an even, balanced engine operation.
Furthermore, the four non-firing cylinders act as air pumps as air is still admitted into the cylinders via valve openings and exhausted through the exhaust system. This substantially reduces pollutant concentrations in the exhaust gases. Furthermore, by alternately firing and then resting subsets of four cylinders, the cylinders remain cooler than if the same subset of four cylinders were firing at all times. Keeping the cylinders cooler further reduces exhaust pollutants, such as NOX, and causes the engine cylinders to wear evenly.
The generation of the IAC output for the engine idle air control will now be described. If the term FOURCO has been set active high, indicating four cylinder operation, by the EC PAL 410, and if the input PW is set active high, and the input FXD -- TP is set active high, indicating that the throttle is in a fixed position, and if the input PWR -- REQ is set low, indicating that no additional power is required, then the output IAC is set active high by the EC PAL 410 which activates the engine idle air control solenoid via the IAC driver 208. The input PW is approximately a 50% duty cycle clock signal. Thus, when the engine requires additional air at idle, such as when an air conditioner is turned on, the term IAC is activated with an approximately 50% duty cycle, causing the idle air control solenoid to open the air valve halfway.
75% Power Mode
The operation of the present invention will now be described when operating in 75% power mode. When operating the engine at 75% of full power, the engine controller 200 alternately enables a first group of four cylinders, then all eight cylinders, and then a second group of four cylinders. Therefore, in the 75% mode, the controller 200 activates the cylinders in a 8-4A-8-4B pattern, as illustrated in FIG. 9. Thus, when a significant percentage of the total available engine power is required, the engine operates in the 75% power mode, while advantageously resting alternate halves of the cylinders one third of the time.
With reference to the PAL equations for the EC PAL 410 and the IC PAL 420 in Appendix A and Appendix B respectively, the preferred embodiment of the split engine controller 200 will place the engine in the 75% power mode when the following equation from Appendix B is satisfied:
(GRPA+GRPB+GRPC+GRPD)·/(GRPA·GRPC)·/(GRPB.multidot.GRPD)·VGTR40 (2)
For Equation 2 be satisfied, the following equation must be satisfied:
/IDLE·FXT.sub.-- TP·/FT·/HT·/PWR.sub.-- REQ·/LOW.sub.-- TEMP=1 (3)
Thus, the engine controller 200 operates the engine in 75% power mode when the engine is not idling, and the throttle position is fixed at substantially steady-state, and the throttle position is neither at full throttle or half throttle, and no additional power is required, and the engine is not cold, and the vehicle is traveling at greater than 40 MPH. Equations 2 and 3 essentially defines the operation of an engine while cruising at a speed greater than 40MPH, and hence when a substantial portion, but not all, of the power offered by operating in eight cylinder mode is required. However, it will be apparent to one skilled in the art, that other equations, using different terms or sensor inputs, may be used in determining when to operate the engine in 75% mode. Furthermore, in other embodiments of the present invention the 75% mode is not used at all.
The terms FIRE -- 8 and FIRE -- 1764, as defined in Appendix B, are used by the engine controller in determining when to transition from operating the first group of four cylinders to operating all eight cylinders and then when to transition to operating the second group of four cylinders. The term FIRE -- 8 is a registered term, clocked by the cam pulse every two engine revolutions. Thus, when the term MODE -- 848 is a `1` the term FIRE -- 8 will change logic states every two engine revolutions. The term FIRE -- 1764 is likewise a registered term, clocked by the cam pulse every two engine revolutions. As defined by the equations in Appendix B, the terms FIRE -- 1764 and FIRE -- 8 act as a modula 4 counter, with the term FIRE -- 1764 as the most significant bit and the term Fire -- 8 as the least significant bit, as illustrated in Table 1, below.
In the 75% mode, an injector will be activated only when the term MODE -- 848 is set to a logic `1` and the appropriate count is reached by the modula 4 counter formed by the terms FIRE -- 1764, FIRE -- 8, as defined by the logic equations for the IC PAL 420 in Appendix B: Table 1 and FIG. 7B illustrate the counts and input conditions necessary to activate a respective injector.
TABLE 1______________________________________ ACTIVATEDMODE.sub.-- 848 FIRE.sub.-- 1764 FIRE.sub.-- 8 INJECTORS______________________________________1 0 0 2, 3, 5, 81 0 1 1, 2, 3, 4, 5, 6, 7, 81 1 0 1, 4, 6, 71 1 1 1, 2, 3, 4, 5, 6, 7, 8______________________________________ `1` = TRUE `0` = FALSE `X` = DON'T CARE
The technique used to implement the 75% mode offers numerous advantages over previous embodiments which typically operate by using only six of the eight cylinders. The 75% mode of the preferred embodiment offers a reduction in fuel consumption while still providing enough engine power to overcome wind resistance while cruising at speeds greater than 40 MPH. Additionally, all injectors and associated cylinders are rested in turn while operating in the 75% mode, ensuring even, reduced wear of the cylinders. Furthermore, when an injector is not activated, the cylinder operates as an air pump, further reducing engine emissions. Thus, the technique used by the preferred embodiment overcomes the limitations of traditional implimentations of the 75% mode, which constantly used the same set of six of the eight cylinders, resulting in the uneven wear of the cylinders and the unbalanced operation of the engine.
As previously noted, the 4.6 liter V8 engine in the 1993 Ford Crown Victoria with the standard engine controller 100, operating in non-split engine mode, fires the injectors 140 in the following order: 1, 3, 7, 2, 6, 5, 4, 8. The aforementioned order causes the ignition of the cylinders to be evenly spaced in time, ensuring that operation of the cylinders is balanced. The present invention likewise follows this sequence when operating in 75% power mode, except when only four injectors are activated, every other cylinder in the 1, 3, 7, 2, 6, 5, 4, 8 sequence is not fired, as illustrated below by Table 2. The split engine controller 200 utilizes the cam pulses to synchronize the operation of the IC PAL 420, and hence the activation of the injectors, with the rotation of the engine. Thus, the split engine controller 200 advantageously provides a method of activating and resting the injectors and associated cylinders, enabling a balanced, smooth, operation of the automobile engine.
TABLE 2__________________________________________________________________________FIRING SEQUENCE OF INJECTORS/CYLINDERS FOR 75% MODECYCLE 1 CYCLE 2 CYCLE 31 3 7 2 6 5 4 8 1 3 7 2 6 5 4 8 1 3 7 2 6 5 4 8__________________________________________________________________________S F S F S F S F F F F F F F F F F S F S F S F S__________________________________________________________________________ "F" = FIRE "S" = SKIP
66.67% Power Mode
The operation of the present invention will now be described when operating in 66.7% power mode. With reference to the PAL equations for the EC PAL 410 and the IC PAL 420 in Appendix A and Appendix B respectively, the split engine controller 200 will place the engine in 66.67% power mode when the following equation is satisfied:
/IDLE·FXT.sub.-- TP·/FT·/HT·/PWR.sub.-- REQ·/LOW.sub.-- TEMP·/MODE.sub.-- 848=1 (4)
Thus, the engine controller 200 operates the engine in 66.67% power mode when then engine is not idling, and the throttle position is fixed at substantially steady-state, and the throttle position is neither at full throttle or half throttle, and no additional power is required, and the engine is not cold, and the term MODE -- 848 is at a logic `0`. Equation 2 essentially defines the operation of an engine while cruising at speeds of 40 MPH or less, and hence when the power offered by operating in 100%, eight cylinder mode, or 75%, six cylinder mode, is not required. However, it will be apparent to one skilled in the art, that other equations, using different terms, may be used in determining when to operate the engine in the 66.67% power mode. Furthermore, in other embodiments of the present invention, the 66.67% power mode is not used at all.
When Equation 4 is satisfied, then the equations which define the IC PAL 420 causes the injectors 140 to activate, as illustrated in FIG. 6, so that over three engine cycles the injectors are activated an average of 66.67% of the time compared to the number injector activations which occurs while the engine is being operated in normal eight cylinder mode. This is accomplished as follows. The terms REV -- CNT -- 0, REV -- CNT -- 1 serve to define a modula 2 counter, with the term REV -- CNT -- 0 being the least significant bit (LSB) and with the term REV -- CNT -- 1 being the most significant bit (MSB). The modula 2 counter is clocked by the signal on the input CLK-CAMPULSE. An injector will be activated when the appropriate count is reached by the modula 2 counter and the inputs GRPA, GRPC, GRPDC, GRPD are set at the appropriate states, as defined by the logic equations for the IC PAL 429 in Appendix B. Table 3 and FIG. 7A illustrate the counts and input conditions necessary to activate a respective injector.
TABLE 3______________________________________ REV REV ACTIVATEDGRPA GRPB GRPC GRPD CNT 1 CNT 0 INJECTORS______________________________________1 X 0 X 0 0 1,2,3,4,6,8X 1 X 0 0 0 1,2,3,4,6,81 X 0 X 0 1 3,5,6,7,8X 1 X 0 0 1 3,5,6,7,81 X 0 X 1 0 1,2,4,5,7X 1 X 0 1 0 1,2,4,5,7______________________________________ `1` = TRUE `0` = FALSE `X`= DON'T CARE
The technique used to implement the 66.67% mode offers several advantages over previous embodiments. The 66.67% offers a reduction in fuel consumption while still providing enough engine power while cruising. Additionally, all injectors and associated cylinders are rested in turn while operating in the 66.67% mode, ensuring even, reduced wear of the cylinders. Furthermore, when an injector is not activated, the cylinder operates as an air pump, further reducing engine emissions.
As previously noted, the 4.6 liter V8 engine in the 1993 Ford Crown Victoria with the standard engine controller 100, operating in non-split engine mode, fires the injectors 140 in the following order: 1, 3, 7, 2, 6, 5, 4, 8. The aforementioned order causes the ignition of the cylinders to be evenly spaced in time, ensuring that operation of the cylinders is balanced. The present invention likewise follows this sequence when operating in 66.67% power mode, except every third cylinder in the 1, 3, 7, 2, 6, 5, 4, 8 sequence is skipped, as illustrated below by Table 4 and by FIG. 7A. The split engine controller 200 utilizes the cam pulses to synchronize the operation of the IC PAL 420, and hence the activation of the injectors, with the rotation of the engine. Thus, the split engine controller 200 advantageously provides a method of activating and resting the injectors and associated cylinders, enabling a balanced, smooth, operation of the automobile engine.
TABLE 4__________________________________________________________________________FIRING SEQUENCE OF INJECTORS/CYLINDERS FOR 66.67% MODECYCLE 1 CYCLE 2 CYCLE 31 3 7 2 6 5 4 8 1 3 7 2 6 5 4 8 1 3 7 2 6 5 4 8__________________________________________________________________________F F S F F S F F S F F S F F S F F S F F S F F S__________________________________________________________________________ "F" = FIRE "S" = SKIP
Although this invention has been described in terms of a certain preferred embodiment, other embodiments apparent to those of ordinary skill in the art are also within the scope of this invention. Accordingly, the scope of the invention is intended to be defined only by the claims which follow.
APPENDIX A______________________________________PALASM DESIGN DESCRIPTION FOR THE ENGINE CONTROLLERPAL 410______________________________________Declaration SegmentTITLE: Engine Control Logic; PIN DeclarationsFOURCO.sub.-- CLK ;CLOCKLOWTEMP COMBINATORIAL ; INPUTFXD.sub.-- TP COMBINATORIAL ; INPUTFT COMBINATORIAL ; INPUTHT COMBINATORIAL ; INPUTPWR.sub.-- REQ COMBINATORIAL ; INPUTPW COMBINATORIAL ; INPUTIDLE COMBINATORIAL ; INPUTFOURCO COMBINATORIAL ; OUTPUTA COMBINATORIAL ; OUTPUTB COMBINATORIAL ; OUTPUTC COMBINATORIAL ; OUTPUTD COMBINATORIAL ; OUTPUTIAC COMBINATORIAL ; OUTPUT; Boolean Equation SegmentEQUATIONSFOURCO = /LOWTEMP * IDLE;IAC = PW * /LOWTEMP * FXD.sub.-- TP * FOURCO * /PWR.sub.-- REQ;A = FOURCO + /IDLE * FXD.sub.-- TP * /FT * /HT * /PWR.sub.-- REQ * /LOWTEMP;B = FOURCO + /IDLE * FXD.sub.-- TP * /FT * /HT * /PWR.sub.-- REQ * /LOWTEMP;C = FOURCO;D = FOURCO;______________________________________
APPENDIX B______________________________________PALASM DESIGN DESCRIPTION FOR THE INJECTORCONTROLLER PAL 420______________________________________Declaration SegmentTITLE Injector Controller; DeclarationsCLOCK COMBINATORIAL INPUTMODE.sub.-- 848 REGISTERED OUTPUTFIRE.sub.-- 8 REGISTERED OUTPUTFOURCLYMODE REGISTERED OUTPUTFIRE.sub.-- 1764 REGISTERED OUTPUTGRPD COMBINATORIAL INPUTGRPC COMBINATORIAL INPUTGRPB COMBINATORIAL INPUTGRPA COMBINATORIAL ; INPUT/INJ.sub.-- 1 COMBINATORIAL ; OUTPUT/INJ.sub.-- 2 COMBINATORIAL ; OUTPUT/INJ.sub.-- 3 COMBINATORIAL ; OUTPUT/INJ.sub.-- 4 COMBINATORIAL ; OUTPUT/INJ.sub.-- 5 COMBINATORIAL ; OUTPUT/INJ.sub.-- 6 COMBINATORIAL ; OUTPUT/INJ.sub.-- 7 COMBINATORIAL ; OUTPUT/INJ.sub.-- 8 COMBINATORIAL ; OUTPUTREV.sub.-- CNT.sub.-- 0 REGISTERED ; OUTPUTREV.sub.-- CNT.sub.-- 1 REGISTERED ; OUTPUT______________________________________; Boolean Equation SegmentEQUATIONS;8-4A-8-4B-8 MODEMODE.sub.-- 848 = GRPA * /(GRPA*GRPC) * /(GRPB*GRPD) * VGTR40 + GRPB * /(GRPA*GRPC) * /(GRPB*GRPD) * VGTR40 + GRPC * /(GRPA*GRPC) * /(GRPB*GRPD) * VGTR40 + GRPD * /(GRPA*GRPC) * /(GRPB*GRPD) * VGTR40;FIRE 8 TOGGLEFIRE 8 = /FIRE 8 * MODE.sub.-- 848;;FOUR CYLINDER MODEFOURCLYMODE = GRPA * GRPC + GRPB * GRPD;;FOUR CYLINDER TOGGLE (4A-4b)FIRE.sub.-- 1764 = FIRE.sub.-- 8 * /FIRE.sub.-- 1764 * MODE.sub.-- 848 + FOURCLYMODE * /FIRE.sub.-- 1764;;Counter Set UPREV.sub.-- CNT.sub.-- 0 = /REV.sub.-- CNT.sub.-- 0 * /REV.sub.-- CNT.sub.-- 1REV.sub.-- CNT.sub.-- 1 = REV.sub.-- CNT.sub.-- 0 * /REV.sub.-- CNT.sub.-- 1;;INJECTOR SELECTION EQUATIONSINJ.sub.-- 1 = GRPA * GRPC * FOURCLYMODE * FIRE.sub.-- 1764 + GRPA * /GRPC * /REV.sub.-- CNT.sub.-- 0 * /REV.sub.-- CNT.sub.-- 1 */MODE.sub.-- 848 + GRPB * /GRPD * /REV.sub.-- CNT.sub.-- 0 * /REV.sub.-- CNT.sub.-- 1 */MODE.sub.-- 848 + GRPA * /GRPC * /REV.sub.-- CNT.sub.-- 0 * REV.sub.-- CNT.sub.-- 1 */MODE.sub.-- 848 + GRPB * /GRPD * /REV.sub.-- CNT.sub.-- 0 * REV.sub.-- CNT.sub.-- 1 */MODE.sub.-- 848 + /GRPA * /GRPB * /GRPC * /GRPD + MODE.sub.-- 848 * FIRE.sub.-- 8 + MODE.sub.-- 848 * /FIRE.sub.-- 8 * FIRE.sub.-- 1764;INJ.sub.-- 2 = GRPB * GRPD * FOURCLYMODE * /FIRE.sub.-- 1764 + GRPA * /GRPC * /REV.sub.-- CNT.sub.-- 0 * /REV.sub.-- CNT.sub.-- 1 */MODE.sub.-- 848 + GRPB * /GRPD * /REV.sub.-- CNT.sub.-- 0 * /REV.sub.-- CNT.sub.-- 1 */MODE.sub.-- 848 + GRPA * /GRPC * /REV.sub.-- CNT.sub.-- 0 * REV.sub.-- CNT.sub.-- 1 */MODE.sub.-- 848 + GRPB * /GRPD * /REV.sub.-- CNT-0 * REV.sub.-- CNT.sub.-- 1 */MODE.sub.-- 848 + /GRPA * /GRPB * /GRPC * /GRPD + MODE.sub.-- 848 * FIRE.sub.-- 8 + MODE.sub.-- 848 * /FIRE.sub.-- 8 * /FIRE.sub.-- 1764;INJ.sub.-- 3 = GRPB * GRPD * FOURCLYMODE * /FIRE.sub.-- 1764 + GRPA * /GRPC * /REV.sub.-- CNT.sub.-- 0 * /REV.sub.-- CNT.sub.-- 1 */MODE.sub.-- 848 + GRPB * /GRPD * /REV.sub.-- CNT.sub.-- 0 * /REV.sub.-- CNT.sub.-- 1 */MODE.sub.-- 848 + GRPA * /GRPC * /REV.sub.-- CNT.sub.-- 0 * /REV.sub.-- CNT.sub.-- 1 */MODE.sub.-- 848 + GRPB * /GRPD * /REV.sub.-- CNT.sub.-- 0 * /REV.sub.-- CNT.sub.-- 1 */MODE.sub.-- 848 + /GRPA * /GRPB * /GRPC * /GRPD + MODE.sub.-- 848 * FIRE.sub.-- 8 + MODE.sub.-- 848 * /FIRE.sub.-- 8 * /FIRE.sub.-- 1764INJ.sub.-- 4 = GRPA * GRPC * FOURCLYMODE * FIRE.sub.-- 1764 + GRPA * /GRPC * /REV.sub.-- CNT.sub.-- 0 * /REV.sub.-- CNT.sub.-- 1 */MODE.sub.-- 848 + GRPB * /GRPD * /REV.sub.-- CNT.sub.-- 0 * /REV.sub.-- CNT.sub.-- 1 */MODE.sub.-- 848 + GRPA * /GRPC * /REV.sub.-- CNT.sub.-- 0 * /REV.sub.-- CNT.sub.-- 1 */MODE.sub.-- 848 + GRPB * /GRPD * /REV.sub.-- CNT.sub.-- 0 * /REV.sub.-- CNT.sub.-- 1 */MODE.sub.-- 848 + /GRPA * /GRPB * /GRPC * /GRPD + MODE.sub.-- 848 * FIRE.sub.-- 8 + MODE.sub.-- 848 * /FIRE.sub.-- 8 * /FIRE.sub.-- 1764INJ.sub.-- 5 = GRPB * GRPD * FOURCLYMODE * FIRE.sub.-- 1764 + GRPA * /GRPC * /REV.sub.-- CNT.sub.-- 0 * /REV.sub.-- CNT.sub.-- 1 */MODE.sub.-- 848 + GRPB * /GRPD * /REV.sub.-- CNT.sub.-- 0 * /REV.sub.-- CNT.sub.-- 1 */MODE.sub.-- 848 + GRPA * /GRPC * /REV.sub.-- CNT.sub.-- 0 * /REV.sub.-- CNT.sub.-- 1 */MODE.sub.-- 848 + GRPB * /GRPD * /REV.sub.-- CNT.sub.-- 0 * /REV.sub.-- CNT.sub.-- 1 */MODE.sub.-- 848 + /GRPA * /GRPB * /GRPC * /GRPD + MODE.sub.-- 848 * FIRE.sub.-- 8 + MODE.sub.-- 848 * /FIRE.sub.-- 8 * FIRE.sub.-- 1764INJ.sub.-- 6 = GRPB * GRPD * FOURCLYMODE * FIRE.sub.-- 1764 + GRPA * /GRPC * /REV.sub.-- CNT.sub.-- 0 * /REV.sub.-- CNT.sub.-- 1 */MODE.sub.-- 848 + GRPB * /GRPD * /REV.sub.-- CNT.sub.-- 0 * /REV.sub.-- CNT.sub.-- 1 */MODE.sub.-- 848 + GRPA * /GRPC * /REV.sub.-- CNT.sub.-- 0 * /REV.sub.-- CNT.sub.-- 1 */MODE.sub.-- 848 + GRPB * /GRPD * /REV.sub.-- CNT.sub.-- 0 * /REV.sub.-- CNT.sub.-- 1 */MODE.sub.-- 848 + /GRPA * /GRPB * /GRPC * /GRPD + MODE.sub.-- 848 * FIRE.sub.-- 8 + MODE.sub.-- 848 * /FIRE.sub.-- 8 * FIRE.sub.-- 1764INJ.sub.-- 7 = GRPB * GRPD * FOURCLYMODE * FIRE.sub.-- 1764 + GRPA * /GRPC * /REV.sub.-- CNT.sub.-- 0 * /REV.sub.-- CNT.sub.-- 1 */MODE.sub.-- 848 + GRPB * /GRPD * /REV.sub.-- CNT.sub.-- 0 * /REV.sub.-- CNT.sub.-- 1 */MODE.sub.-- 848 + GRPA * /GRPC * /REV.sub.-- CNT.sub.-- 0 * /REV.sub.-- CNT.sub.-- 1 */MODE.sub.-- 848 + GRPB * /GRPD * /REV.sub.-- CNT.sub.-- 0 * /REV.sub.-- CNT.sub.-- 1 */MODE.sub.-- 848 + /GRPA * /GRPB * /GRPC * /GRPD + MODE.sub.-- 848 * FIRE.sub.-- 8 + MODE.sub.-- 848 * /FIRE.sub.-- 8 * FIRE.sub.-- 1764INJ.sub.-- 8 = GRPB * GRPD * FOURCLYMODE * FIRE.sub.-- 1764 + GRPA * /GRPC * /REV.sub.-- CNT.sub.-- 0 * /REV.sub.-- CNT.sub.-- 1 */MODE.sub.-- 848 + GRPB * /GRPD * /REV.sub.-- CNT.sub.-- 0 * /REV.sub.-- CNT.sub.-- 1 */MODE.sub.-- 848 + GRPA * /GRPC * /REV.sub.-- CNT.sub.-- 0 * /REV.sub.-- CNT.sub.-- 1 */MODE.sub.-- 848 + GRPB * /GRPD * /REV.sub.-- CNT.sub.-- 0 * /REV.sub.-- CNT.sub.-- 1 */MODE.sub.-- 848 + /GRPA * /GRPB * /GRPC * /GRPD + MODE.sub.-- 848 * FIRE.sub.-- 8 + MODE.sub.-- 848 * /FIRE.sub.-- 8 * FIRE.sub.-- 1764______________________________________ | An automobile includes an engine and an engine controller. The engine includes multiple cylinders. Each cylinder hyas a fuel injector connected to the engine controller. The engine controller has a first output which activates a first fraction of the fuel injectors. In addition, the engine controller has a second output which activates a second fraction of the fuel injectors. The engine controller also has an input which provides a timing signal synchronous with rotation of the engine and a sequencing circuit responsive to the timing signal. The sequencing circuit periodically alternates between the first and second output in synchronization with the rotation of the engine. | 5 |
BACKGROUND OF THE INVENTION
One of the most successful technologies applied to industry is the single stage (back pressure) steam turbine. These reliable prime movers are used throughout the chemical and petroleum industries to produce electrical power and to drive pumps and compressors from process steam. Currently over 100,000 units are installed and operating at an average power level of about 250 kW.
Unfortunately, current single stage steam turbines are also one of the largest sources of wasted energy in these industries and others. The average efficiency of single stage, back pressure steam turbines is in the 30-45% range. Another problem commonly encountered with industrial steam applications is structural erosion produced by liquid or solid particles in poor quality steam. If the efficiencies of the current industrial steam turbine population were increased from the current average of 40%, to 80%, steam consumption could be halved (or power output doubled). For the above population this amounts to an energy savings of 467 trillion Btu per year (at 50% capacity factor). This energy savings is the energy equivalent of 74 million barrels of oil per year.
The current “new” industrial steam turbine market is 600 units per year at an average power level of 350 kW, with the same “old” efficiency level of 40%. If the efficiencies of these units were increased to 80%, the energy savings would be 3.9 trillion Btu per year (at 50% capacity factor). This energy savings is the equivalent of 623,000 barrels of oil per year. Clearly, a huge energy savings, and reduction of carbon and NO x emissions can be achieved if a more efficient, reliable and less costly steam turbine can be made available on a commercial basis.
Another application for steam turbines is the generation of power from high pressure geothermal steam. This technology has been successful for installations where the geothermal flow is flashed to low pressures, the steam separated and extensively scrubbed and cleaned. However, attempts to generate power from the steam from the geothermal wells at higher pressures have been unreliable because of structural erosion by liquid and solid particles.
SUMMARY OF INVENTION
A primary objective of this invention is the provision of a high efficiency, less expensive steam turbine, in the form of a dual pressure Euler steam turbine, which has a higher efficiency than conventional industrial steam turbines.
A further objective is the provision of a steam turbine which is resistant to erosion damage from poor quality steam, such as commonly occurs in industrial applications or geothermal applications.
Another objective is provision of a steam turbine driven electric generator which minimizes required floor space and which requires no alignment during installation.
An added objective is provision of a steam turbine which enables and employs multiple expansion stages with a single rotor.
A yet further objective is provision of a steam reaction turbine in which the axial thrust produced by the pressure drop is minimized.
An additional objective is provision of a steam turbine having no steam leakage, and no contacting seal surfaces.
Another objective is provision of a steam turbine combining significant erosion resistance with variable nozzle vanes which can be used for flow control.
Yet another objective is provision of a self contained electric generating system incorporating the above referenced new steam turbine which can be easily installed to generate power from wasted steam energy.
The new turbine is embodied in a dual Euler turbine, which can be applied to operation with steam to achieve these advantages. The innovations necessary to achieve these and other advantages will be demonstrated by the following description and figures.
These and other objects and advantages of the invention, as well as the details of an illustrative embodiment, will be more fully understood from the following specification and drawings, in which:
DRAWING DESCRIPTION
FIG. 1 is a cross-section taken through a dual Euler turbine, for operation with steam;
FIG. 2 is a view showing operation of a seal or seal assembly in the FIG. 1 turbine;
FIG. 3 is a cross-sectional view of the nozzles and rotor blades;
FIGS. 4 a and 4 b are velocity diagrams and FIG. 4 c shows stationary and rotary blades;
FIG. 5 is a partial cross-section through blades of a two-stage, dual pressure Euler turbine;
FIG. 5 a is a section taken on lines 5 a - 5 a of FIG. 5 ;
FIG. 5 b is a section taken on lines 5 b - 5 b of FIG. 5 ;
FIG. 6 is a view showing installation if a dual pressure Euler turbine on a vertical axis, in a power system;
FIG. 7 is a view showing operation of the FIG. 6 system; and
FIG. 8 is a diagram showing an electrical system and control functions of a power system.
DETAILED DESCRIPTION
In the FIG. 1 cross section, a single expansion stage is illustrated. Steam is introduced through a port 1 , at the centerline of the turbine assembly 2 . The steam is expanded radially outwardly through a nozzle assembly 3 , and comprising stationary blades 3 a which are configured to efficiently accelerate the steam to a high velocity.
The steam at the exit 4 , of the nozzles flows in a generally tangential direction to a rotor structure 5 , and flows radially outwardly through vanes 6 , attached to the rotor structure. Metal projections 7 are carried by the rotor structure, and seal against non-rotating abradable surface or surfaces 8 , restricting the amount of flow which could otherwise bypass the passage or passages 9 , formed by the rotor blades. See FIGS. 5 , 5 a and 5 b.
High velocity flow from the nozzles enters the rotor passages, the rotor rotational speed being selected to minimize the relative velocity between the steam and the moving blades and to minimize the absolute value of the velocity of the steam leaving the blades.
Any liquid or solid particles, heavier than the steam, are centrifuged out from the radially extending space 10 between the nozzles and the rotor blades. The residence of uncentrifuged particles is limited to a fraction of a revolution. This is in contrast to radial inflow turbines where solid or liquid particulate matter tries to flow in a direction opposite the centrifugal forces, resulting in trapped particles which continue to impact the moving blades and nozzles causing extensive erosion damage.
Steam leaving the rotating blades flows into the annular diffuser passage, 10 , which recovers the absolute leaving velocity as pressure. This enables the pressure at the exit of the moving blades to be lower than the process imposed pressure, increasing the power output. The steam then flows into an annular plenum, 11 , and subsequently to exit port 12 ′ of the turbine assembly, where it is returned to the process.
A non-contact seal assembly, 12 , is provided to reduce the leakage of steam between the stationary surfaces of the casing 13 , and the shaft 14 , to which the rotor is attached. FIG. 2 shows the action of the seal. Compressed air or another pressurized gas is introduced to the seal through an inlet port 15 . The pressurized gas flows to annular space 16 , and flows to the seal assembly through transfer holes 17 . The pressurized gas is provided at a pressure above the pressure of the steam at the location 18 , where the steam is exposed to the seal. The pressurized gas flows to the space 19 , outboard of the seal. The centrifugal resistance of the rotating face 20 of the seal reduces the air flow into the steam location. The centrifugal resistance of a second rotating face 21 , reduces the flow of the pressurized air into the surroundings 22 .
To reduce the imbalance of axial forces on the rotor, both internal and external passages are provided. FIG. 2 shows the placement of passages 23 in the rotor, allowing the steam pressure at the nozzle exit 24 , and the steam pressure at the top part 26 of the rotor to communicate with the space 25 , on the bottom side of the rotor. In addition, a passage 27 , is provided external to the rotor such that the nozzle exit pressure communicates with the bottom side of the rotor. The only force imbalance is due to the pressure drop resulting from the small leakage flow through the seal face 28 , between the rotor and casing structure 28 a . The torque transferred to the rotor shaft 29 , is used to drive an electrical or mechanical load, indicated at 100 .
FIG. 3 shows a cross-sectional view of the nozzles and rotor blades. Steam at 29 ′, enters the stationary nozzles 30 , in a generally radial direction. The flow is accelerated in the passages formed by the nozzle blades 30 a . The high velocity flow leaving the nozzles at 31 is directed into the Euler passages 32 , formed by the rotating rotor blades 33 . The flow head is increased as the steam flows outward caused by the centrifugal forces from the rotating structure. Simultaneously, the flow is accelerated by the decreasing areas of the passages and the lower exhaust pressure, resulting from the seals provided. The steam tangential velocity leaving the blades is typically low, resulting in a high efficiency.
FIG. 4 a is a typical velocity diagram showing the velocities of the steam and blades for certain blade inlet representative conditions. The steam velocity 34 leaving the nozzles is 1872 ft/s. When combined with the rotor blade velocity 35 at the inlet, a relative entering velocity 36 , having a value of 947.3 ft/s results. This gives an entrance angle, 37 , of 26.6 degrees. Acceleration of steam, in the blades to the exit conditions shown in FIG. 4 b gives a relative steam leaving velocity 38 , of 1246.8 ft/s. When combined with the blade velocity 39 at the exit, the leaving steam absolute velocity is only 355.1 ft/s and the leaving angle is 94.2 degrees. This gives an absolute leaving tangential velocity of only 26 ft/s. For the conditions of the velocity triangle, an analysis of the mean path flow and losses gives an efficiency of 73% of isentropic power, a substantial gain above current steam turbines. FIG. 4 a shows stationary and rotating blades 42 and 43 .
The dual pressure Euler steam turbine also enables the use of four or more expansions with a single wheel. FIG. 5 is a partial cross section of a typical two-stage dual pressure Euler steam turbine. Steam enters the first stage stationary nozzles 44 , at 52 . The steam is accelerated in the passages to a high velocity at the nozzle exit area 45 . The high velocity steam then enters passages formed by the first stage rotor blades 46 . The head is increased in the Euler passage and the steam is accelerated by the passage area and the pressure difference between inlet and outlet 47 , which is maintained by a seal 7 of FIG. 1 . The entering impulse forces and reaction forces produce torque on the rotor to which the blades are attached as shown by 5 and 6 of FIG. 1 .
The steam is further accelerated by a second stage of stationary nozzles, 48 . The steam is accelerated to a high velocity at the exits 49 , of the second stage nozzles. The steam then enters a second row of blades, 50 , also attached to the same rotor. The entering impulse forces and reaction forces again transfer additional torque to the rotor. Additional stages of stationary nozzles and moving blades may be provided, all with a single rotor structure. The result is an efficient, multistage turbine with very low fabrication costs and complexity. For an inlet pressure of 150 psig and an exit pressure of 15 psig and a steam flow rate of 10,000 lb/h, a two stage dual pressure Euler steam turbine typically has an efficiency of 80% using a mean line path analysis and all loss coefficients. This is believed to be the first time any steam turbine of this size has reached an efficiency of 80%.
The dual pressure Euler steam turbine can be arranged on a vertical axis in a power plant system to reduce the required space for installation. FIG. 6 shows the arrangement. Steam enters the power system through an inlet, such as at flange 53 . The steam flows through duct 62 to a separator 54 , to remove solid or liquid contaminants. The flow of the steam is controlled by a combined throttle and trip valve 55 . The steam then flows into the dual pressure Euler steam turbine 56 , which is mounted with a vertical axis 56 a . The shaft 14 (from FIG. 1 ) drives gearing in a gearbox 57 , to reduce the turbine speed to the speed of the generator 58 . The generator converts the shaft torque to electric power which is connected to circuitry in the electric switchgear cabinet 61 . A support stand 61 a is provided to absorb any steam piping forces.
A control system 60 is provided as seen in FIG. 7 with a programmable logic controller to control the operation of the power system. Measurement of the pressure of the steam leaving the steam turbine 71 , is accomplished with a pressure transmitter. In response to steam demand, the pressure drops or increases for the same steam flow. The control system senses any change in pressure, and actuates the control valve to change the steam flow in a manner to keep the outlet pressure constant.
The operation of the power system is shown in FIG. 7 . Steam flow enters the system through a separator 62 , which removes solid or liquid particulate matter. A pressure gauge 63 , is provided for visual indication of the steam pressure. The steam flows through a strainer 101 , to remove any debris from the inlet piping or separator welds. The steam flow enters a combined trip and control (t&c) valve 64 . The t&c valve has two functions: control of the steam flow rate and shutoff of the steam flow in the event of various malfunctions in the power system.
The control of steam flow rate is accomplished by a current-to-pressure converter 65 , which converts electrical signals from the control system 98 , to air pressure to actuate the t&c valve diaphragm.
The t&c valve is closed by a signal from the control system to a solenoid valve 67 , which opens instantaneously, exhausting the air which had been holding the t&c valve open. When the air is exhausted a spring closes the t&c valve instantaneously.
The steam flow enters the dual pressure Euler steam turbine 71 , at an inlet port, 72 . After imparting torque to the rotor 5 as seen in FIG. 1 , the steam leaves the turbine at 72 in FIG. 7 . A pressure gauge 70 , and a temperature transducer 69 , are provided at the inlet to the turbine. The pressure gauge is provided to enable visual determination of the inlet steam pressure. The temperature transducer sends a signal to the control system, which is used to determine if a safe value of steam temperature exists. If the steam temperature is too high the control system actuates the solenoid valve to close the t&c valve.
A temperature transducer 74 , is provided in the steam exhaust line 73 , to provide a signal to the control system. The temperature reading is checked against the pressure reading of a pressure transmitter 76 , to ensure that the pressure reading is correct.
The pressure transmitter 76 , measures the pressure of the steam leaving the turbine and transmits its value to the control system. The control system has been set to maintain a value of the pressure which is required by any uses of the steam outside of the power system. If pressure drops, it is an indication that the device using steam, such as a steam absorption chiller or water heater, requires more steam than the power system is providing. The control system sends a signal to open the t&c valve to admit more steam until the pressure is at the required value. Conversely, if the pressure increases above the set value, it is an indication that steam demand is less than is being provided. The control system sends a signal to close the t&c valve until the pressure is at the required value.
If the pressure exceeds a safe value for the outside steam system, the control system closes the t&c valve completely, using the trip solenoid.
A pressure switch 75 , is also provided to close the t&c valve completely if the pressure exceeds a safe value. The pressure switch is a backup to the pressure transmitter, in the event the pressure transmitter does not measure the pressure correctly or fails.
To seal the turbine shaft 14 of FIG. 1 , pressurized gas is provided to the casing 84 , and introduced to the turbine seal 12 of FIG. 1 . In this system air from the plant air is reduced in pressure by a regulator 78 seen in FIG. 7 . The air flows through a flow indicator 79 , a filter 80 , and a check valve 81 . A pressure switch 82 , is provided which closes a relay to close the t&c valve in the event the seal air pressure is too low to prevent steam leakage.
The turbine shaft provides torque to gearing in a gearbox 85 , which reduces the speed of the turbine shaft, for example 28,000 rpm in this case, to a speed of 1,800 rpm for the gearbox output shaft 102 . The gearbox has a speed measurement device 87 , which sends a signal to an amplifier 89 , which sends a corresponding indication to the control system. The amplifier output is also connected to a relay which closes the t&c valve if the turbine speed is above a safe level. Another speed pickup signal at 86 , is supplied to another amplifier 88 , which is also connected to the control system, giving a backup speed signal if one of the two indicators or amplifiers fails.
A vibration probe 93 , is also applied to the gearbox to determine if the vibration is within safe limits. A temperature indicator 94 , is supplied to indicate if the bearing temperature is within safe limits. Both instruments provide a signal or signals to the control system which will indicate an alarm if the parameter is too high and which will close the t&c valve if an unsafe condition exists.
The lubrication oil pressure is measured by pressure transmitters 91 and 92 , to determine if the temperature is within normal limits. The temperatures are transmitted to the control system which activates an alarm if the pressure is too low and closes the t&c valve if the oil pressures are at an unsafe level.
The temperature of the lube oil for the rotating elements is measured by a temperature instrument 90 . The signal is transmitted to the control system which activates an alarm if the temperature is too high and closes the t&c valve if the lube oil temperature is at an unsafe level.
The gearbox shaft rotates the rotor of the electric generator 95 , producing electric power. The power is transmitted to the circuit breaker panel 99 , from where it is supplied to an electrical load.
Water drains from the separator 62 , and from the turbine 71 , are piped at 96 and 97 to associated steam traps, which permit water to drain but which prevent steam from leaking.
To enable startup a temperature instrument 77 , is provided on the turbine casing. The turbine is warmed up with steam before opening the t&c valve. The temperature instrument signal is transmitted to the control system. The control system prevents opening the t&c valve until the temperature instrument indicates a safe turbine temperature has been reached.
FIG. 8 shows the electrical system and control functions for the power system incorporating a dual pressure Euler steam turbine.
When the steam is causing the shaft 14 of FIG. 1 , of the turbine 103 , to rotate, the shaft rotates the rotor of the electric generator 105 , through a gearbox 104 . The electric current from the generator is conducted through current transformers, 106 , to generate an electrical signal which is proportional to the current. The voltage of the electric current generated is transformed by potential transformers 110 , to a signal which is proportional to the voltage. The current signal and voltage signals are connected to a multifunction digital relay which contains several measuring devices and relays.
During normal operation the electric current flows through a contactor 107 , and a shunt trip 108 , to a motor control center panel 109 .
The multifunction digital relay senses over current 111 , instantaneous over current 112 , time-over current 113 , negative sequence over voltage 114 , under voltage 115 , over voltage 116 , underfrequency 117 , and over frequency 118 . If any of these parameters exceeds the safe limits, the multifunction digital relay sends a signal to the master control relay 134 , which closes the t&c valve 137 , which stops the steam flow to the turbine.
In addition the multifunction digital relay sends a signal to a latching lockout relay 119 and 120 , which open the contactor 107 . The multifunction digital relay also sends a signal to a shunt trip 121 , which opens the intertie circuit breaker, 108 . These actions completely isolate the power system from the steam and electrical loads, placing it in a safe condition.
The power 122 , energy 123 , reactive power 124 , power factor 125 , volts 127 , and current 126 are measured and the signals sent via a data link 139 , to the programmable logic controller (PLC) 128 , which is a part of the control system. See also circuitry at 130 - 133 between 128 and 134 , and pressure control 132 .
The electrical and other instrumentation parameters of FIG. 7 , are displayed by the PLC on a “touch screen” display. The touch screen display has “touch buttons” on the screen which can be manipulated to change the power system settings and/or manually adjust the parameters, such as the opening of the t&c valve 137 , through the current to pressure converter 136 .
The PLC is programmed to perform automatic functions such as determining when the turbine casing is hot enough to start the system, determining when the lube oil pressure is high enough to start the system, automatically opening the t&c valve at a controlled rate until the desired turbine speed is reached, automatically closing the contactor when the proper speed is reached, automatically opening the t&c valve further until the set value for the steam exhaust pressure transmitter 76 of FIG. 7 , is reached, and automatically adjusting the t&c valve to limit the power generated to a safe value.
The dual pressure Euler steam turbine is a distinctly new type of steam turbine. Provision of an intermediate expansion pressure results in a turbine having impulse forces and reaction forces with internal head rise. This results in higher efficiency than is characteristic of existing steam turbines. A dual pressure Euler steam turbine and power system provides several advances relative to conventional steam turbines as follows:
1. Use of a low radial velocity and nozzles for expansions, instead of the use of high velocities and a multiplicity of blades, means that high efficiencies can be realized in the high pressure-low flow regime.
2. The dual pressure Euler steam turbine provides two stages of expansion with a single rotor instead of the usual one stage with one rotor. This enables a greater head difference to be used efficiently for the turbine compared to conventional turbomachninery. The efficiency is higher than other steam turbines in this flow regime.
3. The dual pressure Euler steam turbine is a pure radial flow machine. There is no flow induced thrust in the axial direction. This reduces the losses and unreliability associated with thrust bearings, which are required to support the axial forces resulting in conventional turbomachinery from axial impulse forces or from axial forces resulting from reaction.
4. Flow in the radial outward direction means any liquids produced during the expansion or any solids in the flow will be ejected without causing erosion of the first nozzle.
5.The annular diffuser at the exit is a natural consequence of the geometry and has a greater efficiency than a diffuser for either axial flow or radial inflow machinery.
6. A compact, complete power system is enabled by the vertical shaft arrangement. This reduces the installation space required and results in a minimum installation costs in existing equipment rooms having steam piping. | A turbine, including a rotor on a shaft, and having in combination stationary nozzles discharging steam at a first pressure or pressures thereby producing impulse forces on the rotor; internal passages in the rotor producing a pressure head increase in the discharged steam, while simultaneously accelerating the steam, the steam discharged to a second pressure lower than the first pressure, producing reaction forces on the rotor; seal means between the stationary nozzles and the rotor, maintaining the pressure difference between the first pressure and the second pressure while minimizing steam leakage past the internal passages, turbine operations producing shaft power. | 5 |
PRIORITY CLAIM
[0001] The present application claims priority from U.S. Provisional Application No. 60/690,953 filed Jun. 17, 2005, entitled “Clan-Lab Home Test Kit—A novel concept and method for sampling and analyzing suspect properties to determine qualitative and quantitative evidence of chemical hazards pursuant to suspected, or known, former illegal drug manufacturing activities.”
BACKGROUND OF THE INVENTION
[0000] Situation
[0002] Although, great progress has been made during recent years in the battle against most aspects of the illegal narcotics trade, clandestine drug manufacturing and processing activities are now publicly recognized as portions of our national crime problem that continue to expand despite law enforcement's efforts. In fact, the problem presented by these illegal clandestine drug laboratories may be the fastest growing segment of crime in America today; and undisputedly, it has negatively affected and endangered many people . . . and many others are suffering harm even now who may have no idea of the dangers awaiting them within their own home.
[0003] The crime of clandestine drug manufacturing and processing has primarily developed over the last three decades. Over the last decade, the development of the internet has dramatically increased the development and distribution of the illegal, “do-it-yourself” drug manufacturing enterprise by disseminating drug manufacturing technology and made available a variety of narcotics chemistry recipes to the general public.
[0004] Methamphetamine (or meth) labs are one such type of clandestine laboratory operation that has grown rapidly during the last decade in part because of the internet's influence and the fact that demand for such drugs has continued to rise as well. However, the demand for meth has not been met by a few large clandestine labs, as was the case in the previous decades, but rather over the last decade, this demand has been satisfied by many clandestine labs dispersed across the nation in both rural and metropolitan areas alike. This clandestine drug manufacturing trend is most certain to continue its rapid rate of growth as more demand for illegal narcotics and more criminal ingenuity combine to create new dangers and problems for our nation.
[0005] When an illegal drug manufacturing operation, or clandestine drug laboratory, is seized by law enforcement all containerized drugs and chemical substances, discovered at the crime scene, are taken by the authorities. Generally, whatever chemicals may have spilled, absorbed, or have otherwise been released, are simply left behind. This residual contamination issue is a serious unchecked problem from both a human health and safety standpoint as well as from an environmental perspective.
[0006] In most scenarios where a clandestine drug lab is being operated, the suspect lab operator is not the owner of the property where the crime is being committed. Illegal drug labs are typically located on properties that are owned by others and are either being rented or trespassed upon by the perpetrator. In the vast majority of these situations, the crime scene property is chemically contaminated to some degree by the clandestine drug manufacturing process and is not properly remediated. Therefore, the unabated contamination issue remains and continues to present a danger to the safety and health of future occupants and to the community. 7
[0007] There are two affected groups of individuals within the class of victims, which are most severely impacted by this problem:
1 st Group This group consists of the innocent tenants of properties formerly used for the manufacture of illegal drugs. This innocent third-party (I3P) victims group includes those persons (i.e.: residents, workers, visitors, playing children, etc.) who may have been exposed to chemical hazards in or upon the crime scene property. 2 nd Group This group consists of the innocent property owner of the clandestine drug laboratory crime scene property.
[0010] It is anticipated that these affected groups will either be the end user or customer to this invention or be the object of a service or benefit by a customer or end user to this Kit.
[0000] Unique Dangers
[0011] It is widely known that many of the individual chemicals typically involved in clandestine methamphetamine manufacturing process not only cause cancer, but also lead to other serious health effects and/or birth defects. 6 These carcinogens and toxic mixtures, over time, impact those who have been chronically exposed; and the latency period of many such exposure related illnesses may not actually manifest themselves into symptoms that are easily medically detectable for years to come. Then once revealed, the innocent victim is seriously endangered because the damage has advanced into a more progressive, life threatening disorder.
[0012] Despite multiple warnings from a variety of Government agencies, drug lab crime scenes throughout the majority of the United States are most often neither restricted nor monitored after the point of seizure. Generally, property owners at their own discretion are left to fend for themselves and determine the necessity and extent of whatever, if any, cleanup activities are to be conducted. Many times, new tenants are moved in as soon as possible with little or no cleanup activity taking place, whatsoever.
[0013] Today, one of the most publicly provoking aspects of this problem is the debuting crisis of “Drug Endangered Children,” or DEC. In recent years, bio-monitoring studies have overwhelmingly concluded that innocent children are the most seriously impacted by the physical and chemical hazards associated with living in a residence that either is, or was, used as a clandestine drug laboratory. In fact, of the children tested thus far in these various studies, a substantial percentage have demonstrated elevated levels of toxic substances in their bloodstream. 5 This development raises the priority of this problem to a crisis level.
[0014] Of those children tested, who have lived in homes containing clandestine drug laboratories, over 40% have demonstrated elevated levels of toxic substances in their bloodstream according to a California Bureau of Narcotic Enforcement research study. 6 Other sources, such as the U.S. Dept. of Justice, have published similar findings, which also demonstrate a rising trend of blood borne toxins discovered in these Drug Endangered Children. 7 The problem is indeed serious and warrants serious consideration on behalf of the many innocent victims involved.
[0015] In 2005, the EPA released new findings and proposed cancer risk management guidelines, which reveal strong evidence that changes its previously assumed position that cancer risks to children were no greater than to similarly exposed adults. In their newly published findings, the EPA has stated that “children two years old and younger are ten times more vulnerable than adults to certain chemicals and that children between the ages of two and sixteen are three times more vulnerable to certain chemicals.” 25
[0016] It is not an unlikely assumption to project that potentially today more children are being placed at risk of cancer due to the methamphetamine crisis than any other known environmental hazard within our nation. Karen P. Tandy, Administrator of the U.S. Drug Enforcement Administration was quoted in a National Jewish Medical and Research Center article as saying, “The high levels of toxins dispersed during meth manufacturing expose innocent and unwary citizens to poisons that can be silent killers. ” 26
[0017] U.S. Department of Justice's National Drug Intelligence Center recently released its annual report titled, “The National Drug Threat Assessment 2006” wherein it declares that the clandestine laboratory problem, “continues to jeopardize the safety of citizens, adversely affect the environment, and strain law enforcement resources. Children, law enforcement personnel, emergency responders, and those who live at or near methamphetamine production sites have been seriously injured or killed as a result of methamphetamine production. Chemical waste from methamphetamine laboratories has killed livestock, contaminated streams and soil, and destroyed vegetation.” 1
[0000] Unique Challenges
[0018] The problem is unique; in that, the chemicals associated with clandestine drug manufacturing vary widely from application to application due to the illegal nature of the enterprise. Many chemicals are quite volatile and have odors that are offensive enough to warn occupants of the presence of a hazard. Other chemicals may be present in these situations, which continually release vapors into the indoor air at or below olfactory threshold levels whereas a normal person's sense of smell will not be sensitive enough to warn them of the potential dangers.
[0019] It is widely known that many of the individual chemicals typically involved in clandestine methamphetamine manufacturing process cause cancer and other serious health effects as well as birth defects. The nature of this crime is also such that many different kinds of chemicals are combined into an infinite variety of mixtures with a wide range of toxic exposure consequences that are impossible to accurately predict and many are very difficult to detect and identify using standard toxic chemical monitoring protocol.
[0000] Need for This Invention
[0020] The issue of toxic hazards facing innocent citizens nationally due to the illegal past drug manufacturing acts of others, is a complex, highly variable, ever-changing puzzle of obstacles that encompasses many problems in the areas of logistics, legalities, and economic constraints. It is a national problem without a solution. It has been a cause without a crusader.
[0021] This invention is a legitimate necessity to fulfill a national need and will make it possible for relief and remedy measures to reach those who are harmed by this crime. Furthermore, this Clandestine Lab Home Test Kit invention allows the customer or end user to decide how much accuracy and precision they can afford since they are, more often than not, forced to bear the burden of discovery. The concept offers customers a general screening option and either a piece of mind or a healthy concern for whatever said screening may have revealed.
[0022] In most situations, the average citizen is:
1. not able to understand the danger involved with meth chemical residues, 2. not able to quantify the nature and extent of the contamination problem, 3. not able to adequately address the cleanup of the toxic hazard, and they are 4. not able to present a qualified claim for victims' benefits, insurance coverage, or other forms of public or private assistance.
[0027] Obviously, the current tenants to these problem properties and the owners of these properties are at an incredible disadvantage. The unique nature of a danger that may or may not be easily detectible, and even more difficult to communicate and quantify, has rendered a great injustice onto the shoulders of these innocent victims.
[0000] Application Scenario
[0028] The particular arrangement of any given clandestine laboratory defies most attempts categorize and classify according to a standard; in as much as, the variability of the illegal drug making process and chemistry is as diverse as the human imagination. However, most operations include a “cook” process of some sort and therein lies the primary mechanism of contaminate transport within a structure. Mishandling of chemical related substances including spilling and/or dumping of such materials is the other predominant mode of contaminate distribution observed at clandestine laboratory sites. Accordingly, the Clandestine Lab Home Test Kit is designed as a tool for discovering contaminates related to the “cooking” and mishandling processes relative to a past or present clandestine narcotics manufacturing or processing activities.
[0029] The “cook” mechanism in a drug lab releases steams, aerosols, vapors, and gases into the atmosphere. Some of these chemicals substances precipitate or settle out as a film upon the surfaces of the structure as well as upon items of real and personal property. Other chemical substances are absorbed into the structural materials themselves as well as into items of both real and personal property.
[0030] The Clandestine Lab Home Test Kit, in its various configurations, is designed to answer a progression of customer or end user questions?
1) Is there evidence of clandestine narcotics manufacturing or processing activities? 2) What chemicals are present and how strong is the concentration of said chemicals? 3) Where are these chemical substances coming from and how much area and property or objects have been impacted or contaminated?
[0034] In its basic or Q1 configuration the Kit is designed to answer the first question by investigating surface deposit residues for narcotics related precipitates or films and also provides for air sampling to yield evidence of absorbed chemical substances that may be volatilizing or desorbing from the property itself or from objects within the structure. The other Kit configurations and variations thereof are designed to provide a means and method for more detailed investigation activities pursuant to the Kit's comprehensive assessment purposes.
REFERENCES CITED
[0035] U.S. Patent Documents
7,060,505 June 2006 Guirguis 436/514 5,994,144 November 1999 Nakajima, et al 436/116 5,419,209 May 1995 Sepe 73/863 4,840,912 October 1988 Glattstein 436/92
Other Publications:
1) “National Drug Threat Assessment 2006.” National Drug Intelligence Center, U.S. Department of Justice. Product No. 2006-Q0317-001, Page 3, 37 2) “Review of Contaminant Levels: Guidelines for Clandestine Drug Lab Cleanup”, By Harriet Amman, Ph.D. Office of Environmental Health Assessments, September 2000. 3) “Meth-coated homes spur new push for Federal research (AP)” Article written by Devlin Barrett of The Associated Press, Feb. 16, 2005. 4) “Methamphetamine Situation: A Growing Domestic Threat.” Methamphetamine Situation in the United States, U.S. Dept of Justice, Drug Enforcement Administration. http://www.fas.org/irp/agency/doj/dea/product/meth/threat.htm 5) “Children in Clandestine Laboratories: the California Experience” paper presented May 29, 1997 by Thomas J. Gorman, California Bureau of Narcotic Enforcement at the National Methamphetamine Drug Conference, Omaha, Nebr. 6) “Children at Risk.” U.S. Dept. of Justice, National Drug Intelligence Center, Information Bulletin, July 2002. Publication No. 2002-LO424-001. 7) “Children at Clandestine Methamphetamine Labs: Helping Meth's Youngest Victims” by Karen Swetlow, U.S. Dept. of Justice, Office for Victims of Crime, OVC Bulletin. June 2003. Pg. 6. 8) Testimony presented before the U.S. House of Representatives Committee on Government Reform, Subcommittee on Criminal Justice, Drug Policy and Human Resources, Jun. 28, 2004, by Shirley Louie, M. S., CIH, Chief Environmental Epidemiologist, Arkansas Department of Health, Little Rock, Ark. 9) “Multi-Agency Partnerships: Linking Drugs with Child Endangerment,” Governor's Office of Criminal Justice Planning (OCJP), May 12, 2003. Sacramento, Calif., p. 9. 10) Testimony of James MacDonald, U.S. E.P.A. On-Scene Coordinator before the U.S. House of Representatives Committee on Government Reform, Subcommittee on Criminal Justice, Drug Policy and Human Resources Committee on Government Reform, Jun. 28, 2004. 11) “Unauthorized Production of Methamphetamine: Legal Responsibilities of Land and Rental Property Ownership” Written by William H. Fortune, May, 2004. Professor University of Kentucky, College of Law. Publication HEEL-HEH.206. http://www.ca.uky.edu/fcs/FACTSHTS/HEEL-HEH.206.pdf 12) “Dangers of Exposure to Chemicals Used in Meth Labs,” Written by Holly E. Hopper, M. R. C. Extension Associate for Health, October, 2004. University of Kentucky, College of Agriculture, Publication HEEL-HEH.205. http://www.ca.uky.edu/fcs/FACTSHTS/HEEL-HEH.205.pdf 13) “Protecting First-Responders from Clandestine Meth Labs.” Georgia Institute of Technology. May 10, 2005. http://www.newswise.com/articles/view/511687/ 14) “Walk Your Land: The Extension Agent's Guide For Protection of Private Property Against Unauthorized Clandestine Methamphetamine Production.” Published by the University of Kentucky, College of Agriculture Health Education through Extension Leadership, HEEL Program. Page9. 15) “Ordering Restitution to the Crime Victim”, USDOJ OVC Legal Bulletin #6. November 2002. 16) “If You Don't Have a Dime, Who Pays for the Crime?—The Mandatory Victims Restitution Act” Written by Kristin I. Tolvstad. United States Attorneys' Bulletin. Victims Rights, January 1999, Volume 47, Number 1. Pages 13-14. 17) “The Attorney General Guidelines for Victim and Witness Assistance: United States Attorneys' Offices' Responsibilities to Victims” by Camille Bennett, United States Attorneys' Bulletin. Victim - Witness Issues II, March 2003, Volume 51, Number 2. Pages 2-7. 18) “Restitution Update” Written by Catharine M. Goodwin. United States Attorneys' Bulletin. Victim - Witness Issues, January 2003, Volume 51, Number 1. Pages 13-19. 19) “Overview.” DEA's Victim Witness Assistance Program. DEA Website Resource. http://www.dea.gov/resources/victims crime.html 20) “National Clandestine Laboratory Seizure Report—Form EPIC 143 (06-2004).” U.S. Drug Enforcement Administration, EPIC Group. OMB No. 1117-0042. 21) “Attorney General Guidelines for Victim and Witness Assistance,” 2000 Edition, Section F. Page 10. 22) “Asset Forfeiture Policy Manual.” U.S. Dept. of Justice, Criminal Division, July 1996. 23) “Exposure risk higher for kids: EPA worries about carcinogens” by John Heilprin, Associated Press. Mar. 31, 2005. 24) “Attachment to the Attorney General Guidelines for Victim and Witness Assistance,” 2000 Edition. U.S. Department of Justice Policy Document. http://www.usdoj.gov/ag/readingroom/2000victim2.htm 25) Smiths Detection/Barringer Instruments Website. IONSCAN® 400B Product Information Section. http://194.105.117.18/products/Default.asp?Product=16 26) “Toxic Brew of Chemicals Cooked Up in Methamphetamine Laboratories.” National Jewish Medical and Research Center, Jan. 19, 2004. http://www.nic.org/news/meth results.html
DISCUSSION OF PRIOR ART
[0062] Currently, there are no comprehensive screening or measurement technologies available for the average citizen to assess the impact of this particular type of hazard presented by illegal drug manufacturing activities. In fact for this unique application, there are also no comprehensive screening kits available to professional investigators in the law enforcement or public health fields. The Clan-Lab Home Test Kit invention offers a system, a protocol, a method, and an apparatus collectively designed to address this need and national problem with an innovative solution.
[0063] Present EPA recommended analytical criteria for the identification of unknown chemical substances in both ambient air concentrations and surface residues represents the ideal, this Clandestine Lab Home Test Kit invention is designed to satisfy the “real” and provide an economical alternative to current industrial hygiene methods that may be applied toward the evaluation of such properties. In reality, both the price and complexity of the “one size fits all”, or ideal, analysis have effectively separated an estimated quarter of a million innocent citizens from any analysis relief at all and the associated hazards of this national scale problem have continued to impact and harm many innocent citizens for over a decade now. The Clandestine Lab Home Test Kit is a fresh attempt to establish a new technological invention and, in doing so, lay the foundation for a new field of science related to the identification and abatement of the nationally dispersed and escalating problem caused by illegal drug manufacturing acts.
[0064] This invention differs from all prior art environmental investigative techniques; in that, this invention has various quantitative and qualitative components with a designed flexibility incorporated into the process. Additionally, this invention, by design, benefits from perpetual research toward the analysis of subject properties and will identify local, regional, and nation trends in clandestine manufacturing and processing chemistry.
[0065] The only so-called drug lab home test kits being promoted today are based upon a calorimetric indicator principle; whereas, a reagent solution is applied to a sample of the suspected narcotic substance and a color change occurs from the chemical reactions thereof. The single or multiple reagent kits are effective and useful as a field expedient method for qualification determination of raw narcotics substances, but have limited utility in identifying residual narcotics substances in trace amounts that may still be harmful to human life and health. Additionally, these reagent only kits are not effective standalone devices to be used for ascertaining the airborne contamination levels and surface chemical deposits typically associated with past or present illegal clandestine drug manufacturing or processing activities.
[0066] This invention does not rely upon calorimetric indicator solutions to identify narcotic substances; rather this invention only includes calorimetric tests at a customer or end user's request to help identify suspicious solid or liquid substances. The calorimetric indicator tests rely upon having a substantial portion of narcotic's residue in order to facilitate the desired reaction. Trace quantities of narcotic substances, such as a methamphetamine residue left upon walls and other interior dwelling surfaces after an illegal drug manufacturing act has taken place, do not allow for identification via the colorimetric indicator process. Conversely, Ion Mobility Spectrometry (IMS) technology, Ion Track technology and Gas Chromatograph Surface Ionization Detector (GC-SID) are capable of detecting residues in the picogram to nanogram range.
[0067] Currently Smiths Detection (http://trace.smithsdetection.com) manufactures an IMS IonScan Technology based product known as the Sabre 4000. Likewise, Scintrex Trace Corporation (http://www.scintrextrace.com/) manufactures another portable narcotics detection device known as the N2000, which operates off the GC-SID technology. Each of these devices is portable and was developed for drug interdiction and law enforcement purposes to detect minute quantities of narcotics substances. These devices are advantageous for giving the user an almost instantaneous reading at the scene of the investigation effort. Unfortunately, these devices are expensive and are relatively rare in commercial application outside of official government use. Additionally, these portable devices are subject to error and malfunction when taken into contaminated atmospheres such as those that may be presented by an illegal drug lab operation.
[0068] The Phase Zero Environmental Assessment (U.S. Pat. No. 5,419,209) consisted of a system an protocol designed for the environmental assessment of residential properties; yet the patent contains no mention of evaluating properties for past or present evidence or impact associated with drug manufacturing or processing activities upon residential properties.
[0069] Additionally, the Phase Zero kit was prepared for use by “environmental home inspectors” using EPA testing methodology and conventional industrial hygiene apparatus. Conversely, the Clan-Lab Home Test Kit was designed for use by normal citizens of average intelligence; whereas, the training needed to conduct said test does not come from special schools or classes, but by audio-visual training media included in said Kit. Furthermore, the Clan-Lab Home Test Kit is not limited to established sampling methodology or equipment; rather, said Kit was specially prepared to comprehensively provide all training, equipment, materials, and documentation necessary for performing a regimen of sampling activities unique to this application
SUMMARY OF THE INVENTION
[0070] This invention consists of an all-inclusive kit comprised of individual components necessary to evaluate gaseous, liquid, and solid substance residues relative to determining the nature and extent of chemical contamination of subject properties with suspected or known histories of clandestine manufacturing and/or processing of illegal narcotic and toxic substances.
[0071] This invention also includes a system and protocol for a comprehensive home test kit to be used to detect, identify, and delineate toxic chemical hazards associated with illegal clandestine drug manufacturing or processing activities.
[0072] This Clandestine Lab Home Test Kit invention is the first self-test concept kit of its kind designed to comprehensively evaluate the toxic hazards relative to the residues of illegal drug manufacturing acts. This approach represents a novel technological concept; whereas, regular private citizens are provided within the kit both the training and resources to conduct the tests themselves. This invention further provides a method for giving customers the option of being able to specify the content of custom configured kits via a menu of testing components and costs. Conversely, ambient air sampling and surface wipe tests have been historically conducted exclusively by trained health and safety professionals, industrial hygiene personnel, or other such environmental technicians, all of whom have received specialty training and have been equipped for this manner of on-site sampling and analysis.
[0073] This invention extensively utilizes audio-visual media to instruct private citizens as to how to perform the necessary Clandestine Lab Home Test Kit tests. Accordingly, these private citizens are also instructed as to how they can properly return said kit for analysis to a laboratory, which is specially equipped and configured for this manner of analysis. The training formats for this audio visual component will include standard instructional media presentations in both DVD and VHS formats as well as on-line web based video media formats such as presentations prepared using Quicktime, Windows Media, and other such audio visual electronic on-line video presentation formats. Additionally, printed instructional booklets will also be included within the kit configuration for procedural reference and information reinforcement.
OBJECTS OF THE INVENTION
[0074] It is an object of this invention to provide a system, protocol, method and apparatus for a test kit to be used to identify and/or quantify chemical substances pursuant to the illegal manufacture of controlled narcotic substances as specifically defined by the schedules of controlled substances known as Schedules I, II, III, IV, and V as identified in 21 USC Sec. 812 (TITLE 21—FOOD AND DRUGS CHAPTER 13—DRUG ABUSE PREVENTION AND CONTROL SUBCHAPTER I—CONTROL AND ENFORCEMENT Part B—Authority To Control; Standards and Schedules), and/or a variety of organic and inorganic chemical ingredients, precursors and recursors associated with illegal controlled substance manufacturing or processing activities.
[0075] It is another object of this invention to provide a system, protocol and method for incorporating an audio-visual media training component into said Clan-lab Home Test Kit to safely enable average citizens to conduct the various tests and return the kit to a qualified laboratory facility, equipped to analyze the components of said Test Kit and provide a report of the findings thereof.
[0076] It is yet another object of this invention to provide a system, protocol, method and apparatus for enabling law enforcement officers, child protection workers, public health officials, medial personnel, representatives of the court systems, home inspectors, health and safety officials, environmental officials, municipal workers, park rangers, academic and research personnel, and other government or military personnel to safely test suspect premises or properties to identify, distinguish, and measure evidence of chemical hazards pursuant to suspected, or known, former illegal drug manufacturing and/or processing activities.
[0077] It is yet another object of this invention to provide a system, protocol, method and apparatus for cost effective environmental and safety hazard screening of real estate properties for impact and damage relative to illegal drug manufacturing and/or processing activities and to provide assurances to those individuals who either are currently, or plan to be, in contact with said suspect properties.
[0078] It is yet another object of this invention to provide a system, protocol, method and apparatus to assist buyers of real estate property in determining whether or not said properties have been subject to impact and damage relative to illegal drug manufacturing and/or processing activities and as such to provide a mechanism for ascertaining the damages to said properties as well as the cost for the remediation of the toxic contaminants that may have impacted said properties.
[0079] It is yet another object of this invention to provide a method and apparatus for collecting contaminates from indoor atmospheres suspected of past or present illegal drug manufacturing and/or processing activities and provide for the extraction of said contaminates through a thermal desorption process and provide for the qualitative and/or quantitative analysis of the same.
BRIEF DESCRIPTION OF DRAWINGS
[0080] FIG. 1 is an artistic rendering showing the contents of the Clandestine Laboratory (or Clan-Lab) Home Test Kit in its most basic qualification (or Q1) configuration;
[0081] FIGS. 2A-2F (6 charts) are a flowchart diagram, which describes the steps taken by the Clan-Lab Home Test Kit user, who is conducting the sampling and assessment activity pursuant to the nature of the Kit.
[0082] FIG. 3 is an apparatus drawing showing two views of the Vapotrap Air Toxics Sample Canister Assembly. The cutaway view shows a profile of said Canister Assembly and identifies the components of this particular embodiment. The perspective view shows how the Canister Assembly's primary external components are arranged in its operational form.
[0083] FIG. 4 is a process drawing showing Vapotrap Sample Processing Method 1, which relates to a means of taking a Vapotrap capsule and/or subpod component and subjecting said capsule or component to a thermal source of heat and/or steam; whereas the chemical components trapped therein are extracted or released by said thermal forces and are routed by the system into a vapor expansion and mixing chamber either directly or through a chilling unit. This drawing is identified into three major operational segments or units of sample preparation comprising: (1) the extraction unit, (2) the chiller unit, and (3) the vapor measurement unit.
[0084] FIG. 5 is a process drawing showing Vapotrap Sample Processing Method 2, which relates to a means of taking a Vapotrap Canister Assembly, which contains the Vapotrap capsule and subpods, and subjecting said Canister to a thermal source of heat and/or steam; whereas the chemical components trapped therein are extracted or released by said thermal forces and are routed by the system into a vapor expansion and mixing chamber either directly or through a chilling unit. This drawing is identified into three major operational segments or units of sample preparation comprising: (1) the extraction unit, (2) the chiller unit, and (3) the vapor measurement unit.
[0085] FIG. 6 is a process drawing showing the final step of the Vapotrap Air Toxics Sample Analytical Testing Process, which is a continuance of the processes identified in FIG. 4 and FIG. 5 . This drawing identifies the fourth major operational segment or unit of sample preparation and processing activity or (4) the Analytical Unit; whereas, said unit graphically presents a number of analytical measurement mechanisms to be employed given the known or suspected chemistry of the potential clandestine laboratory operation being investigated.
DETAILED DESCRIPTION OF THE INVENTION
[0000] Clandestine Laboratory (or Clan-Lab) Home Test
[0086] While this invention is satisfied by embodiments in many different forms, there is shown in the drawings and will herein be described in detail, preferred embodiments of the invention with the understanding that the present disclosure is to be considered exemplary of the invention and is not intended to limit the invention to the embodiments illustrated. The scope of the invention will be measured by the appended claims and their equivalents. Additionally, this invention offers other objects and many advantages as will be readily appreciated as said invention becomes better understood by reference to the following description:
[0087] The first embodiment of this invention is the Clandestine Laboratory (or Clan-Lab) Home Test Kit, which is comprised by the assortment of components contained therein. FIG. 1 is an illustration, which shows the contents of the Clandestine Laboratory (or Clan-Lab) Home Test Kit in its most basic qualification (or Q1) configuration. The actual number and type of components selected for the Kit will be dictated by the end user or customer, giving respect to the anticipated or known risks to the property, which will be subject to the application and use of said Test as well as the customer's ability to afford investigative assurances.
[0088] The three major Kit configurations are qualitative (or Q1), quantitative (or Q2) and combination (or Q3). Table 1 outlines the general list of available analytes per given general Kit configuration and an inventory arrangement is included for each said Kit configuration. Typically, an initial property screening will be a more qualitative nature and follow-up testing, if necessary, will include a second battery of testing to be performed upon said subject premises employing either a Test Kit in the quantitative (or Q2) and combination (or Q3) configuration. The availably of information or knowledge of the site suggesting that it was indeed used for clandestine drug manufacturing or processing activities, and/or in the case that distinct evidence of chemical contamination upon said premises is obvious, the end user or customer of said Kit may elect to custom configure a Q3 or combination Kit to expedite the investigation activities to be conducted pursuant to the Kit's purpose.
[0089] In a basic format or Q1 configuration ( FIG. 1 ), the Clan-Lab Home Test Kit is intended to investigate several surface deposit samples as well as evaluate indoor air quality for evidence absorbed, spilled, and/or released chemical substances consistent with illegal drug manufacturing and/or processing activities. Even though some degree of chemical identity and quantity information may be developed in the testing process, the objective of the Q1 or qualitative test is to answer the question as to whether or not a clandestine laboratory has impacted the premises. Rather, the quantitative or Q2 test kit configuration is specifically ordered to both identity and quantify the chemical substances present at the site being investigated.
[0090] In the Q1 Kit configuration, the purpose of said Kit is to provide the means, methods, and tools for investigating surface deposit residues for narcotics related precipitates or films and also provides for air sampling to yield evidence of absorbed chemical substances that may be volatilizing or desorbing from the property itself or from objects within the structure. The other Kit configurations and variations thereof are designed to provide the means, methods, and tools more detailed investigation activities pursuant to the Kit's comprehensive assessment purposes.
[0091] When circumstances dictate, a combination kit or Q3 configuration can be custom assembled by the Kit provider giving consideration for the user's particular needs and budget. There are many unique embodiments and possible combinations present in the Q3 Kit arrangement. In this manner, a very custom solution can be tailored to the unique challenge of the individual application as opposed to the “one size fits all” approach that may not be practical or affordable to the user.
[0092] Table 1 is a summary of Kit configuration inventories and lists a number of elements that can be chosen by a Kit user to qualify, quantify, fingerprint, delineate, and estimate contamination impact due to the alleged influence of clandestine drug manufacturing or processing activities.
TABLE 1 Clandestine Laboratory (Clan-Lab) Home Test Kit Inventory of Content per Configuration Kit Config- Index uration # Item Q1 Q2 Q3 Return? 1 Container/Cooler X X X X 2 Instruction Manual X X X 3 AV Instructional Media Pack X X X 4 Sampling Report & Checklist X X X X 5 Wipe Sample Packs (Drugs 1) X X X X 6 Vapotrap Cylinder X X X X 7 Air Pump, Hose, Fittings, & Inline Filter X X X X 8 Iodine Wipe Test Pack X X X X 9 Electronic Timer, Thermometer, X X X X & Hygrometer 10 Return Label Preprinted X X X X 11 InkPen X X X 12 Blue Ice Pack X X X X 13 Plastic Bag for wipe pack bags X X X X 14 Extra Latex Gloves X X X 15 Sample Swab Pack X X X 16 Wipe Sample Packs (Drugs 2) X X X 17 pH Test Strip Pack X 18 Distilled or Deionized Water flask X 19 Ammonia Wipe Test Pack X X 20 Phosphine Wipe Test Pack X X 21 Lead and Mercury Wipe Test Pack X X 22 Diffussive Media Sampling Pack - X X Badge, Wafer, Cartridge, and/or Tube 23 Suspect Materials Test Pack X X 24 Photoionization Meter Pack X X 25 Colorimetric Narcotics Reagent Pack X X 26 Colorimetric Test-Strip Pack for Narcotics X X Precursor & Recurser Substances. 27 Septic Tank sample pack X X 28 Soil Test sample pack X X 29 Well water sample pack X X 30 Surface water sample pack X X 31 Unknown Liquids sample pack X X 32 Unknown Solids sample pack X X 33 Colormetric Sample Kits X (Inorganic Compounds) 34 Toxicology Reference Primer X 35 Wipe Sample Packs (Other) X 36 Safety Glasses X 37 Chemical Gloves X
The Self-Test Nature of a Comprehensive Home Test Kit
[0093] It is another unique embodiment of this invention that this is a home test kit in the sense that it was prepared not only for an industrial hygienist, an environmental specialist or even a health and safety expert, but that an average citizen would have the means of safely being able to sample a premises themselves thus making the benefits offered by this invention available, and affordable to a far greater populace.
[0094] By making extensive use of audio-visual media and illustrated documentation, the Clandestine Lab Home Test Kit will safely and efficiently instruct private citizens as to how they can perform the necessary sampling test activities. A key, and extremely valid concern is the health and safety of the Kit user. Obviously, there are situations where entering an area formerly or currently used as a clandestine lab operation may endanger a person's life and health. The instructional training media and documentation included in said Kit will strongly assert and reinforce the message that if danger signs are observed and/or expected the Kit user is to cease immediately all sampling efforts and contact appropriately trained professionals for assistance. However, it should also be noted that such instances are the rare exception and not the rule for clandestine laboratory operations. In fact, it is anticipated that many users of said Kit may actually already be residing or otherwise occupying a premises and have a valid concern for the safety of themselves or their family.
[0095] It is an assumption that potential Kit users have already visited the site subject to suspicion and thus desire to ascertain whether or not such premises are chemically contaminated and if so, to what degree is the damage distributed upon said premises and how can it be safely removed? The Clan-Lab Home Test Kit offers answers that most persons can afford. Conversely, typical “worst case assumptions” and standard industrial hygiene protocol have placed the price for answers and assistance beyond all, but the most affluent Americans. For this reason on a very tiny fraction of the more than one hundred thousand sites documented thus far in the DEA's Clandestine Laboratory Seizure System database have been assessed for hazards, not to mention the number of sites that are not reported by law enforcement officials into this record system, which many officials estimate only 1 of every 4 sites are actually reported because of the time it takes a law enforcement officer to fill out the four page EPIC/CLSS reporting form. 20 When the true scale of this problem is appraised, the potential victim distribution estimates are staggering. It is an urgent objective of this invention to place real relief in the grasp of those who are needlessly suffering because they can't afford the price of conventional scientific protocol.
[0096] As long as the Kit's instructions are followed and warnings are heeded, a Kit user or customer is placed in no greater degree of danger than that they would normally face by physically wandering around a suspect property observing sights and smells while they attempt to assess, clean, paint, or deodorize the suspected damages. The time actually required for a user to conduct the necessary sampling activities for the Kit is minimal because the air-monitoring portion of the Kit's testing protocol can operate on an unattended basis until the designated test period has been completed and at such time the Kit user can later return to the premises and retrieve the Kit's remaining articles.
[0097] Table 2 outlines the Audio-Visual (AV) Instructional Media Content embodiment of the Clandestine Laboratory (Clan-Lab) Home Test Kit; whereas, the Kit utilizes a recognized learning characteristic approach to effect the dissemination and retention of the desired information and communicate said information in an audio-visual context to the extent that a citizen, of average intelligence, can understand the purpose of the Kit and be able to perform the sampling procedure upon a premises subject to investigation.
TABLE 2 Clandestine Laboratory (Clan-Lab) Home Test Kit Audio-Visual (AV) Instructional Media Content I. Introduction II. Toxic Dangers from Clandestine Drug Manufacturing III. Personal Safety Precautions IV. The Clandestine Home Test Kit A. General Introduction to Concept and Configurations B. Q1 Kit Configuration 1 Inventory of Kit Content 2 How to Use a. Unpack and Identify Content b. Assess Sampling Locations c. Filling Out Sampling Report d. Sampling Instructions (Step by Step) e. Repacking Kit for Shipment 3 Return Shipping Instructions 4 Test Results C. Q2 Kit Configuration 1 Inventory of Kit Content 2 How to Use a. Unpack and Identify Content b. Assess Sampling Locations c. Filling Out Sampling Report d. Sampling Instructions (Step by Step) e. Repacking Kit for Shipment 3 Return Shipping Instructions 4 Test Results D. Q3 Kit Configuration Options V. Toxic Hazards A. Responsible Risk Management B. Remediation Options C. Calculating Cleanup Costs D. Selecting a Contractor E. Do-It-Yourself Resources VI. Relief Resources A. Crime Victim Assistance Resources B. Property Insurance Coverage VII. Miscellaneous Information
[0098] The training formats for this audio visual component will include standard instructional media presentations in both DVD and VHS formats as well as on-line, web-based video media formats such as presentations prepared using Quicktime, Windows Media, and other such electronic audio-visual on-line video presentation formats. Additionally, printed instructional manuals will also be included within the Kit a basic procedural reference and reinforcement aid as well as a supplemental information resource.
[0000] Narcotics Surface-Deposit Residue Sampling Process
[0099] The Clan-Lab Home Test Kit includes a system, protocol, method and materials for instructing an individual of average intelligence in the practice of taking wipe samples from suspect surface areas and returning said samples to the Kit provider or to another specified specialty laboratory location for analysis measurement of trace narcotic residues.
[0100] The step-by-step procedure for this aspect of the embodiment is as follows:
1) The Kit user reviews in advance the DVD disk or VHS tape included in said Kit and reviews the written procedure as a point of reference and review prior to initiating physical sampling activity. FIG. 2A demonstrates the process by which the user is trained through the instructional media component of said Kit and thereby gains a competency to perform said sampling procedure. 2) Using the knowledge gained through the instructional media training component of the Kit and after physically inspecting said premises for the most likely locations said clandestine drug manufacturing acts may have occurred, the Kit user selects the wipe sample test pack from the Kit's shipping container and opens said sampling pack. Portions of FIG. 2B , all of FIG. 2C , and portions of FIG. 2D illustrate the operational flow of the wipe sampling process and how this series of individual test relate to the comprehensive function of the Kit as a whole. 3) After putting on a pair of disposable gloves included in the Clan-Lab Home Test Kit, the individual user would take a pre-packaged wipe* from its sealed package and wipe a desired section of the suspect area or device and then place the wipe inside a pre-marked, color-coded, plastic bag for the wipe and seals the bag accordingly. The user will follow the detailed instructions given in the Kit's instructional media pack, which details the proper techniques for using the Kit's wipe test packages to properly take representative samples across sections of a structures wall, floor, ceiling, or other interior surface areas (* Depending upon the chemistry of the suspected or known clandestine laboratory operation or that of similar labs discovered in the vicinity of the investigated premises, the Kit provider may elect to provide either a dry wipe or to pre-saturate said wipe with a fluid substance that may include water, a surfactant solution, alcohol, or other solvent material.) 4) The individual would then discard the gloves after taking each sample to avoid possibility of cross contaminating other samples. 5) The used wipe sample bag is then placed inside the larger sample bag, which originally contained both the wipe sample bag and the gloves, and sealed accordingly. 6) A notation is made on the sample log sheet identifying the respective wipe sample identification code as well as the location, type of substrate sampled, and the estimated area dimensions covered by the sample. 7) The sealed sample pack bag is placed in the return-mailing container along with the other tests required in the Clan-Lab Home Test Kit. 8) When all tests required in the Clan-Lab Home Test Kit are completed the User inspects said Kit for all items of sampling equipment and/or samples and double checks the Kit's documentation for completeness. The Kit is then closed, sealed, labeled, and shipped back to the Kit provider or the designated laboratory for analytical processing of the samples contained therein. 9) The returned sample will be analyzed at a specially prepared laboratory facility and the results from said analysis will be communicated to the individual via the method of contact requested by the user. This test will yield qualitative and/or quantitative evidence of the presence or absence of narcotics residue when analyzed.
[0110] In the Narcotics Qualification Process, this invention promotes using a selection of electronic detection methodologies for the analysis of this Kit component. Along with the expected degree of variability in clandestine drug manufacturing chemistry, there is also significant degree of variability in vapor pressure and vapor concentration in illicit narcotic substances. For instance in four major and relatively commonplace drug substances such as methamphetamine, cocaine, heroin, and LSD, the vapor concentrations vary by more than eight orders of magnitude. Whereas methamphetamine at normal temperatures has a vapor concentration of over 200 parts per million, heroin only has a vapor concentration of 1 part per trillion. Likewise, LSD has a vapor concentration only slightly higher than heroin and cocaine is only a fraction of one part per billion.
[0111] The nature of clandestine drug manufacturing introduces a wide degree of homemade drug recipes, which contributes to variability even within the same type of narcotic substance. As a general consideration, it is recognized that a temperature increase of 9° F. or 5° C. will approximately double the amount of vapor that is present at equilibrium above a solid compound at or near room temperature. In effect, this means that when the ambient temperature rises by heating an object that is suspected of containing illicit drugs an increasing amount of vapor will be present for detection. This invention varies from other narcotics wipe sample approaches by using several type of drug detection apparatus and benefiting from the accuracy one detection methodology has over another in the investigation of a given narcotic substance.
[0112] One skilled in the art of electronic drug detection practice will appreciate this invention's flexibility and novelty by not restricting its analytical resource selection to that of one technology provider. This novel approach to investigating narcotic wipe samples results represents a new and useful improvement to any singular electronic detection methodology by yielding fewer false positive results and thus adds an element of quality assurance confirmation; in that, some samples will be processed by more than one detection methodology (given the particular type of suspected clandestine laboratory chemistry thus indicated by other evidence and samples taken from the premises subject to the investigation effort).
[0113] The narcotics detection technology chosen by this invention is based upon the selective ion mobility principle; whereas, one or more of the following drug detection technologies will be employed to ascertain the identity of the potential narcotics residues collected upon said wipe sample tests as per this aspect of the Narcotics Qualification Process. The analytical test protocol will employ one or more of the following detector types:
a.) Ion Mobility Spectrophotometer (IMS)* b.) Surface Ionization Detector (SID)* c.) Differential Mobility Spectrophotometer (DMS)* d.) Field Ion Spectrophotometer (FIS)* e.) Surface Acoustic Wave Detector (SAW)* f.) Raman Spectrophotometer (RS) * May be subject to analytical configuration as a recipient of a pre-separated exit gas flow from a gas chromatograph.
[0121] In instances where the end user requests a quantitative analysis of the narcotics detection wipe samples a Gas Chromatograph Mass Spectrophotometer (GCMS) may be employed either acting solely or in conjunction with one of the previously identified detection technologies; whereas, an optional Doplant or Carrier Gas may be employed to a sure that the detector is functioning appropriately and that the suspected narcotics substance peak signature is contextualized to a standard. In this scenario, the Kit user will be provided with a template to be taped or affixed to said area being sampled to restrict the sample to a given dimension, which will expressed in a units of contaminate detected per given square area format.
[0000] Airborne Residual Chemical Concentration Testing
[0122] The Clan-Lab Home Test Kit includes a system, protocol, method and materials for instructing an individual of average intelligence in the practice of taking samples from suspect indoor air atmosphere and returning said samples to the Kit provider or to another specified specialty laboratory location for analysis measurement of airborne residual chemical concentration or contamination residues.
[0123] The step-by-step procedure for this aspect of the embodiment is as follows:
1) The Clan-Lab Home Test Kit user reviews in advance the DVD disk or VHS tape included in said Kit ( FIG. 1 ) and reviews the written procedure as a point of reference and review prior to initiating physical sampling activity. FIG. 2A demonstrates the process by which the user is trained through the instructional media component of said Kit and thereby gains a competency to perform said sampling procedure. 2) Using the knowledge gained through the instructional media training component of the Kit and after physically inspecting said premises for the most likely locations said clandestine drug manufacturing acts may have occurred, the Kit user selects the air sample test equipment elements from the Kit's shipping container and opens said sampling pack. FIG. 2B and portions of FIG. 2D illustrate the operational flow of the air sampling process and how this individual test activity relates to the comprehensive function of the Kit as a whole. 3) After putting on a pair of disposable gloves included in the Clan-Lab Home Test Kit, the individual user would take the air sampling device and place said device in the area most likely to have been the site of suspect drug making activity or other such area that has yielded evidence of such contamination possibilities. The air-sampling device should be placed in a “worst case” location low to the floor in said suspect area; whereas, the vapor density of many chemicals used in the clandestine drug making process are heavier than air and, as such, low areas are where children often play and would be subject to the greatest exposure risks from this manner of contamination hazard. 4) If the particular air-sampling device selected by the Kit user is a static device, which relies solely upon the diffusive principle of adsorption or absorption, the device is placed in the area most likely to be impacted by a potential chemical influence. In like manner, if the particular air-sampling device selected by the Kit user is a vented or powered air-sampling device, which relies a flow of air being forced or drawn through a diffusive adsorption or absorption media or media collection, the device is placed in the area most likely to be impacted by a potential chemical influence and the integral or attached air pumping or vacuum system is turned on to begin the sampling event. 5) The Kit user, with the instruments, materials, and documentation provided in said Kit ( FIG. 1 ), then records the time, date, location, mode of sampling selected, temperature and relative humidity of the conditions at the time the sampling event occurs on the sample log sheet along with an estimate of the area dimensions covered by the sample. 6) When the allotted time period for the sampling event is completed ( FIG. 2D ), as specified by the Kit provider, the user retrieves the air sampling device and/or sampling equipment and returns said equipment to the Kit's shipping container. 7) If a static air-sampling device was employed, said device is then returned to its pre-marked, color-coded sample container and also placed inside said Kit's shipping container. 8) If a vented air-sampling device was employed, said device is:
a) unloaded of its sampling media, which is then returned to its pre-marked, color-coded sample container and also placed inside said Kit's shipping container along with the pump and ancillary connecting hose and associated equipment apparatus; or b) the inlet and outlet valves of the Vapotrap Canister assembly ( FIG. 3 ) are shut and the device along with the medias contained therein are placed inside said Kit's shipping container along with the pump and ancillary connecting hose and associated equipment apparatus.
9) The Kit user, with the instruments, materials, and documentation provided in said Kit, then records the time, date, temperature and relative humidity of the conditions at the time the sampling event ends on the sample log sheet. 10) When all tests required in the Clan-Lab Home Test Kit are completed the User inspects said Kit for all items of sampling equipment and/or samples and double checks the Kit's documentation for completeness. The Kit is then closed, sealed, labeled, and shipped back to the Kit provider or the designated laboratory for analytical processing of the samples contained therein. 11) The returned sample will be analyzed at a specially prepared laboratory facility and the results from said analysis will be communicated to the individual via the method of contact requested by the user. (FIGS.: 4 , 5 , & 6 ) This test will yield qualitative and/or quantitative evidence of the presence or absence of airborne chemical contamination when analyzed.
Vapotrap Capsule
[0137] The Vapotrap Capsule represents a novel device, system, and method for qualifying and/or quantifying chemical substance concentrations from an atmosphere.
[0138] The device can absorb and/or absorb airborne contaminants and gasses through the diffusion process from either a normal, static convectional airflow or the device can be used with a forced flow of air being introduced into said capsule. Obviously, the static mode of sampling is simpler to perform and takes a long sampling period than the more efficient vented method. FIG. 2B shows an operational flowchart sequence the Clan-Lab Home Test Kit process and how this embodiment fits into the inspection process.
[0139] The Capsule device itself consists of a breathable mesh bag or pouch with a sealing mechanism to prevent its contents from becoming displaced. In a typical configuration, the Vapotrap Capsule contains three to five smaller capsules or sub-pods, each containing a pre-measured unit of adsorbent or absorbent media. In like manner, the subpods are constructed of a natural or synthetic porous mesh material to allow for unrestricted ventilation within the adsorbent and/or absorbent medias contained therein; whereas, each mesh packet or pod has a sealing component to:
(a) prevent the spillage of the individual adsorbent and/or absorbent media material contained therein, (b) allow for respective sub-pod to be opened and emptied as may be deemed necessary given the circumstances and facts available relative to the premises being investigated; whereas, an alternative analytical process may become necessary due to the particular challenges presented by the clandestine chemistry considerations by the test location, and (c) allow the subpods to be either emptied or filled by the receiving or supplying laboratory personnel and/or recycled through desorption or the disposal of the same.
[0143] The specific content of the Vapotrap Capsule is dictated by the physical and chemical parameters of the application; whereas, the use of various types of media can more effectively capture and retain a wider range of chemical substances than any single media can accomplish. This adsorption performance flexibility is very effective for monitoring airborne contaminants related to past or present clandestine laboratory activity, given the enormous range of diverse chemical ingredients, which are known to be used in this unique and dangerous criminal enterprise.
[0144] The Vapotrap Capsule is generally comprised of at least two or more sub-capsules (or subpods), each being individually filled with a certain type, grade and mesh size of separate elements of adsorbent and/or absorbent medias specially selected by the Kit provider based upon information that may have been provided by the end user, law enforcement, and/or regionally observed trends in clandestine drug chemistry. The composite Capsule unit serves the purpose of collecting airborne contaminants from either a static or forced airflow within a structure's interior or indoor atmosphere and includes at least two or more of the following components:
a) activated carbons, b) zeolites, c) organic polymers, d) metal chlorides, e) silicates, f) sulfates, g) silicas, and/or h) aluminas.
[0153] The isotherm capacity for any particular media form is the numerical coefficient of its relative adsorption strength. There are a number of factors that influence a media's capacity to adsorb or absorb chemical compounds. The media itself for instance, even within various grades of the same media substance there is a substantial variability per given chemical. Activated carbon for instance, is available in a variety of grades with different properties, pore sizes, and affinities for adsorption of contaminants. Other factors also come into play in the adsorption process such as the type and concentrations of chemicals present in the atmosphere, the temperature and relative humidity, as well as the time allotted for the testing episode or residence time.
[0154] From an activated carbon perspective, it is generally recognized that chemical compounds are good candidates for adsorption provided that they have a molecular weight above 50 and a boiling point greater than 50° C. The nature of clandestine drug manufacturing is such that many different types of compounds are blended, cooked and synthesized by “cookers” with little or no chemistry background and most often with a reckless disregard for consequences that themselves or others may have to face for their acts. Accordingly, the supplies of ingredients range from whatever they can buy off the shelf or steal from commercial or industrial sources; therefore, no hard and fast rules apply to the clandestine drug manufacturing process and activated carbons alone do not possess the capacity and flexibility necessary to keep pace with this problem.
[0155] In today's information age, an illegal drug recipe or manufacturing technique can theoretically be published on an internet website one week and be put into practice on worldwide basis within a matter of days. The novelty of the approach presented in this embodiment of using multiple adsorption medias in a sub-pod arrangement is such the composite adsorption capsule can be reformulated rapidly enough to meet the elusive challenges presented by this unique hazard and problem to society.
[0156] Another advantage to the embodiment of this invention is its ability to be formulated with a media selection to account for the range of temperature anticipated for the sampling event. At a given airborne chemical concentration, temperature changes from 32° F. to 140° F. can impact the adsorption capacity of some medias several orders of magnitude. The vapor pressure of a chemical substance is always a function of temperature and increases exponentially with increasing temperature. Again because of the unusual characteristics of the application pursuant to the intent of this invention, sampling temperature cannot always be adjusted to the ideal; whereas, this invention can be custom prepared for whatever range of temperatures are anticipated to be premises subject to investigation.
[0157] Still another advantage to the embodiment of this invention is its ability to benefit from the dynamics of one media's ability to retain and preserve a certain chemical compound over that of another. For instance, many times activated carbon will adsorb a given reactive solvent substance, such as acetone, methyl ethyl ketone, or styrene, and in doing so will begin to catalyze its decomposition. By incorporating other adsorption medias into the Vapotrap capsule, such as organic polymer medias for example, this type of catalyzation does not occur at significantly measurable levels and the true airborne contaminant ratios subject to the investigation effort will be reported without being as dramatically distorted as an adsorption based assessment solely dependant upon using activated carbon media alone. Therefore, it is another embodiment of this invention that multiple grades and types of adsorbent and absorbent compounds are used in unison to more effectively capture, preserve, and retain chemical substances and effectively release said substances during a subsequent extraction, measurement, and analysis process.
[0158] It is a well known fact, that the clandestine laboratory issue is an unsolved national problem that has hazardous impact potential that is as yet undefined. Several legislative initiatives are underway at present trying to stimulate the development of science and gain an understanding of these problems. One such example can be referenced in a recently introduced bill (H.R. 798 & S.2019) otherwise known as the “Methamphetamine Remediation Research Act of 2005” which seeks to “provide for a research program for remediation of closed methamphetamine production laboratories, and for other purposes.”
[0159] One such embodiment of this invention is that significant portions of the aforementioned problem can be discovered and solved and while the problem being studied in unison. It is an inherent characteristic of this invention that it has an ability to benefit from the perpetual research opportunities offered as a synergistic bonus to the immediate advantage the Clandestine Laboratory (or Clan-Lab) Home Test Kit presents as an economical solution that is made available to the general public at large. As a means of determining hidden hazards presented by past or present clandestine manufacturing or processing activities, the Clan-Lab Home Test Kit can perform its primary function and develop, by means of the component embodiment presented in the Vapotrap Capsule, a significant amount of strategic scientific information about the national impact this manner of crime is causing. Whereas, the Vapotrap Capsule offers opportunities to study a problematic adsorption application that has, through its wide variety of clandestine chemistries, defied the conformity necessary for predictive adsorption modeling and has thus allow the problem to evade scientific understanding for over a decade while hundreds of thousands of innocent persons have been impacted to some degree.
[0160] The Vapotrap Capsule, when used as a static monitoring device or when specific conditions relative to the particular investigation so warrant, the returned Capsule assembly is prepared for analysis as follows:
a) removing said sample from shipping container and cross referencing the attached identification label thereto to the sample log sheet also retrieved from said sample shipping container; b) entering the appropriate sample identification code into the customer or end users account file; c) removal of said sample from its container packaging; d) placing said sample inside an air tight Extraction Chamber apparatus ( FIG. 4 —Extraction Unit Detail, Drawing Segment 1) and sealing said chamber; e) introducing a heat and/or steam source to said Extraction Chamber ( FIG. 4 —Extraction Unit Detail, Drawing Segment 1, Valve S 1 ); f) opening the outlet valve located on said Extraction Unit assembly once the desired temperature, pressure, and time period are achieved ( FIG. 4 —Extraction Unit Detail, Drawing Segment 1, Valve U 1 ); g) routing off-gas flow directly from said Extraction Chamber into the Vapor Expansion/Mixing Tank assembly ( FIG. 4 —Measurement Unit Detail, Drawing Segment 3, Valve U 4 ); or routing said off-gas flow indirectly into a Vapor Expansion/Mixing Tank via an attached Chilling Unit assembly ( FIG. 4 —Chilling Unit Detail, Drawing Segment 2, Valve U 2 ) designed to reduce the temperature of the off-gas flow as it passes through a length of chilled tube or pipe; h) opening a valve on the Vapor Expansion/Mixing Tank network ( FIG. 4 —Measurement Unit Detail, Drawing Segment 3, Valve T 3 ) leading to the analytical instrumentation network ( FIG. 6 —Analytical Unit Detail, Drawing Segment 4); i) recording the measurements observed into the end user's account file; j) releasing all residual vapors that may be contained said Extraction Chamber, Chilling Unit, and/or Vapor Expansion/Mixing Tank or the associated piping thereto; k) removing sampling media (Capsule or Subpod) from the Extraction Chamber and re-sealing the lid assembly; and l) purging the remainder of the Extraction, Chiller, Measurement, and Analytical systems with high temperature steam and/or water flow for cleaning prior to processing another sample Capsule and/or Subpod assembly for analysis.
Vapotrap Canister
[0173] Although the Vapotrap Capsule can be used as a static monitoring device, which simply adsorbs chemical substances by diffusion through normal indoor convectional air currents, the dynamics of moving a flow of ambient air through the medias contained therein is more efficient process when forced ventilation is applied. The Vapotrap Canister offers a variety of embodiment advantages as a component to the Clan-Lab Home Test Kit ( FIG. 1 ). FIG. 3 illustrates one form of the embodiment of this invention.
[0174] The Canister device itself ( FIG. 3 ) consists of four primary mechanisms (Reference Table 3 for inventory of apparatus componentry):
[0175] First, a chamber ( FIG. 3 —Article 9) that serves to: a) hold the Capsule ( FIG. 3 —Article 12) of segregated medias thus allowing a flow of gas ( FIG. 3 —Article 11) to be passed through said medias, b) act as a housing for the media and function not only in a sampling capacity, but also in an analytical capacity ( FIG. 5 ); whereas when a metallic version of the chamber is employed in the investigation process, the media does not have to be unloaded at the analysis laboratory, but rather can function as an extraction apparatus and contain both the pressures and temperatures necessary for thermal desorption of the contaminants contained within the spent media Capsule.
[0176] Second, one or more lids or sealing mechanisms ( FIG. 3 —Articles: 7 and 8) that:
a) can be opened for extracting and replacing said Capsule ( FIG. 3 —Article 12), b) can be sealed to prevent escape, bypass or short-circuiting of gas flow ( FIG. 3 —Article 11) around the Capsule's media components ( FIG. 3 —Article 12), c) can be opened and/or disassembled for cleaning and sterialization purposes, and d) can contain the internal steam pressures generated by the thermal desorption process.
[0181] Third, an inlet and outlet valve assembly ( FIG. 3 —Article 6) that:
a) can be to control air flow ( FIG. 3 —Article 11) to and from the Canister assembly, b) can allow the Canister to be closed securely prior to and immediately after sampling to lock in and prevent the escape of collected contaminants and eliminate the need, unnecessary bulk, and inconveience for another container, and c) can allow for the desorbed contaminants to be controlled and released as required in the subsequent analytical process.
[0185] Fourth, a pump, hose, and hose attachment fitting assembly ( FIG. 3 —Articles: 1, 4, 5, and 10) that:
a) can allow the Canister to either have an air flow ( FIG. 3 —Article 11) forced through it by pressure or drawn through it by vacuum, b) can allow the use of an inline particulate filter assembly ( FIG. 3 —Articles 2 and 3) to capture airborne particles for subsequent analysis, c) be readily disconnected as the Canister is reattached to the analysis network and used as an extraction chamber ( FIG. 5 —Extraction Unit Detail), and d) can be inspected, cleaned, and reattached to a freshly prepared Canister, shipped to an end user and reused again as a ventilation component in another sampling event.
[0190] Another embodiment of this invention is the flexibility of being able to configure a lower cost, lower weight capsule assembly apparatus, which assembled from synthetic plastic and/or fiber substrate materials and performs essentially the same in a sampling mode. Conversely, analytical processing of this variation is accomplished by opening the Canister at the receiving laboratory facility; whereas, the said Capsule assembly content is then emptied from said Canister and transferred into a heat resistant Canister assembly (made of metallic components) which is then placed in a heating source holster assembly ( FIG. 5 —Extraction Unit Detail) to facilitate direct analysis of the contaminants contained in the adsorbent and/or absorbent components contained therein and thus extract an off-gas flow via the thermal desorption process.
[0191] The Vapotrap Canister assembly is prepared for laboratory analysis by:
(a) removing said sample canister assembly from shipping container and cross referencing the attached identification label thereto to the sample log sheet also retrieved from said sample shipping container; (b) entering the appropriate sample identification code into the customer or end users account file; (c) placing said sample canister assembly inside a heated yoke assembly for vapor extraction processing ( FIG. 5 —Extraction Unit Detail, Drawing Segment 1); (d) connecting system hoses to said canister assembly and opening both the inlet valve; (e) introducing a heat source to the heating holster assembly unit containing or enveloping the prepared Canister assembly ( FIG. 3 ); (f) introducing a pressure, heat, and/or steam source to said canister assembly ( FIG. 5 —Extraction Unit Detail, Drawing Segment 1, Valve S 1 ); (g) opening the outlet valve located on said Extraction Unit assembly once the desired temperature, pressure, and time period are achieved ( FIG. 5 —Extraction Unit Detail, Drawing Segment 1, Valve U 1 ); (h) routing off-gas flow directly from said Extraction Chamber into the Vapor Expansion/Mixing Tank assembly ( FIG. 5 —Measurement Unit Detail, Drawing Segment 3, Valve U 4 ); or routing said off-gas flow indirectly into a Vapor Expansion/Mixing Tank via an attached Chilling Unit assembly ( FIG. 5 —Chilling Unit Detail, Drawing Segment 2, Valve U 2 ) designed to reduce the temperature of the off-gas flow as it passes through a length of chilled tube or pipe; (i) opening a valve on the Vapor Expansion/Mixing Tank network ( FIG. 5 —Measurement Unit Detail, Drawing Segment 3, Valve T 3 ) leading to the analytical instrumentation network ( FIG. 6 —Analytical Unit Detail, Drawing Segment 4); (j) recording the measurements observed into the end user's account file; (k) releasing all residual vapors that may be contained said canister assembly, chilling unit, and/or vapor expansion/mixing tank or the associated piping thereto; (l) removing canister assembly from the heating yoke unit ( FIG. 5 —Extraction Unit Detail, Drawing Segment 1), empty sampling media Capsule from therein and subject said Canister assembly ( FIG. 3 ) to disassembly, cleaning, drying, and reloading with sanitized, prepared composite media Capsule before being redeployed; and
[0204] (m) purging the remainder of the Extraction, Chiller, Measurement, and Analytical systems with high temperature steam and/or water flow for cleaning prior to processing another sample Canister assembly for analysis.
TABLE 3 Clandestine Laboratory (Clan-Lab) Home Test Kit Vapotrap Canister Assembly No. Item Units Description Function 1 Hose 1 Synthetic plastic (variable sized Inlet air flow diameter) 2 In-line Filter 1 Synthetic plastic (variable sized orifice) Container for filter element (3) Assembly 3 Filter Element 1 Synthetic (variable sized micron mesh Filtration of particulates and hose diameters) 4 Hose 1 Synthetic plastic (variable sized Routing air flow into Vapotrap cylinder diameter) assembly 5 Hose Nipple 2 Metallic or synthetic plastic (variable Attaching hose to Vapotrap cylinder sized threading and hose diameter) assembly 6 Shutoff - Ball 2 Metallic or synthetic plastic (variable Controlling air flow Valve sized threading and orifice diameter) 7 O-Ring Gasket 2 Synthetic plastic (variable diameter and Sealing Vapotrap cylinder chamber (9) thickness) cap (8) seating 8 Cap Assembly 2 Metallic or synthetic plastic (variable Cap for Vapotrap cylinder (9) and sized threading and diameter) bushing for attachment of Shutoff - Ball Valve (6). 9 Cylinder Body 1 Metallic or synthetic plastic (variable Container for Vapotrap capsule and sized threading and diameter) subpods (12) 10 Hose 1 Synthetic plastic (variable sized Outlet air flow diameter) 11 Air flow NA Variable flow rate given air Transport medium for airborne pump/vacuum volume and velocity contaminates into Vapotrap cylinder regulated by diameter and resistance. assembly and allow for filtered exit gas to depart from the same. 12 Vapotrap Varies Various adsorption media packets Adsorb and contain airborne capsule and contaminates from air flow (11) subpods | This invention is comprised of a system, protocol, method and apparatus for the assessment of properties that may have been, or are being, subject to clandestine drug manufacturing and/or processing activities. The invention includes a comprehensive home test kit to be used in or upon a suspect premises to detect, identify, and delineate toxic chemical hazards that may have originated from an illegal drug making operation. The test kit is designed to be conveniently equipped with all-inclusive content consisting of an assortment of user-selected sampling equipment, media, containers, materials, documentation, instruction manual, as well as an audio-visual instructional media pack. This Kit is designed to enable a person of average intelligence to conduct the sampling activities and the Kit to a designated analytical laboratory for processing and reporting of results in order to determine the risk presented by a property and damages it may have sustained. | 1 |
RELATED APPLICATIONS
The present invention was first described in and claims the benefit of U.S. Provisional Application No. 61/292,999 filed Jan. 7, 2010, the entire disclosures of which are incorporated herein by reference.
FIELD OF THE INVENTION
The present invention relates generally to deployable automobile sun visors, and in particular, to a motorized deployable automobile sun visor with an electronic control.
BACKGROUND OF THE INVENTION
Bright sunlight is a prominent cause of poor visibility, distraction, and discomfort when driving an automobile. In a case where a driver is forced to drive towards the sun, particularly during sunny periods and periods where the sun is low in the sky, bright sunlight is directly incident upon the driver's field of vision. This causes discomfort due to the high intensity of the light and decreased visibility when attempting to look in a direction near the sun.
A common solution to decrease direct incident sunlight and increase visibility during such conditions is the use of automobile sun visors. These visors commonly pivot downwardly from a front roof position of the automobile and provide an opaque shield to a top portion of the windshield while leaving the direct-forward view unhindered. In most cases, the sun is high enough in the sky that such visors block a significant portion of the incident rays.
However, use of such visors contributes to what is possibly the most significant safety concern in the field of automobiles—attempting to operate or focus on non-driving manual tasks while driving a vehicle. Such distractions are a leading cause of accidents and injuries. The deployment of a sun visor is such a distraction in and of itself; however, in particular, the adjustment of the visor once it is deployed is particularly troublesome. This is due to the fact that the driver generally must look directly at the visor in order to dislodge it and position it in a desired spot, thereby taking their eyes off of the road ahead for a period of time.
Various attempts have been made to provide automatic vehicle shade or visor assemblies. Examples of these attempts can be seen by reference to several U.S. patents, including U.S. Pat. No. 3,226,151; U.S. Pat. No. 3,343,868; U.S. Pat. No. 4,178,035; U.S. Pat. No. 4,468,062; U.S. Pat. No. 5,298,732; U.S. Pat. No. 5,873,621; and U.S. Pat. No. 6,318,788.
While these apparatuses fulfill their respective, particular objectives, each of these references suffer from one (1) or more of the aforementioned disadvantages. Many such apparatuses are not adapted for use with both a windshield and a side window portion of a vehicle. Also, many such apparatuses are not readily retrofittable to existing vehicles and require installation by the original manufacturer. Furthermore, many such apparatuses are not adjustable or movable once installed. In addition, many such apparatuses do not provide simple controls which can be selectively located by the driver for ease of access during driving. Accordingly, there exists a need for an automated sun visor for motor vehicles without the disadvantages as described above. The development of the present invention substantially departs from the conventional solutions and in doing so fulfills this need.
SUMMARY OF THE INVENTION
In view of the foregoing references, the inventor recognized the aforementioned inherent problems and observed that there is a need for an automated sun visor for a motor vehicle which is utilizable with existing vehicles in a variety of adjustable configurations to allow a user to safely and automatically provide sun protection while driving, according to their preference. Thus, the object of the present invention is to solve the aforementioned disadvantages and provide for this need.
To achieve the above objectives, it is an object of the present invention to provide an automated electrically deploying sun visor for a motor vehicle in order to reduce sun radiation through a windshield or window. The system comprises a housing enclosure, a motor, and a switch.
Another object of the present invention is to allow a user to retrofit the system to an existing vehicle. The system can also be incorporated into the original equipment of a desired vehicle during manufacturing.
Yet still another object of the present invention is to replace a conventional sun visor on a driver side portion of a desired vehicle. The system is installed adjacent to the front windshield on an interior portion of the vehicle between a head liner and the roof of the vehicle. In this position, the system also provides shade to a steering wheel to prevent excessive heating of the steering wheel while driving.
Yet still another object of the present invention is to provide unobtrusive and customizable positioning of the housing enclosure within a motor vehicle. The housing enclosure comprises a flat generally rectangular structure which is attachable to an underside of the roof, preferably with a plurality of threaded studs and nuts. The studs can be installed in a desired position and orientation along the roof so as to retain the housing enclosure flush against the roof and minimize the amount of space disrupted by the system.
Yet still another object of the present invention is to provide a shading visor extendable from within the housing enclosure. The visor is constructed of a semi-rigid plastic which provides slight flexibility and allows the visor to conform to the profile of a windshield or window during deployment.
Yet still another object of the present invention is to enable the visor to move smoothly along the windshield or window during deployment by providing a slightly rounded front edge. This front edge also inhibits the visor from retracting entirely within the housing enclosure.
Yet still another object of the present invention is to provide even, secure, and controlled motorized motioning of the visor using the motor, a pair of gears, and a plurality of guiding pins within the enclosure. When the motor is actuated, it motions the gears which engage a corresponding toothed exterior track integrally molded within the visor. The visor is secured in a vertical position by the pins to prevent disruptive motion of the visor within the enclosure.
Yet still another object of the present invention is to allow a user to deploy or retract the visor in an electronically controlled manner using a microprocessor control unit located adjacent to the housing enclosure.
Yet still another object of the present invention is to allow a user to relay control signals to the control unit using a bi-directional switch. The switch can be installed in a desired location along a dashboard, a steering wheel, a door panel, or the like to facilitate safe use by a driver while operating a vehicle. The switch and control unit are interconnected to the vehicle's wiring harness with an appropriately gauged electrical wiring.
Yet still another object of the present invention is to allow a user to position the housing enclosure in such a manner that deployment of the visor provides shade within a side window of the vehicle.
Yet still another object of the present invention is to provide a method of utilizing the device that provides a unique means of acquiring the system; if retrofitting the system, removing the existing sun visors from the drivers-side portion in a desired vehicle, removing the head liner, installing the studs to the roof, fastening the housing enclosure to the studs with the nuts, and installing the switch to a desired location; routing electrical wiring from the control unit to the switch and to the vehicles wiring harness; depressing the switch to extend or retract the visor; repeating the abovementioned process to install the system on various locations in the vehicle; and, enjoying glare free driving in vehicles.
Further objects and advantages of the present invention will become apparent from a consideration of the drawings and ensuing description.
BRIEF DESCRIPTION OF THE DRAWINGS
The advantages and features of the present invention will become better understood with reference to the following more detailed description and claims taken in conjunction with the accompanying drawings, in which like elements are identified with like symbols, and in which:
FIG. 1 is an environmental fragmental view of an automated sun visor for a motor vehicle 10 depicting an active state within a vehicle, according to a preferred embodiment of the present invention;
FIG. 2 is a perspective view of the automated sun visor for a motor vehicle 10 depicting a slightly deployed state, according to a preferred embodiment of the present invention;
FIG. 3 is another perspective view of the automated sun visor for a motor vehicle 10 depicting a removed upper panel and a slightly deployed state, according to a preferred embodiment of the present invention;
FIG. 4 is a bottom perspective view of the automated sun visor for a motor vehicle 10 depicting a slightly deployed state, according to a preferred embodiment of the present invention;
FIG. 5 is an environmental view of a vehicle interior, according to a preferred embodiment of the present invention; and,
FIG. 6 is an environmental view of an alternate embodiment 80 positioned about a side window 71 and depicting an active state within a vehicle, according to an alternate embodiment of the present invention.
DESCRIPTIVE KEY
10 automated sun visor for a motor vehicle
15 driver
17 sun radiation
20 visor
21 a housing enclosure
21 b upper panel
21 c side panel
21 d rear panel
21 e front panel
21 f opening
21 g bottom panel
22 ear
23 aperture
24 stud
25 nut
30 track
35 visor front edge
50 motor
51 shaft
52 side groove
53 gear
54 intermediate pin
55 rear pin
60 switch
65 electrical wiring
67 control unit
70 driver-side portion
71 side window
72 front windshield
74 steering wheel
75 head liner
76 roof
78 dashboard
80 alternate embodiment
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The best mode for carrying out the invention is presented in terms of its preferred embodiment, herein depicted within FIGS. 1 through 5 and alternately within FIG. 6 . However, the invention is not limited to the described embodiment and a person skilled in the art will appreciate that many other embodiments of the invention are possible without deviating from the basic concept of the invention, and that any such work around will also fall under scope of this invention. It is envisioned that other styles and configurations of the present invention can be easily incorporated into the teachings of the present invention, and only one particular configuration shall be shown and described for purposes of clarity and disclosure and not by way of limitation of scope.
The terms “a” and “an” herein do not denote a limitation of quantity, but rather denote the presence of at least one of the referenced items.
The present invention describes an automated sun visor for a motor vehicle (herein described as the “system”) 10 , which provides a means for electrically deploying at least one (1) sun visor 20 in a vehicle. The system 10 is preferably a part of the original equipment of a desired vehicle, yet may also be retrofitted without limiting the scope of said system 10 . The system 10 is preferably utilized on the driver-side portion 70 in the vehicle to reduce sun radiation 17 from the front windshield 72 in a simple but high-tech manner for the safety of not just the driver 15 of a motor vehicle but all surrounding motorists and pedestrians as well. The system 10 may also be installed in various other positions within the vehicle such as the side window 71 (see FIG. 6 ) or the like.
Referring now to FIG. 1 , an environmental view of the system 10 depicting an active state within a vehicle, according to the preferred embodiment of the present invention, is disclosed. The system 10 replaces a conventional sun visor utilized on the driver side portion 70 of the desired vehicle. The system 10 is installed adjacent to the front windshield 72 on an interior portion of the vehicle particularly between the head liner 75 and the roof 76 . During the original equipment manufacturing process of the vehicle an opening should be left vacant between the head liner 75 and the roof 76 nearest to the windshield 72 to enable the visor 20 to freely deploy and retract. The system 10 comprises a housing enclosure 21 a , a motor 50 , and a switch 60 , and other mechanical and electrical components as mentioned herein below. The system 10 is preferably installed above the front windshield 72 to eliminate sun radiation 17 which is directed to the driver 15 in multiple directions during driving. The visor 20 reduces the sun radiation 17 from the driver 15 by blocking a portion of the windshield 72 similar to conventional vehicle sun visors, yet in an electrically deployable manner. The visor 20 also reduces the steering wheel 74 from becoming overly heated by reducing sun radiation 17 from coming in contact with said steering wheel 74 . The visor 20 is fabricated from a semi-rigid plastic and made available in a variety of colors and designs to complement the existing vehicle interior.
Referring now to FIG. 2 , a perspective view of the system 10 depicting a slightly deployed state, according to the preferred embodiment of the present invention, is disclosed. The housing enclosure 21 a comprises a six-sided rectangular shape further including an upper panel 21 b , a pair of side panels 21 c , a rear panel 21 d , a front panel 21 e , and a bottom panel 21 g . The housing enclosure 21 a is fabricated from materials such as metal or plastic. The housing enclosure 21 is preferably manufactured in various dimensions to accommodate various vehicles. Each opposing longitudinal perimeter edge of the side panels 21 c comprises a pair of ears 22 which are utilized to secure said housing enclosure 21 to an underside surface of the roof 76 , above the head liner 75 . Threaded studs 24 are attached to the underside surface of the roof 76 by common welding techniques and align with an aperture 23 located on each ear 22 . Each stud 24 is inserted into each aperture 23 and a common nut 25 secures to said stud 24 to further secure the housing enclosure 21 to a fixed position. Other attachment means may also be utilized without limiting the scope of the system 10 .
Referring now to FIG. 3 , another perspective view of the system 10 depicting a removed upper panel and a slightly deployed state and FIG. 4 , a bottom perspective view of the system 10 depicting a slightly deployed state, according to the preferred embodiment of the present invention, are disclosed. Internally, the housing enclosure 21 a comprises the visor 20 , a motor 50 , a shaft 51 , and a pair of gears 53 . A portion of the visor 20 is depicted as being cut-away for illustration purposes only. The visor 20 is fabricated from a semi-rigid plastic material with shading or shielding characteristics as abovementioned which provides a flexibility to conform to the shape of the windshield 72 when deployed. The visor 20 is preferably a length similar to the housing enclosure 21 a and a width slightly smaller than said housing enclosure 21 a . The visor 20 is deployed from an opening 21 f on the front panel 21 e of the housing enclosure 21 a which comprises dimensions slightly larger than the dimensions of the visor 20 . A proximal perimeter edge of the visor 20 comprises a visor front edge 35 which enables said visor 20 to move smoothly with the curvature of the front windshield 72 . The visor front edge 35 is integral to the visor 20 and comprises a slightly rounded shape which also prohibits the visor 20 from being retracted completely within the housing enclosure 21 a due to the fact that the visor front edge 35 is slightly larger than the opening 21 f.
Each opposing intermediate perimeter edges and the distal perimeter edge of the visor 20 comprises an intermediate pin 54 and a rear pin 55 , respectively which are integral to said visor 20 . The rear pin 55 spans an entire rear edge of the visor 20 . The pins 54 , 55 engage a side groove 52 which is located on an inner surface of each side panel 21 c to enable the visor 20 to be retracted and deployed in an even and secured manner. The intermediate pins 54 also prohibit the visor 20 from coming completely deployed from the housing enclosure 21 a because said intermediate pins 54 come in contact with a rear portion of the opening 21 f upon the front panel 21 e.
The motor 50 and the pair of gears 53 are oriented below a proximal portion of the visor 20 and are secured about a shaft 51 mounted to interior surfaces of said pair of side panels 21 c . The motor 50 is comprised of a conventional direct current (DC) motor, yet other similar devices may be utilized without limiting the scope of the system 10 . The gears 53 comprise a toothed exterior surface which engages a corresponding toothed track 30 . The track 30 is located on an underside surface of the visor 20 and is integrally molded into said visor 20 . The motor 50 rotates the shaft 54 which concurrently rotates each gear 53 to retract or deploy the visor 20 wherein the intermediate pins 54 and rear pin 55 slide laterally within the side grooves 52 . The visor 20 , motor 50 , and gears 53 are interconnected via electrical wiring 65 to a switch 60 and a control unit 67 which enables the driver 15 to deploy or retract said visor 20 as necessary. The control unit 67 is depicted within FIG. 1 as being located between the head liner 75 and the roof 76 , yet other locations may be utilized without limiting the scope of the system 10 . The control unit 67 is comprised of a microprocessor or the like and other similar electronics that will relay the state of the switch 60 (see FIG. 5 ) to the motor 50 to correspondingly retract or deploy the visor 20 from the housing enclosure 21 a.
Referring now to FIG. 5 , an environmental view of a vehicle interior, according to the preferred embodiment of the present invention, is disclosed. The switch 60 is preferably located on the dashboard 78 of the vehicle, yet other positions may be utilized such as, but not limited to: the steering wheel 74 , the door panel, or the like. The switch 60 is interconnected to the motor 50 and control unit 67 as abovementioned, yet is also routed to the vehicles wiring harness via appropriately gauged electrical wiring 65 to supply the system 10 with power. The switch 60 is comprised of a conventional single pole double throw switch, yet other switching devices may be utilized such as, but not limited to: a toggle switch, a pushbutton, or the like. The switch 60 , in use, is depressed in one (1) direction to deploy the visor 20 to a desired length and may depressed in an opposing direction to retract said visor 20 . In a retrofit embodiment the switch 60 would be attached to a desired area upon the dashboard 78 with attachment means such as, but not limited to: mechanical fasteners, adhesives, or the like.
Referring now to FIG. 6 , an environmental view of an alternate embodiment 80 positioned about a side window 71 and depicting an active state within a vehicle, according to the alternate embodiment of the present invention, is disclosed. As abovementioned the system 10 may alternately be utilized for a side window 71 particularly on the driver-side portion 70 . The alternate embodiment 80 would block sun radiation 17 from the driver 15 upon a side orientation. The alternate embodiment 80 is preferably original equipment to the vehicle, yet may also be retrofitted to a desired vehicle without limiting the scope of the system 10 . To be arranged for utilization on the side window 71 , the system 10 is turned ninety degrees (90°) with the front panel 21 e toward said side window 71 . Internally, the system 10 would remain as abovementioned and the switch 60 may also remain upon the dashboard 78 .
It is envisioned that other styles and configurations of the present invention can be easily incorporated into the teachings of the present invention, and only one particular configuration shall be shown and described for purposes of clarity and disclosure and not by way of limitation of scope.
The preferred embodiment of the present invention can be utilized by the common user in a simple and effortless manner with little or no training. After initial purchase or acquisition of the system 10 , it would be installed as indicated in FIG. 1 .
The method of utilizing the system 10 as an original equipment embodiment may be achieved by performing the following steps: acquiring the system 10 ; depressing the switch 60 to send a signal to the control unit 67 to activate the motor 50 , rotating the shaft 51 and gears 53 which engage the tracks 30 to extend the visor 20 to a desired length to block sun radiation 17 from the driver 15 on the front windshield 72 ; depressing the switch 60 in an opposite direction to retract the visor 20 to an original state; and, enjoying glare free driving in vehicles.
The method of utilizing the system 10 as a retrofit may be achieved by performing the following steps: acquiring the system 10 ; removing the existing sun visors from the drivers-side portion 70 in a desired vehicle; removing the head liner 75 ; installing the studs 24 to the roof 76 ; fastening the housing enclosure 21 a to the studs 24 with the nuts 25 with the front panel 21 e toward the front windshield 72 ; altering the head liner 75 to enable the visor 20 to retract and deploy in an expected manner; reinstalling the head liner 75 ; installing the switch 60 to a desired location; routing electrical wiring 65 from the control unit 67 to the switch 60 and to the vehicles wiring harness; repeating the abovementioned process to install the system 10 on various locations in the vehicle; depressing the switch 60 to extend the visor 20 to a desired length; depressing the switch 60 in an opposite direction to retract the visor 20 to an original state; and, enjoying glare free driving in vehicles.
The alternate embodiment 80 of the present invention can be utilized by the common user in a simple and effortless manner with little or no training. After initial purchase or acquisition of the system 10 , it would be installed as indicated in FIG. 6 .
The method of utilizing the alternate embodiment 80 as original equipment may be achieved by performing the following steps: acquiring the alternate embodiment 80 ; depressing the switch 60 to send a signal to the control unit 67 to activate the motor 50 , rotating the shaft 51 and gears 53 which engage the tracks 30 to extend the visor 20 to a desired length to block sun radiation 17 from the driver 15 on the side window 71 ; depressing the switch 60 in an opposite direction to retract the visor 20 to an original state; and, enjoying glare free driving in vehicles.
The method of utilizing the alternate embodiment 80 as a retrofit may be achieved by performing the following steps: acquiring the alternate embodiment 80 ; removing the existing sun visors from the drivers-side portion 70 in a desired vehicle; removing the head liner 75 ; installing the studs 24 to the roof 76 ; fastening the housing enclosure 21 a to the studs 24 with the nuts 25 with the front panel 21 e toward the front windshield 72 ; altering the head liner 75 to enable the visor 20 to retract and deploy in an expected manner; reinstalling the head liner 75 ; installing the switch 60 to a desired location; routing electrical wiring 65 from the control unit 67 to the switch 60 and to the vehicles wiring harness; repeating the abovementioned process to install the alternate embodiment 80 on various locations in the vehicle; depressing the switch 60 to extend the visor 20 to a desired length; depressing the switch 60 in an opposite direction to retract the visor 20 to an original state; and, enjoying glare free driving in vehicles.
The foregoing descriptions of specific embodiments of the present invention have been presented for purposes of illustration and description. They are not intended to be exhaustive or to limit the invention and method of use to the precise forms disclosed. Obviously many modifications and variations are possible in light of the above teaching. The embodiment was chosen and described in order to best explain the principles of the invention and its practical application, and to thereby enable others skilled in the art to best utilize the invention and various embodiments with various modifications as are suited to the particular use contemplated. It is understood that various omissions or substitutions of equivalents are contemplated as circumstance may suggest or render expedient, but is intended to cover the application or implementation without departing from the spirit or scope of the claims of the present invention. | An electrically-deployable sun visor system for use on motor vehicles wherein the sun visor retracts upward and deploys downward upon a track system, are located on the front windshield and alternately on the side window. The sun visor is operated by a motor-operated gear system wired into the electrical system of the motor vehicle. The sun visor is operated by a dash-mounted switch. The amount of deployment is controlled by holding the switch in either an up or down position for the necessary period of time similar to an electrically operated window. | 1 |
CROSS REFERENCE TO RELATED APPLICATIONS
The present application claims the benefit of U.S. Provisional Application No. 60/978,606, filed Oct. 9, 2007, which is hereby incorporated by reference in its entirety.
BACKGROUND
Exhaust hoods are used in many situations where pollutants are generated. Examples include kitchens, laboratories, factories, and spray paint booths, as well as other examples. In a commercial kitchen environment, multiple exhaust hoods and exhaust ducts may be provided for different appliances at different locations. The load varies with the type of appliance and the way it is being used. Broilers, grills, and fryers, for example, may produce a great deal of smoke and fumes, including grease particles and moisture. Other devices such as ovens and steam tables may produce less. To provide sufficient flow to remove pollutants without removing excessive amounts of air creates a real time flow balancing problem in the commercial kitchen environment. Typical exhaust hoods and ducting systems may be ill-suited to addressing this problem in an optimum way.
A typical exhaust hood has an inlet for fumes and air that leads to an exhaust duct. Filters may be provided at the point where air and fumes enter the duct. An exhaust plenum may also connect the hood with the exhaust duct. Hoods are often long and narrow and accommodate multiple cooking units. Variations include exhaust ceilings, wide canopy hoods, and other configurations.
Prior art systems have used flow restrictions in the path of the exhaust air to balance the flow of air and fumes. Dampers or other chokes may be used to make adjustments to the flow and real time control systems have been proposed. But fouling is a persistent problem particularly in systems that handle fumes and air with water vapor and grease particles.
SUMMARY
Generally, the invention is a blocking mechanism that has surfaces, which may or may not be planar, in which the surfaces of the blocking elements remain at angles that form angles greater than 30 degrees from the horizontal and preferably more than 30 degrees such as more than 45 degrees. Balancing dampers suitable for use in ducts carrying grease laden fumes have generally air blocking elements that move between high resistance and low resistance positions to regulate the amount of grease-laden fumes that pass through the duct.
A flow control device has a duct section with a plurality of damper blocking elements, each having a major plane. The damper blocking elements are pivotably connected to the duct section and movable in a range that is limited to ensure that, when the duct section is mounted in a preferred orientation, the damper blocking element major planes always form an angle of at least 45 degrees from the horizontal throughout the range. The range is such that the plurality of damper blocking elements can selectively close and open the duct. Preferably the blocking elements are capable of completely closing the duct, for example to block natural convection. In a variation, there are two damper blocking elements. The damper blocking elements may be configured such that they are interconnected to pivot in opposite directions and further such that edges thereof meet in the middle of the duct section when the blocking elements are in a closed position. For example, in a preferred configuration, the major planes are substantially vertical when the blocking elements are in the open position.
The blocking elements can be configured each with a flat portion, such as by means of a bend in a plate, that come into parallel abutment with each other when the blocking elements are in the closed position. The damper blocking elements pivot on bearings mounted outside the duct section. Preferably the bearings are durable and low resistance bearings such as roller or ball bearings to allow the damper to be used continuously and adjusted frequently throughout the day over a long lifetime without sticking or breaking down.
The blocking elements may be carried on shafts which are mounted to the bearings, and liquid proof seals located at the duct walls may be provided that permit the shafts to rotate while preventing fluid in the duct from escaping to the outside of the duct. The duct may be sealed against fluid within the duct escaping the duct section. The damper blocking elements pivot on bearings mounted inside the duct on one side of the duct and mounted outside the duct on the opposite side of the duct such the one side has no protrusions. A motor drive may be located on the opposite side so that the side with the bearing on the inside can present a flush outer face.
A motor drive may be configured to position the damper blocking elements and a controller configured to control the motor drive responsively to a detected fume load. The controller may be configured to control the motor drive responsively to a fume load detected by at least one of a gas sensor, an optical sensor, a temperature sensor, and a flow sensor.
Any of the foregoing variations may be applied to another flow control device with a duct section that has a plurality of damper blocking elements, each having a major plane. In this device, the damper blocking elements pivot on bearings connected to the duct section and are movable from an open position in which the blocking elements are in a vertical position in which the major planes are spaced apart and parallel to closed position in which the major planes form an angle of at least 45 degrees with the horizontal. The range is such that the plurality of damper blocking elements can selectively substantially close the duct section completely and open the duct section completely.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a perspective view of a balancing damper.
FIGS. 2A-2D are figurative views of the balancing damper blade positions in various stages of adjustment.
FIG. 3 shows the blades of a balancing damper.
FIG. 4A shows a partial section view of a balancing damper assembly.
FIG. 4B shows a perspective view of a balancing damper.
FIGS. 5A-5D show alternative damper blade configurations and mechanisms.
FIGS. 6A and 6B show another alternative blade configuration.
FIG. 7 shows a damper unit mounted in a duct of an exhaust hood and various associated features.
FIG. 8 shows a configuration of a damper with trough shaped blades.
DETAILED DESCRIPTION OF EMBODIMENTS
Referring to FIG. 1 , a balancing damper in a duct segment 100 that carries grease laden fumes has two generally air blocking elements 102 and 112 that rotate on bearings 108 A and 108 B. As illustrated in FIGS. 2A to 2D , the blocking elements 102 and 112 rotate symmetrically between settings for high resistance 90 , low resistance 93 , and a range of positions in-between including those indicated at 91 and 92 positions.
Note that in all of the positions shown, the blocking elements 102 and 112 remain at a minimum angle with respect to the horizontal 80 of more than about 45 degrees, for example, end portions 113 of blocking elements 102 and 112 as well as the major portions 115 all form angles, such as angles φ 1 and φ 2 . For example the minimum angle can be at least about 45 degrees, the closed position being the least vertical.
A motor drive 104 may be used to rotate the blocking elements 102 and 112 . The drive 104 may include an indicator 114 that shows the position of the damper. The drive 104 may be replaced by a manual positioning device. A synchronization mechanism, such as a kinematic mechanism (for example, one using linkages including the links 106 and 109 ) may be provided to cause the blocking elements 102 and 112 to pivot back and forth in synchrony. Such a kinematic mechanism could employ gears, hydraulic couplings, electronically synchronized drives or any suitable mechanism.
The blocking elements may be planar or any other suitable shape. The embodiment of FIG. 1 may be modified to fit in a round duct with blocking elements shaped as cylindrical sections to permit the same overall effect as the embodiment of FIG. 1 .
Preferably, bearings are provided, such as bearings 108 a and 108 b , to support the blocking elements 102 and 112 for pivoting. The bearings may be located inside the duct section 100 or outside. In one configuration, bearings may be located on the inside on a side of the duct opposite the drive motor and on the outside on the side with the drive motor. In the latter configuration, the duct can be located with the side opposite the drive motor lying directly against the wall. Referring to FIG. 4A , where the bearings are located outside as indicated by 180 , the duct section may have a housing 144 to enclose the external bearing. The bearings may also be provided with a seal 184 to ensure that gas, grease or condensed vapor or any other liquid cannot leak from the duct. FIG. 4B illustrates a configuration in which a housing 150 encloses a drive 155 as well as the externally-mounted bearing. Bearings 182 inside the duct may be constructed, as shown in FIG. 4A , such that no duct wall penetration is required. Preferably, a notch 172 in blocking element 102 provides clearance for any internal bearing.
As illustrated, one end of each blocking element 102 and 112 may have a bend at the end. This may enhance rigidity and also help to act as a stop to prevent the blocking elements pivoting too far. Such features may be provided on one or both ends or not at all. FIG. 3 shows the damper with the duct section 100 removed. FIGS. 5A to 5D show alternative mechanisms. FIGS. 5A and 5B show blocking elements 202 and 204 that pivot at their ends. In other configurations, the pivot location may be anywhere along the blocking elements. As in the other configurations, the blocking elements are partially vertical, preferably at least 45 degrees to the horizontal, in the closed position ( FIG. 5 a ) and more vertical in the open position ( FIG. 5 b ), to help prevent the accumulation of grease by encouraging grease to drip quickly off the blocking elements 202 and 204 . A linkage 206 , which may be located outside the duct 100 , causes the blocking elements 202 and 204 to move in synchrony. An embodiment of FIGS. 5C and 5D has blocking elements 208 and 210 configured for a round duct 100 A.
FIGS. 6A and 6B show closed and open positions, respectively, of a mechanism with a single blocking element 220 that pivots at 224 . As in the above embodiments, in the closed position, the blocking element 220 forms a substantial minimum angle with the horizontal. In this and other embodiments the minimum angles are as discussed above with regard to the other embodiments.
The above embodiments may be varied in terms of details, such as the shape of the blocking elements and the angle formed by the blocking elements in all positions, even the closed position. For example, although in the above embodiments, the blocking elements form a 45 degree angle, a greater or smaller angle may be used. In preferred embodiments, the angle is at least 30 degrees from the horizontal. In more preferred embodiments, the angle is at least 40 degrees, and more preferably 45 degrees to the horizontal. In alternative embodiments, the angle is greater than 45 degrees to the horizontal.
Note in the above embodiments that the blocking elements have bent portions at one or more edges. These also form substantial angles with the horizontal in all positions. Preferably the angles are greater than 45 degrees.
FIG. 8 shows a damper configuration 160 with damper blocking elements that are trough shaped with bends 164 providing rigidity and no bends on the upstream 166 and downstream 162 edges. The bends 164 can extend the entire distance between the edges 162 and 166 or they can be interrupted, as shown, at one or more points along that distance.
Referring to FIG. 7 , preferably, grease conveyance 314 is provided below the damper 300 to carry grease that drips from the damper unit 300 . FIG. 7 shows the damper unit 300 mounted in a duct 316 of an exhaust hood 318 above an exhaust plenum 310 . The exhaust hood 318 is mounted over an appliance 320 that emits fumes. A controller 324 controls the damper unit 300 responsively to an indicator 312 which indicates the conditions of the exhaust stream or the operational state of the appliance 320 . In a preferred configuration, when the appliance 320 is on, the damper 300 is controlled by a controller 324 such that it never fully closes and continues to drain grease generated by the appliance back into the hood grease conveyance or the plenum, depending on the configuration. However, when the appliance is off, the damper fully closes to seal the ductwork to prevent outside air from getting pulled back into the ductwork and into the interior space in which the exhaust hood 318 is located. It is believed that this provides the benefit of reducing the load on any space conditioning system responsible for maintaining enthalpy conditions in the interior space. The indicator 312 may include a cooking sensor (such as an infrared sensor, direct communication with the appliances, etc.), gas sensor, opacity sensor, temperature sensor or any device that can indicate whether exhaust flow is required to eliminate fumes. Loads can be detected in other indirect ways, for example by detecting the fuel or electricity consumed by an appliance, the time of day, or the number of orders placed for cooked food.
U.S. Pat. Nos. 6,170,480 and 6,899,095, which are hereby incorporated by reference as if fully set forth in their entireties herein, illustrate various ways to detect the amount of fumes in an exhaust system that may be used to control the damper units of the above embodiments. These documents also discuss applications for a damper, such as balancing of hoods mounted to a common exhaust. The embodiments of the invention can be used with these applications.
It is, therefore, apparent that there is provided, in accordance with the present disclosure, a damper suitable for liquid aerosol-laden flow streams and associated methods. Many alternatives, modifications, and variations are enabled by the present disclosure. Features of the disclosed embodiments can be combined, rearranged, omitted, etc. within the scope of the invention to produce additional embodiments. Furthermore, certain features of the disclosed embodiments may sometimes be used to advantage without a corresponding use of other features. Accordingly, Applicants intend to embrace all such alternatives, modifications, equivalents, and variations that are within the spirit and scope of this invention. | A flow control device has a duct section with a plurality of damper blocking elements, each having a major plane. The damper blocking elements are pivotably connected to the duct section and movable in a range that is limited to ensure that, when the duct section is mounted in a preferred orientation, the damper blocking element major planes always form an angle of at least 45 degrees from the horizontal throughout the range. The range is such that the plurality of damper blocking elements can selectively close and open the duct. The blocking elements can completely close the duct, for example, to block natural convection. | 5 |
This Application is a DIV of Ser. No. 10/399,282 filed on Apr. 16, 2003, now U.S. Pat. No. 7,025,200, which is a 371 of PCT/EP01/12300 filed on Oct. 24, 2001.
BACKGROUND OF THE INVENTION
The present invention relates to a bottle for two-component extemporaneous products.
In the pharmaceutical sector there are products composed of two substances that are mixed together just before administering the products; the individual separated substances in fact remain stable longer than the product obtained from them.
One of the two substances is generally in powder or granular form and the other is in liquid form; the former dissolves or disperses in the latter.
Single- or multiple-dose bottles for two-component extemporaneous products are known which comprise a container for one of the two components that is provided with a mouth in which a reservoir of the other component is inserted hermetically; the reservoir is open in an upward region and its bottom is constituted by a membrane-like diaphragm that separates the reservoir from the container.
Known bottles further comprise a closure cap that is fixed to the container and is provided with a perforator that is internal and coaxial thereto and is partially inserted hermetically in the reservoir.
The cap is usually constituted by three portions: a lower annular portion, which is fixed to the outer walls of the mouth of the container; an upper portion, which is constituted by a hood that is coaxial to the perforator; and an intermediate portion, which is constituted by sealing means such as a removable annular band that is connected to the lower and upper portions along respective fracture lines and is provided with a grip tab; the elimination of such band by tearing disengages the upper portion from the lower one.
In order to prepare the product to be administered, it is necessary to tear off and eliminate the band and apply pressure to the head of the hood; the hood moves towards the container, while the perforator descends into the reservoir and tears its diaphragm-like bottom.
In this manner, the component contained in the reservoir is poured into the container, where it mixes with the other component in order to prepare the product to be administered.
As an alternative, the cap is partially screwed onto the outer walls of the mouth of the container and is provided with sealing means such as an annular band; in order to prepare the product, it is necessary to eliminate the sealing means and screw the cap more tightly in order to make the perforator descend into the reservoir until it tears the diaphragm-like bottom.
In single-dose bottles, the perforator is fixed to the cap; the elimination of the cap in order to open the bottle accordingly entails extracting the perforator from the reservoir.
In this last case, however, the torn diaphragm tends to return to a substantially horizontal position, thus hindering the complete dispensing of the prepared product.
Known types of bottle, therefore, are not devoid of drawbacks, including the fact that they make it very time-consuming and difficult to prepare the two-component product to be administered and they entail significant consumption and waste of materials.
Preparation of the product in fact entails a first operation for eliminating the sealing means (the annular band) and a second operation for moving the hood towards the container, by pushing or screwing it on, so that the perforator tears the diaphragm.
The sealing means to be eliminated entail consumption of material and constitute waste material that is difficult to recover.
Another disadvantage of known types of single-dose bottle is constituted by the fact that they do not allow complete dispensing of the product prepared in them, since after the perforator is eliminated together with the cap the diaphragm tends to close the reservoir again.
SUMMARY OF THE INVENTION
The aim of the present invention is to eliminate the above noted drawbacks of known bottles by providing a bottle for two-component extemporaneous products that allows the preparation of the product to be administered to become quick, simple and manually easy and allows to contain the consumption and waste of material.
An object of the present invention is to allow full dispensing of the products prepared in individual administration doses, thus ensuring that they are taken fully by their users.
Within this aim, another object of the present invention is to provide a structure that is simple, relatively easy to provide in practice, safe in use, effective in operation, and relatively low in cost.
This aim and these and other objects which will become better apparent hereinafter are achieved by the present bottle for two-component extemporaneous products, of the type that comprises: a container for a first component, which is provided with an upper mouth; a reservoir for containing a second component, which is inserted substantially coaxially in said mouth, is open upward and has a bottom constituted by a diaphragm; a perforator, which can be inserted in said reservoir and is suitable to pierce said diaphragm in order to mix the two components; and a removable cap for closing the container in an upward region, characterized in that said cap comprises a lower annular portion that is fixed to said container and an upper cylindrical portion that is suitable to cooperate with said perforator and is rigidly coupled to said annular portion at an intermediate weakened region suitable to act as sealing means, a downward pressure on said cylindrical portion being suitable to disengage it from said annular portion and to make said perforator slide in said reservoir in order to pierce the underlying diaphragm.
BRIEF DESCRIPTION OF THE DRAWINGS
Further characteristics and advantages of the present invention will become better apparent from the detailed description of a preferred but not exclusive embodiment of a bottle for two-component extemporaneous products, illustrated only by way of non-limitative example in the accompanying drawings, wherein:
FIG. 1 is a longitudinal sectional view of a bottle according to the invention before the preparation of the product to be administered;
FIG. 2 is an enlarged-scale view of the upper portion of the bottle of FIG. 1 after piercing the diaphragm to prepare the product to be administered;
FIG. 3 is a view of the upper portion of the bottle of FIG. 2 , open in order to dispense the prepared product;
FIG. 4 is a perspective view of the bottle of FIG. 1 ;
FIG. 5 is a longitudinal sectional view of the perforator of the bottle of FIG. 1 ;
FIG. 6 is a longitudinal sectional view of the reservoir of the bottle of FIG. 1 ;
FIG. 7 is a longitudinal sectional view of the closure cap of the bottle of FIG. 1 ;
FIG. 8 is a longitudinal sectional view of a further embodiment of the bottle according to the invention before the preparation of the product to be administered;
FIG. 9 is a view of the bottle of FIG. 8 after piercing the diaphragm to prepare the product to be administered;
FIG. 10 is a view of the bottle of FIG. 9 , open in order to dispense the prepared product;
FIG. 11 is a longitudinal sectional view of the container of the bottle of FIG. 8 ;
FIG. 12 is a longitudinal sectional view of the closure cap of the bottle of FIG. 8 ;
FIG. 13 is a longitudinal sectional view of the reservoir of the bottle of FIG. 8 .
DESCRIPTION OF THE PREFERRED EMBODIMENTS
With reference to the figures, the reference numeral 1 generally designates a bottle for two-component extemporaneous products such as, for example, pharmaceutical products and drugs composed of two substances, generally one in powder form P and one in liquid form L, which are mixed at the time of their first administration in order to produce a final product S.
In the embodiment shown in FIGS. 1 to 7 , the bottle 1 comprises a container 2 that is filled with a preset amount of liquid L and is provided, in an upward region, with a neck 3 in which a mouth 4 is formed.
A reservoir 5 , which contains a preset amount of powder P, is inserted hermetically in the mouth 4 ; the reservoir 5 is shaped like a hollow cylinder and is coaxial to the mouth 4 , has an open upper face 5 a and a lower face 5 b that is closed by a diaphragm 6 that separates it and isolates it from the container 2 , and is provided externally with longitudinal ridges 7 for resting on the upper rim of the neck 3 .
The diaphragm 6 is like a membrane that is connected peripherally to the edge of the lower face 5 b along a preset tear line 8 .
A perforator 9 , such as a tubular body, is inserted coaxially and slidingly in the reservoir 5 and has, in an upward region, an abutment collar 10 and, in a downward region, a beveled piercing profile 11 that is suitable to tear the diaphragm 6 at the line 8 .
The bottle 1 further comprises a removable cap 12 that closes in an upward region the container 1 and is constituted by a lower annular portion 13 , which externally surrounds the neck 3 to which it is fixed, and by an upper cylindrical portion 14 , which is suitable to cooperate with the perforator 9 ; the inside diameter of the annular portion 13 is greater than the outside diameter of the cylindrical portion 14 .
The two portions 13 and 14 are arranged coaxially to the reservoir 5 and, by having different diameters, form a horizontal annular base 15 at which they are mutually coupled along a weakened intermediate region constituted for example by a prefracture line 16 that is suitable to act as a means for sealing the bottle.
The annular portion 13 is fixed to the neck 3 by way of interlocking coupling means that are constituted by an annular tooth 17 that is provided so as to protrude on the inner lateral wall of the annular portion 13 and enters by interlocking in a corresponding recess 18 formed at the base of the outer side wall of the neck 3 .
The cylindrical portion 14 is shaped like a hollow cylindrical body, whose upper end 14 a is closed and whose lower end 14 b is open and protrudes inside the annular portion 13 .
A frustum-shaped circumferential expansion 19 is formed on the outer lateral wall of the cylindrical portion 14 ; its smaller end face is directed towards the upper end 14 a and its larger end face is coupled to the annular base 15 at the prefracture line 16 .
A downward axial pressure on the cylindrical portion 14 is sufficient to uncouple it from the annular portion 13 by breaking the sealing means formed by the line 16 .
FIG. 1 illustrates a bottle 1 as packaged before the preparation of the product S, in which the annular portion 13 is fixed to the neck 3 and is still rigidly coupled to the cylindrical portion 14 , whose lower end 14 b is partially inserted in the top of the perforator 9 .
By applying a downward pressure to the cylindrical portion 14 ( FIG. 2 ), the sealing means formed by the line 16 are broken and the cylindrical portion 14 is uncoupled from the annular one 13 , which remains anchored to the neck 3 .
By continuing to apply the pressure, the uncoupled cylindrical portion 14 slides inside the annular portion 13 and the lower end 14 b penetrates further into the perforator 9 until the larger end face of the expansion 19 abuts against the collar 10 .
Then the perforator 9 , pushed by the cylindrical portion 14 , slides inside the reservoir 5 , descending and piercing the diaphragm 6 along the line 8 .
The sliding stroke of the perforator 9 is determined by a stroke limiting surface 20 , which is formed on the inner wall of the reservoir 5 and against which the collar 10 abuts; said stroke is such as to tear the diaphragm 6 along a preset circular arc, so that the tom diaphragm 6 remains attached to the reservoir 5 at at least one point 21 .
The lower end face 5 b of the reservoir is thus opened and the powder P is poured by gravity into the container 2 , where it mixes with the liquid L; the product S is ready for administration.
Advantageously, the reservoir 5 is internally provided with a seat 22 for the interlocking insertion of the collar 10 , which is formed at the stroke limiting surface 20 ; once the diaphragm 6 has been torn, the collar 10 interlocks in the seat 22 , stably anchoring the perforator 9 to the reservoir 5 .
The bottle 1 is opened ( FIG. 3 ) by pulling out and removing the cylindrical portion 14 : the perforator 9 remains fixed to the reservoir 5 and thus keeps the torn diaphragm 6 lowered, preventing it from closing the lower flat surface 5 b and hindering the dispensing of the product S.
The cylindrical portion 14 can be used to reclose the open bottle 1 , since its lower end 14 b can be inserted hermetically in the perforator 9 .
FIGS. 8 to 13 illustrate an alternative embodiment of the bottle 1 .
In such alternative embodiment, the bottle 1 comprises a container 23 for the liquid L that is provided, in an upward region, with a neck 24 in which a mouth 25 is formed.
A reservoir 26 , which contains the powder P, is inserted hermetically in the mouth 25 ; the reservoir 26 is shaped like a hollow cylinder whose upper end face 26 a is open and whose lower end face 26 b is closed by a diaphragm 27 that isolates it and separates it from the container 23 .
The diaphragm 27 is of the membrane type and is connected to the edge of the lower end face 26 b along a preset fracture line 28 .
The bottle 1 further comprises a removable cap 29 , which closes in an upward region the container 23 and is constituted by a lower annular portion 30 , which externally surrounds the neck 24 to which it is fixed, and by an upper cylindrical portion 31 .
The two portions 30 and 31 are coaxial to the reservoir 26 and are mutually coupled at a weakened intermediate region 32 constituted by a prefracture line 33 .
The annular portion 30 is fixed to the neck 24 by way of interlocking coupling means constituted by an annular tooth 34 that is formed so as to protrude on its inner lateral surface and interlocks in a corresponding recess 35 formed in the outer side wall of the neck 24 .
The annular base 32 is internally provided with a vertical circumferential tooth 36 that engages a corresponding notch 37 formed in the upper rim of the reservoir 26 .
The cylindrical portion 31 is constituted by an internally hollow elongated cylindrical body 38 , in which the upper end 38 a is closed and the lower end 38 b is open and protrudes into the annular portion 30 and directly enters the reservoir 26 coaxially and slidingly; the edge of the lower end 38 b is constituted by a beveled piercing profile 39 .
The lower end 38 b thus acts as a perforator; in this embodiment of the bottle 1 , therefore, the upper cylindrical portion of the closure cap and the perforator of the diaphragm are provided monolithically as the body 38 .
Conveniently, on the outer side wall of the lower end 38 b there is a lower annular step 40 and an upper annular step 41 , while the reservoir 26 is internally provided with a complementary annular seat 42 .
FIG. 8 illustrates the bottle 1 in the alternative embodiment, as packaged before preparing the product S.
The annular portion 30 is fixed to the neck 24 and is rigidly coupled to the body 38 at the line 33 ; the lower piercing end 38 b of the body 38 is slidingly inserted in the reservoir 26 and the lower step 40 is engaged in the annular seat 42 .
By applying a downward axial pressure to the top of the body 38 , the sealing means formed by the line 33 are broken and the body 38 is disengaged from the annular portion 30 , which remains anchored to the neck 24 .
By continuing to apply the pressure ( FIG. 9 ), the body 38 slides within the reservoir 26 and the profile 39 tears the diaphragm 27 at the line 28 .
The profile 39 is such as to tear the diaphragm 27 along a circular arc, so that once it has been torn it remains attached to the rim of the lower end face 26 b in at least one point 43 .
The sliding of the body 38 stops when the upper step 41 engages the annular seat 42 .
The lower end face 26 b of the reservoir is thus open and the powder P pours by gravity into the container 23 , where it mixes with the liquid L.
The bottle 1 ( FIG. 10 ) is opened by pulling out and removing the body 38 from the reservoir 26 .
Conveniently, the body 38 can be inserted again in the reservoir 26 and removed from it to subsequently close and open the bottle 1 and can be used as a measurer for the product S, since it is provided with a plurality of reference notches 44 for the level of the product S.
In practice it has been found that the described invention achieves the proposed aim and objects.
The invention thus conceived is susceptible of numerous modifications and variations, all of which are within the scope of the appended claims.
All the details may further be replaced with other technically equivalent ones.
In practice, the materials employed, as well as the shapes and the dimensions, may be any according to requirements without thereby abandoning the scope of the protection of the appended claims.
The disclosures in Italian Patent Application No. MO2000A000233 from which this application claims priority are incorporated herein by reference. | A bottle for two-component extemporaneous products, of the type that comprises: a container for a first component, which is provided with an upper mouth; a reservoir for containing a second component, which is inserted substantially coaxially in the mouth, is open upward and has a bottom constituted by a diaphragm; a perforator, which can be inserted in the reservoir and is adapted to pierce the diaphragm in order to mix the two components; and a removable cap for closing the container in an upward region; the cap comprises a lower annular portion that is fixed to the container and an upper cylindrical portion that cooperates with the perforator and is rigidly coupled to the annular portion at an intermediate weakened region suitable to act as sealing means, a downward pressure on the cylindrical portion being adapted to disengage it from the annular portion and to make the perforator slide in the reservoir in order to pierce the underlying diaphragm. | 0 |
FIELD OF INVENTION
[0001] The present invention relates to a fan blade for a gas turbine engine.
BACKGROUND
[0002] Turbofan gas turbine engines (which may be referred to simply as ‘turbofans’) are typically employed to power aircraft. Turbofans are particularly useful on commercial aircraft where fuel consumption is a primary concern. Typically a turbofan gas turbine engine will comprise an axial fan driven by an engine core. The engine core is generally made up of one or more turbines which drive respective compressors via coaxial shafts. The fan is usually driven directly off an additional lower pressure turbine in the engine core.
[0003] The fan comprises an array of radially extending fan blades mounted on a rotor and will usually provide, in current high bypass gas turbine engines, around seventy-five percent of the overall thrust generated by the gas turbine engine. The remaining portion of air from the fan is ingested by the engine core and is further compressed, combusted, accelerated and exhausted through a nozzle. The engine core exhaust mixes with the remaining portion of relatively high-volume, low-velocity air bypassing the engine core through a bypass duct.
[0004] Conventionally the fan blades are manufactured from a metallic material, such as titanium. The titanium blades generally have a honeycomb centre or a diffusion bonded super plastically formed internal structure so that the weight of the blades can be reduced.
[0005] In recent years there has been a move towards manufacturing blades from composite (non-metallic) materials. Composite materials are generally lighter than titanium alloys, but generally this weight benefit is not seen by the fan blade (or not seen to a great extent) because the fan blade needs to be made as a solid component to meet the strength requirements for a blade.
[0006] U.S. Pat. No. 6,431,837 discloses a composite fan blade having an internal structure that defines four hollow sections. However, there is a desire in the industry to provide a fan blade having improved impact performance and reduced weight compared to the fan blade described in U.S. Pat. No. 6 , 431 , 837 .
SUMMARY OF INVENTION
[0007] The invention seeks to provide a composite fan blade having reduced weight and/or improved impact performance (e.g. in the event of bird strike) compared to fan blades of the prior art.
[0008] A first aspect of the invention provides a composite fan blade for a gas turbine engine. The blade comprises a root portion for connecting the blade to a hub and an aerofoil portion. The aerofoil portion comprises an external cover formed from a non-metallic material and an internal structure enclosed within the cover. The internal structure comprises a plurality of support members extending generally from a pressure side of the internal structure to a suction side of the internal structure. The plurality of support members define a plurality of cells or channels.
[0009] The support members may be walls. The support members or walls may define a plurality of directly adjacent cells or channels.
[0010] A second aspect of the invention provides a composite fan blade for a gas turbine engine. The blade comprises a root portion for connecting the blade to a hub, and an aerofoil portion. The aerofoil portion comprises an external cover formed from a non-metallic material and an internal structure enclosed within the cover. The internal structure defines a plurality of walls that define a plurality of directly adjacent cells or channels.
[0011] The support members or walls of the first and/or the second aspect can increase the stiffness of the blade and the cellular structure can increase energy absorption if the blade is impacted either by a foreign object such as bird or by a released fan blade.
[0012] The cover may also be referred to in the art as a skin.
[0013] One or more of the following optional features may be applied to the first or second aspects.
[0014] At least one of the walls may have a maximum dimension (e.g. thickness, length or width) in a direction lateral to the external cover at a corresponding radial and circumferential position on the cover.
[0015] Open space of the cells or channels of the internal structure may occupy a volume greater than the volume of the support members or the walls defining the cells or channels. For example, the support members or walls provide reinforcement to the hollow structure rather than providing a solid structure that defines holes.
[0016] The internal structure may define at least 10 cells or channels.
[0017] The thickness of the walls or support members may be narrower than the width of the cells or channels, when measured in the same direction.
[0018] At least a portion of the cells of the internal structure may be open cells.
[0019] The cells may be arranged irregularly. For example, the structure may be referred to as an irregular cellular structure. The cellular structure may be open or closed.
[0020] Tests have found that providing an irregular cell structure can further increase the stiffness and energy absorption capability of the blade. A particularly beneficial cell structure may resemble that of a trabecular bone (e.g. a human trabecular bone).
[0021] The inventors of the present invention have taken a step away from the prejudice in the art towards the more conventional fan blade designs, and have realised that stiffness and energy absorption properties of the blade can be improved and the weight of the blade reduced by using an internal structure having an arrangement similar to that found in nature, e.g. in the human bone.
[0022] At least a portion of the cells may be closed cells.
[0023] The cells may be regularly arranged.
[0024] The internal structure may have a honeycomb structure.
[0025] The internal structure may include a plate having a waved profile so as to form a series of elongate channels.
[0026] The internal structure may comprise aluminium and/or titanium, e.g. the internal structure may be made from aluminium or titanium or an alloy thereof.
[0027] The internal structure may be made from a composite material.
[0028] The cover and the root portion may be defined by two members and the internal structure may be positioned between the two members.
[0029] The two members may be connected to the internal structure by bonding or via a connector.
[0030] The two members may be connected using stitching or pinning. The internal structure may be connected to the cover using adhesive.
[0031] The blade may have a metallic leading edge and/or a metallic blade tip.
[0032] A third aspect of the invention provides a method of manufacturing a composite fan blade having a root portion and an aerofoil portion. The method may comprise the steps of providing a cover defining at least part of the aerofoil portion, the cover being made from a composite non-metallic material. Providing an internal supporting structure and surrounding the internal supporting structure with the cover and joining the internal structure to the cover.
[0033] Manufacturing the cover and the internal supporting structure as separate components which are then connected together means that it is possible for the internal supporting structure to have more complex geometry. The complex geometry can be selected for improved stiffness of the blade and increased energy absorption during impact. Current methods of manufacturing a composite blade with a hollow portion, e.g. forming a hollow structure using an inflated balloon, are not capable of forming such complex geometry (e.g. the current methods are not capable of forming closely spaced small cell structures).
[0034] The internal supporting structure may be manufactured using additive layer manufacturing.
[0035] The internal structure may be made using machining, superplastic forming or injection moulding.
[0036] The internal supporting structure may be made from a composite (non-metallic) material or may be made from a metallic material, for example titanium or aluminium or an alloy thereof.
[0037] The additive layer manufacturing may be powder-bed additive layer manufacturing. Powder bed additive manufacturing may be particularly suitable for forming an open cell structure.
[0038] The internal structure may be formed from a gas blown polymer foam. The gas blown polymer foam may have a closed cell structure.
[0039] The blade may be the blade of the first or second aspects.
[0040] A fourth aspect of the invention provides a gas turbine engine comprising the blade of the first or second aspects.
DESCRIPTION OF DRAWINGS
[0041] The invention will now be described, by way of example only, with reference to the accompanying drawings in which:
[0042] FIG. 1 illustrates a cross-section axial view of a gas turbine engine;
[0043] FIG. 2 illustrates a side view of a fan blade;
[0044] FIG. 3 illustrates an exploded view of a fan blade; and
[0045] FIGS. 4 to 6 illustrates alternative internal structures for the fan blade of FIG. 3 .
DETAILED DESCRIPTION
[0046] With reference to FIG. 1 a bypass gas turbine engine is indicated at 10 . The engine 10 comprises, in axial flow series, an air intake duct 11 , fan 12 , a bypass duct 13 , an intermediate pressure compressor 14 , a high pressure compressor 16 , a combustor 18 , a high pressure turbine 20 , an intermediate pressure turbine 22 , a low pressure turbine 24 and an exhaust nozzle 25 . The fan 12 , compressors 14 , 16 and turbines 20 , 22 , 24 all rotate about the major axis of the gas turbine engine 10 and so define the axial direction of the gas turbine engine.
[0047] Air is drawn through the air intake duct 11 by the fan 12 where it is accelerated. A significant portion of the airflow is discharged through the bypass duct 13 generating a corresponding portion of the engine thrust. The remainder is drawn through the intermediate pressure compressor 14 into what is termed the core of the engine 10 where the air is compressed. A further stage of compression takes place in the high pressure compressor 16 before the air is mixed with fuel and burned in the combustor 18 . The resulting hot working fluid is discharged through the high pressure turbine 20 , the intermediate pressure turbine 22 and the low pressure turbine 24 in series where work is extracted from the working fluid. The work extracted drives the intake fan 12 , the intermediate pressure compressor 14 and the high pressure compressor 16 via shafts 26 , 28 , 30 . The working fluid, which has reduced in pressure and temperature, is then expelled through the exhaust nozzle 25 generating the remainder of the engine thrust.
[0048] The intake fan 12 comprises an array of radially extending fan blades 40 that are mounted to the shaft 26 . The shaft 26 may be considered a hub at the position where the fan blades 40 are mounted. FIG. 1 shows that the fan 12 is surrounded by a fan containment system 39 that also forms one wall or a part of the bypass duct 13 .
[0049] In the present application a forward direction (indicated by arrow F in FIG. 3 ) and a rearward direction (indicated by arrow R in FIG. 3 ) are defined in terms of axial airflow through the engine 10 .
[0050] Referring to FIG. 2 , the fan blades 40 each comprise an aerofoil portion 42 having a leading edge 44 , a trailing edge 46 , a concave pressure surface wall 48 extending from the leading edge to the trailing edge and a convex suction surface wall (not shown in FIG. 2 but indicated at 50 in FIG. 3 ) extending from the leading edge to the trailing edge. The fan blade has a root 52 , which may be hollow, the fan blade may also have an integral platform 54 which may be hollow or ribbed for out of plane bending stiffness. The fan blade includes a metallic leading edge and a metallic tip. Methods of connecting a metallic leading edge and a metallic tip to a composite blade are known in the art so are not described in detail here.
[0051] Referring now to FIG. 3 , the fan blade includes a cover or a skin and an internal structure 56 . The internal structure is encased within the cover. The cover is provided in two parts 58 , 60 ; one part of the cover defining the suction surface wall of the blade and one part of the cover defining the pressure surface wall of the blade. In the present embodiment the root portion is formed integrally with the cover and is also formed in two parts. The two parts of the cover are joined together to define the aerofoil and the root portion of the blade. In alternative embodiments, the root may be formed separately to the cover and later joined to the cover.
[0052] Referring now to FIGS. 4 to 6 , various arrangements for the internal structure 56 are shown in more detail.
[0053] In the embodiment shown in FIG. 4 , the internal structure is cellulous. The cells are open. The cells are arranged in an irregular manner. The design of the internal structure is similar to open cell structures found in nature, for example the cellular structure of bone.
[0054] In the embodiment shown in FIG. 5 , the internal structure is again cellulous, but this time the cells are closed. The cells are arranged in a regular arrangement. The design of the internal structure would be recognised in the art as a honeycomb structure.
[0055] In the embodiment shown in FIG. 6 , the internal structure forms a series of channels along the length of the blade. The internal structure is formed from a sheet having a waved profile. The internal structure and the cover together defining the perimeter walls of the blade.
[0056] As can be seen in each of these embodiments, the width of the walls defining the cells is relatively thin compared to the width of the cells. Further it can be seen that the cells are closely packed together. The cells extend over substantially the full extent of the aerofoil portion of the blade. The size of the cells and the close arrangement of the cells contribute to energy absorption in the event of an impact from a foreign object such as a bird, or in the event of impact by a released fan blade. The arrangements shown have also been found to provide a desirable blade stiffness for improved aerodynamic efficiency and reduced noise. Furthermore, the arrangements shown in FIGS. 4 to 6 can result in a fan blade weighing less than fan blades of the prior art. As well as the direct weight saving from the blade, a blade of reduced weight may also mean that the weight of the fan containment system and/or the hub can be reduced.
[0057] The blade is manufactured by forming the two parts of the cover and the internal structure as separate components. The two parts of the cover are formed using composite (non-metallic material), e.g. using tape lay-up methods or other methods such as braiding. These methods are understood in the art so will not be described in more detail here.
[0058] The internal structure illustrated in FIG. 4 may be manufactured using additive layer manufacturing. The internal structure illustrated in FIG. 5 may be manufactured using additive layer manufacturing or using traditional honeycomb production techniques such as expansion, corrugation or moulding. The internal structure illustrated in FIG. 6 may be superplastically formed, injection moulded (e.g. metal injection moulded), machined, forged or manufactured using additive layer manufacturing.
[0059] The material of the internal structure may be composite, plastic or a metal such as aluminium or titanium (or an alloy of aluminium or titanium). The material can be selected using standard modelling techniques and/or basic experiments and will depend on factors such as engine size.
[0060] To assembly the blade, the internal structure is positioned between the two parts of the cover. The two parts of the cover are joined together and the internal structure is joined to the cover. The internal structure can be joined to the cover using, for example, adhesive or stitching. The two parts of the cover can be joined together using, for example, stitching or pinning.
[0061] Manufacturing the blade in three parts (two cover parts and the internal structure) means that the internal structure can have a more complex geometry than would otherwise be possible using currently known manufacturing techniques.
[0062] It will be appreciated by one skilled in the art that, where technical features have been described in association with one or more embodiments, this does not preclude the combination or replacement with features from other embodiments where this is appropriate. Furthermore, equivalent modifications and variations will be apparent to those skilled in the art from this disclosure. Accordingly, the exemplary embodiments of the invention set forth above are considered to be illustrative and not limiting. | A composite fan blade for a gas turbine engine, the blade comprises a root portion for connecting the blade to a hub and an aerofoil portion. The aerofoil portion comprises an external cover formed from a non-metallic material and an internal structure enclosed within the cover. The internal structure comprises a plurality of support members extending generally from a pressure side of the internal structure to a suction side of the internal structure, and wherein the plurality of support members define a plurality of cells or channels. | 8 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention generally relates to an image display apparatus, and particularly relates to a plasma display apparatus.
[0003] 2. Description of the Related Art
[0004] A plasma display panel has two glass substrates which have electrodes formed thereon and define a space therebetween that is filled with discharge gas, and generates electric discharge by applying voltages between the electrodes so as to induce light emission from fluorescent substance provided on the substrates in response to the ultraviolet light generated by the electric discharge, thereby displaying an image. Plasma display panels are widely used as large-screen display apparatuses due to the facts that a large-sized screen is easy to make, that the self-light-emission nature ensures high display quality, and that the response speed is high.
[0005] On a display panel, X electrodes and Y electrodes extending in parallel are formed, and address electrodes are provided to run perpendicularly to the X and Y electrodes. The X and Y electrodes serve to generate sustain discharges for display-purpose light emission. The sustain discharges are generated by applying voltage pulses repeatedly between the X electrodes and the Y electrode. The Y electrodes also serve as scan electrodes for use in the writing of display data. The address electrodes serve to select discharge cells that emit light, and apply address-voltage pulses responsive to display data in order to generate write discharge for selecting the discharge cells between the Y electrodes and the address electrodes.
[0006] FIG. 1 is a block diagram showing a main part of a related-art plasma display apparatus. A plasma display apparatus shown in FIG. 1 includes a plasma display panel 11 , an address-electrode drive circuit 12 , a Y-electrode drive circuit 13 , an X-electrode drive circuit 14 , a scan circuit 15 , a drive control circuit 16 , a signal processing circuit 17 , and an AC/DC power supply circuit 18 .
[0007] The signal processing circuit 17 receives a clock signal, display data, a vertical synchronizing signal, a horizontal synchronizing signal, etc., which are supplied from an external source, and performs various tasks such as the writing of RGB display data to a frame memory in response to the vertical synchronizing signal. The drive control circuit 16 controls the address-electrode drive circuit 12 , the Y-electrode drive circuit 13 , the X-electrode drive circuit 14 , and the scan circuit 15 to display the display data stored in the frame memory on the plasma display panel 11 .
[0008] Specifically, the drive control circuit 16 generates address control signals responsive to the display data in the frame memory in synchronization with the clock signal. The address control signals are supplied to the address-electrode drive circuit 12 . The drive control circuit 16 further generates scan driver control signals for controlling the scan circuit 15 in synchronization with the vertical synchronizing signal and the horizontal synchronizing signal. The scan driver control signals are supplied to the scan circuit 15 . The drive control circuit 16 further drives the Y-electrode drive circuit 13 and the X-electrode drive circuit 14 in synchronization with the vertical synchronizing signal and the horizontal synchronizing signal.
[0009] The address-electrode drive circuit 12 applies address-voltage pulses responsive to the display data to address electrodes A 1 through Am in synchronization with the clock signal. The Y-electrode drive circuit 13 drives Y electrodes Y 1 through Yn independently of each other via the scan circuit 15 . The X-electrode drive circuit 14 drives X electrodes X 1 through Xn all together.
[0010] Through the operations of the address-electrode drive circuit 12 , the Y-electrode drive circuit 13 , the X-electrode drive circuit 14 , and the scan circuit 15 , each display pixel is initialized in a reset period, followed by an address period in which pixels to be displayed are selected, and, in a sustain period that comes last, the selected pixels are caused to emit light.
[0011] In the reset period, a reset/address-voltage generating circuit inside the Y-electrode drive circuit 13 generates a reset voltage, so that the scan circuit 15 applies the reset voltage to all the Y electrodes Y 1 through Yn. Further, a reset voltage generated by a reset/address-voltage generating circuit inside the X-electrode drive circuit 14 is applied to all the X electrodes X 1 through Xn.
[0012] In the address period, the scan circuit 15 drives the Y electrodes Y 1 through Yn successively one by one based on the address voltage generated by the reset/address-voltage generating circuit of the Y-electrode drive circuit 13 , and, in conjunction therewith, the address-electrode drive circuit 12 applies address-voltage pulses for one horizontal line responsive to the display data to the address electrodes A 1 through Am. Cells to be displayed are selected in this manner, thereby controlling the display/non-display (selection/non-selection) of each display cell (pixel).
[0013] In the sustain period, sustain voltage pulses generated by a sustain-pulse circuit of the Y-electrode drive circuit 13 are applied to the Y electrodes Y 1 through Yn via the scan circuit 15 , and sustain voltage pulses generated by a sustain-pulse circuit of the X-electrode drive circuit 14 are applied to the X electrodes X 1 through Xn. The application of these sustain voltage pulses generates sustain discharge between an X electrode and a Y electrode at the cells selected as display cells. These sustain voltage pulses are generated based on a sustain voltage VS 0 . The AC/DC power supply circuit 18 converts a commercial AC power supply voltage into a DC power supply voltage, which is supplied as the sustain voltage VS 0 to the X-electrode drive circuit 14 via an electric cable 18 a . Further, the sustain voltage VS 0 is supplied from the X-electrode drive circuit 14 to the Y-electrode drive circuit 13 via an electric cable 18 b.
[0014] FIG. 2 is a drawing showing an example of the configuration of the related-art AC/DC power supply circuit 18 . The AC/DC power supply circuit 18 includes a rectifying circuit 21 , a pulse generating circuit 22 , a transformer 23 , a diode 24 , a light-emission device 25 , a light-detection device 26 , a smoothing condenser Cvs 0 , and resistors R 1 and R 2 serving as a voltage detection circuit.
[0015] The rectifying circuit 21 rectifies an AC voltage supplied from a commercial AC power supply, and supplies the rectified voltage to the pulse generating circuit 22 . The pulse generating circuit 22 generates a rectangular-pulse voltage waveform based on the rectified voltage supplied from the rectifying circuit 21 . This pulse voltage waveform causes an electric current to be generated at the output terminal of the transformer 23 . This electric current flows into the smoothing condenser Cvs 0 through the diode 24 , thereby charging the smoothing condenser Cvs 0 . A voltage between the opposite ends of the smoothing condenser Cvs 0 is divided by the resistors R 1 and R 2 , so that the light-emission device 25 emits light with intensity responsive to the divided voltage level. The light-detection device 26 receives light from the light-emission device 25 , and supplies a signal responsive to the intensity of the received light to the pulse generating circuit 22 . The pulse generating circuit 22 controls the generation of the pulses in response to the signal from the light-detection device 26 . This feedback control serves to adjust the voltage between the opposite ends of the smoothing condenser Cvs 0 to a predetermined voltage (i.e., to the sustain discharge voltage VS 0 ).
[0016] The transformer 23 transmits an electric power from the primary side to the secondary side via changes in magnetic flux, so that the input side and output side of the transformer 23 are not electrically connected with each other (i.e., not directly connected through an electrical conductor). An optical coupling unit 27 comprised of the light-emission device 25 and the light-detection device 26 transmits information from the input side to the output side via changes in light intensity, so that the input side and output side are not electrically connected with each other (i.e., not directly connected through an electrical conductor). In this manner, the primary side and the secondary side are electrically insulated from each other.
[0017] FIG. 3 is a drawing showing an example of the circuit configuration of the related-art X-electrode drive circuit 14 . The X-electrode drive circuit 14 includes an energy-supply-purpose condenser Cvs 1 , power MOS-field-effect transistors Q 1 through Q 4 , diodes D 1 and D 2 , inductors L 1 and L 2 , and a charge-collection-purpose condenser C 1 . An illustrated capacitance Cp 1 represents the capacitance of the plasma display panel 11 , and, in particular, is the capacitance of the X electrodes of the plasma display panel 11 . What is shown in FIG. 3 is a portion corresponding to the sustain circuit for generating sustain discharges that is provided in the X-electrode drive circuit 14 . The X-electrode drive circuit 14 further includes circuit portions for supplying the reset voltage and the like, which are omitted in FIG. 3 .
[0018] At the initial stage of the performing of sustain discharge, the capacitor Cp 1 has no electric charge accumulated therein and is placed at the ground potential while the charge-collection-purpose condenser C 1 has accumulated electric charge and exhibits a voltage of about VS 0 /2. In this state, the power MOS-field-effect transistor Q 3 is turned on to become conductive, so that the electric charge of the charge-collection-purpose condenser C 1 flows into the capacitor Cp 1 via the diode D 1 and the inductor L 1 . As a result, the capacitor Cp 1 exhibits a voltage of about VS 0 through the resonance of the inductor L 1 and the capacitor Cp 1 . Thereafter, in order to maintain the X electrodes of the plasma display panel 11 at a constant voltage, the power MOS-field-effect transistor Q 1 is turned on to supply the voltage VS 0 from the energy-supply-purpose condenser Cvs 1 to the plasma display panel 11 . Consequently, sustain discharge is generated. Here, the energy-supply-purpose condenser Cvs 1 receives the sustain-discharge voltage VS 0 supplied from the AC/DC power supply circuit 18 .
[0019] After this, the power MOS-field-effect transistor Q 1 is turned off, and the power MOS-field-effect transistor Q 4 is turned on, so that electric charge flows into the charge-collection-purpose condenser C 1 from the capacitor Cp 1 via the inductor L 2 and the diode D 2 . With this arrangement, the electric charge that has been used to charge the capacitor Cp 1 of the plasma display panel 11 can be collected. The power MOS-field-effect transistor Q 2 is then turned on to remove the electric charge of Cp 1 remaining after the collection, thereby setting the X electrodes to the ground potential.
[0020] FIG. 4 is a drawing showing a connection between the X-electrode drive circuit 14 and the AC/DC power supply circuit 18 in the related-art configuration. In FIG. 4 , the same elements as those of FIGS. 1 through 3 are referred to by the same numerals, and a description thereof will be omitted.
[0021] The AC/DC power supply circuit 18 is implemented on an AC/DC-power-supply circuit board 31 . The X-electrode drive circuit 14 is implemented on an X-electrode-drive circuit board 32 . The AC/DC-power-supply circuit board 31 and the X-electrode-drive circuit board 32 are separate boards, and the AC/DC power supply circuit 18 and the X-electrode drive circuit 14 on the respective boards are connected with each other via the electric cable 18 a.
[0022] In such a configuration, proper handling and storing of the electric cable 18 a are necessary, and, also, a thick cable is required to supply a high voltage (VS 0 ), which results in a cost increase. Further, since a voltage drop occurs when an electric current runs through the electric cable 18 a , there is a need to provide the energy-supply-purpose condenser Cvs 1 with a large capacity in the X-electrode drive circuit 14 , which results in a need for a large circuit-board area.
[0023] FIG. 5 is a drawing showing the arrangement of circuits of a related-art plasma display apparatus. What is shown in FIG. 3 is the plasma display panel 11 as viewed from the rear. Various circuits are arranged on the backside (i.e., opposite the display screen side) of the plasma display panel 11 .
[0024] The drive control circuit 16 , the signal processing circuit 17 , and the AC/DC power supply circuit 18 are arranged around the center of the plasma display panel 11 , and the X-electrode drive circuit 14 and the Y-electrode drive circuit 13 are arranged on the opposite sides of the plasma display panel 11 in such a manner as to keep balance. The address-electrode drive circuit 12 is arranged at the bottom of the plasma display panel 11 . The AC/DC power supply circuit 18 positioned at around the center supplies a power supply voltage to the X-electrode drive circuit 14 via the electric cable 18 a . Further, the power supply voltage is supplied from the X-electrode drive circuit 14 to the Y-electrode drive circuit 13 via the electric cable 18 b.
[0025] In the related-art configuration, there is a need to arrange the Y-electrode drive circuit 13 , the X-electrode drive circuit 14 , and the AC/DC power supply circuit 18 in such a manner as to keep proper balance between the left-hand side and the right-hand side as shown in FIG. 5 because these circuits are large and heavy. To this end, the required arrangement is such that the AC/DC power supply circuit 18 is positioned at the center, and supplies the power supply voltage via electric cables to the Y-electrode drive circuit 13 and the X-electrode drive circuit 14 positioned on the opposite sides, respectively. This arrangement, however, leads to a cost increase since a thick electric cable is necessary for the purpose of supplying a high voltage as previously described, and also requires a large circuit-board area since a voltage drop occurring upon the flowing of an electric current through the electric cable 18 a necessitates the provision of the energy-supply-purpose condenser Cvs 1 with a large capacity in the X-electrode drive circuit 14 .
[0026] Moreover, there has been a trend in recent years for plasma display panels to have an increased panel size in response to the demand for large-size screen display, which results in a further increase in the length of the electric cable 18 a.
[0027] [Patent Document 1] Japanese Patent Application Publication No. 2003-302932
[0028] Accordingly, there is a need for a plasma display apparatus for which the cost of an electric cable required to supply a power is reduced, and for which the problem of a voltage drop occurring upon the flowing of an electric current through the electric cable is obviated.
SUMMARY OF THE INVENTION
[0029] It is a general object of the present invention to provide a plasma display apparatus that substantially obviates one or more problems caused by the limitations and disadvantages of the related art.
[0030] Features and advantages of the present invention will be presented in the description which follows, and in part will become apparent from the description and the accompanying drawings, or may be learned by practice of the invention according to the teachings provided in the description. Objects as well as other features and advantages of the present invention will be realized and attained by a plasma display apparatus particularly pointed out in the specification in such full, clear, concise, and exact terms as to enable a person having ordinary skill in the art to practice the invention.
[0031] To achieve these and other advantages in accordance with the purpose of the invention, the invention provides a plasma display apparatus, which includes a display panel in which display cells are constituted at least by a set of electrodes including first electrodes extending in a first direction, second electrodes extending in the first direction, and third electrodes extending in a second direction substantially perpendicular to the first direction, a first drive circuit configured to drive the first electrodes, a second drive circuit configured to drive the second electrodes, a third drive circuit configured to drive the third electrodes in conjunction with successive scanning of the first electrodes, and a power-supply circuit configured to generate a DC voltage based on an AC voltage and to supply the DC voltage to the first drive circuit and the second drive circuit, wherein the power-supply circuit and a given drive circuit that is one of the first drive circuit and the second drive circuit are implemented on a single print circuit board.
[0032] According to another aspect of the present invention, a plasma display apparatus includes a display panel in which display cells are constituted at least by a set of electrodes including first electrodes extending in a first direction, second electrodes extending in the first direction, and third electrodes extending in a second direction substantially perpendicular to the first direction, a first drive circuit configured to drive the first electrodes, a second drive circuit configured to drive the second electrodes, a third drive circuit configured to drive the third electrodes in conjunction with successive scanning of the first electrodes, and a power-supply circuit configured to generate a DC voltage based on an AC voltage and to supply the DC voltage to the first drive circuit and the second drive circuit, a first print circuit board on which the power-supply circuit is implemented, and a second print circuit board on which a given drive circuit that is one of the first drive circuit and the second drive circuit is implemented, wherein the first print circuit board and the second print circuit board are placed side by side and connected via a circuit-board connector.
[0033] According to at least one embodiment of the present invention, the voltage generated by the power-supply circuit is supplied to the given drive circuit via printed wiring on the circuit board or via a circuit-board connector. The length of the printed wiring or the circuit-board connector is substantially shorter than the length of a related-art electric cable, so that a voltage drop caused by the flowing of an electric current can be ignored. Accordingly, the cost of an electric cable required to supply a power is reduced, and the problem of a voltage drop occurring upon the flowing of an electric current through this electric cable is obviated.
BRIEF DESCRIPTION OF THE DRAWINGS
[0034] Other objects and further features of the present invention will be apparent from the following detailed description when read in conjunction with the accompanying drawings, in which:
[0035] FIG. 1 is a block diagram showing a main part of a related-art plasma display apparatus;
[0036] FIG. 2 is a drawing showing an example of the configuration of a related-art AC/DC power supply circuit;
[0037] FIG. 3 is a drawing showing an example of the circuit configuration of a related-art X-electrode drive circuit;
[0038] FIG. 4 is a drawing showing a connection between the X-electrode drive circuit and the AC/DC power supply circuit in the related-art configuration;
[0039] FIG. 5 is a drawing showing the arrangement of circuits of a related-art plasma display apparatus;
[0040] FIG. 6 is a block diagram showing a main portion of a first embodiment of a plasma display apparatus according to the present invention;
[0041] FIG. 7 is a drawing showing an X-electrode drive circuit and an AC/DC power supply circuit implemented on the same circuit board;
[0042] FIG. 8 is a drawing showing a variation of the first embodiment of the plasma display apparatus according to the present invention;
[0043] FIG. 9 is a block diagram showing a main portion of a second embodiment of the plasma display apparatus according to the present invention;
[0044] FIG. 10 is a drawing showing a Y-electrode drive circuit and an AC/DC power supply circuit implemented on the same circuit board; and
[0045] FIG. 11 is a drawing showing a variation of the second embodiment of the plasma display apparatus according to the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0046] In the following, embodiments of the present invention will be described with reference to the accompanying drawings.
[0047] FIG. 6 is a block diagram showing a main portion of a first embodiment of a plasma display apparatus according to the present invention. A plasma display apparatus shown in FIG. 6 includes a plasma display panel 11 , an address-electrode drive circuit 12 , a Y-electrode drive circuit 13 , an X-electrode drive circuit 34 , a scan circuit 15 , a drive control circuit 16 , a signal processing circuit 17 , and an AC/DC power supply circuit 18 . In FIG. 6 , the same elements as those of FIG. 1 are referred to by the same numerals, and a description thereof will be omitted.
[0048] In the plasma display apparatus shown in FIG. 6 , the X-electrode drive circuit 34 is provided in place of the X-electrode drive circuit 14 , and the X-electrode drive circuit 34 and the AC/DC power supply circuit 18 are implemented on the same circuit board (print circuit board) 35 . The provision of the X-electrode drive circuit 34 and the AC/DC power supply circuit 18 on the same circuit board 35 eliminates the need for an electric cable that connects between these two circuits.
[0049] The configuration and operation of the plasma display panel 11 , the address-electrode drive circuit 12 , the Y-electrode drive circuit 13 , the scan circuit 15 , the drive control circuit 16 , and the signal processing circuit 17 shown in FIG. 6 are the same as the configuration and operation described in connection with FIG. 1 .
[0050] FIG. 7 is a drawing showing the X-electrode drive circuit 34 and the AC/DC power supply circuit 18 implemented on the circuit board 35 . In FIG. 7 , the same elements as those of FIG. 4 are referred to by the same numerals, and a description thereof will be omitted.
[0051] Since the AC/DC power supply circuit 18 and the X-electrode drive circuit 34 are implemented on the same circuit board 35 , the voltage VS 0 generated by the AC/DC power supply circuit 18 is supplied to the X-electrode drive circuit 34 via printed wiring 41 on the circuit board 35 . The length of the printed wiring 41 is substantially shorter than the length of the related-art electric cable 18 a , so that the voltage drop of the voltage VS 0 caused by an electric current running through the printed wiring 41 can be ignored.
[0052] The X-electrode drive circuit 34 has the same circuit configuration as the X-electrode drive circuit 14 , except that the energy-supply-purpose condenser Cvs 1 is removed. Since the voltage drop along the printed wiring 41 can almost completely be ignored in this case, the condenser Cvs 0 provided in the AC/DC power supply circuit 18 can be utilized as an energy-supply-purpose condenser, so that there is no need to provide another energy-supply-purpose condenser in the X-electrode drive circuit 34 .
[0053] The circuit configuration and operation of the AC/DC power supply circuit 18 are the same as the circuit configuration and operation described in connection with FIG. 2 . The circuit configuration and operation of the X-electrode drive circuit 34 are the same as the circuit configuration and operation described in connection with FIG. 3 , except that the condenser Cvs 0 is used as an energy-supply-purpose condenser.
[0054] Further, the transformer 23 transmits an electric power from the primary side to the secondary side via changes in magnetic flux (magnetic coupling), so that the input side and output side of the transformer 23 are not electrically connected with each other (i.e., not directly connected through an electrical conductor). Also, the optical coupling unit 27 comprised of the light-emission device 25 and the light-detection device 26 transmits information from the input side to the output side via changes in light intensity (optical coupling), so that the input side and output side are not electrically connected with each other (i.e., not directly connected through an electrical conductor). In this manner, the primary side (hot side) and the secondary side (cold side) are electrically insulated from each other.
[0055] FIG. 8 is a drawing showing a variation of the first embodiment of the plasma display apparatus according to the present invention. In FIG. 8 , the same elements as those of FIG. 7 are referred to by the same numerals, and a description thereof will be omitted.
[0056] In the configuration shown in FIG. 6 and FIG. 7 , the AC/DC power supply circuit 18 and the X-electrode drive circuit 34 are implemented on the same circuit board 35 , whereas in the variation shown in FIG. 8 , an AC/DC power supply circuit 18 A and an X-electrode drive circuit 34 A are implemented separately on an AC/DC-power-supply circuit board 36 and an X-electrode-drive circuit board 37 , respectively.
[0057] The AC/DC-power-supply circuit board 36 and the X-electrode-drive circuit board 37 are placed side by side, and are connected with each other through a circuit-board connector 42 and a circuit-board connector 43 . The voltage VS 0 generated by the AC/DC power supply circuit 18 A is supplied to the X-electrode drive circuit 34 A via the circuit-board connector 42 . The length of the circuit-board connector 42 is substantially shorter than the length of the related-art electric cable 18 a , so that the voltage drop of the voltage VS 0 caused by an electric current running through the circuit-board connector 42 can be ignored.
[0058] The X-electrode drive circuit 34 A has the same circuit configuration as the X-electrode drive circuit 14 , except that the energy-supply-purpose condenser Cvs 1 is removed and that resistors R 3 and R 4 are additionally provided. Since the voltage drop along the circuit-board connector 42 can almost completely be ignored in this case, the condenser Cvs 0 provided in the AC/DC power supply circuit 18 A can be utilized as an energy-supply-purpose condenser, so that there is no need to provide another energy-supply-purpose condenser in the X-electrode drive circuit 34 A.
[0059] The AC/DC power supply circuit 18 A has the same circuit configuration as the AC/DC power supply circuit 18 , except that a switching circuit 44 is provided. The function and operation of the switching circuit 44 will later be described.
[0060] The basic circuit configuration and operation of the AC/DC power supply circuit 18 A are the same as the circuit configuration and operation described in connection with FIG. 2 , except that the switching circuit 44 is provided. The basic circuit configuration and operation of the X-electrode drive circuit 34 A are the same as the circuit configuration and operation described in connection with FIG. 3 , except that the condenser Cvs 0 is used as an energy-supply-purpose condenser.
[0061] In the configuration shown in FIG. 7 , the AC/DC power supply circuit 18 and the X-electrode drive circuit 34 are implemented on the same circuit board 35 , whereas in the configuration shown in FIG. 8 , the AC/DC power supply circuit 18 A and the X-electrode drive circuit 34 A are implemented separately on the AC/DC-power-supply circuit board 36 and the X-electrode-drive circuit board 37 , respectively. With the provision of the AC/DC power supply circuit 18 A and the X-electrode drive circuit 34 A on the respective separate circuit boards, there is a merit in that no modification is necessary to the AC/DC-power-supply circuit board 36 carrying the AC/DC power supply circuit 18 A even when modification is made to the X-electrode drive circuit 34 A.
[0062] Various standards are defined for industrial products. The UL standard, for example, is provided by the UL that is a safety testing organization in the United States that performs an inspection and test relating to the safety of commercial products for the benefit of the public. The UL sets a standard relating to the danger of fire and electric shock caused by products, performs inspections and tests for individual products, and allows a UL mark to be attached to the products that passed its inspections and tests. In order to obtain a UL-standard approval for the AC/DC power supply circuit 18 that is implemented on the circuit board 35 , there is a need to submit the entirety of the circuit board 35 for inspection and to request inspections and tests to be conducted. If modification is made to the X-electrode drive circuit 34 on the circuit board 35 after the approval is obtained, such modification is considered as a modification to the circuit board 35 , so that a further inspection will need to be conducted for the entirety of the circuit board 35 .
[0063] With the configuration shown in FIG. 8 , on the other hand, the AC/DC power supply circuit 18 A and the X-electrode drive circuit 34 A are provided separately on the AC/DC-power-supply circuit board 36 and the X-electrode-drive circuit board 37 , respectively, so that no modification is necessary to the AC/DC-power-supply circuit board 36 carrying the AC/DC power supply circuit 18 A even when modification is made to the X-electrode drive circuit 34 A. Accordingly, once an approval is obtained for the AC/DC-power-supply circuit board 36 , there is no need to request an approval again, no matter what modification is thereafter made to the X-electrode drive circuit.
[0064] Moreover, the configuration shown in FIG. 8 is provided with the resistors R 3 and R 4 , which serve as a voltage detection circuit in the X-electrode drive circuit 34 A. The voltage VS 0 that appears between the opposite ends of the smoothing condenser Cvs 0 is divided by the resistors R 3 and R 4 . The divided voltage is supplied to the optical coupling unit 27 via the circuit-board connector 43 and the switching circuit 44 . In the optical coupling unit 27 , the light-emission device 25 emits light with the intensity responsive to the divided voltage level. The light-detection device 26 receives light from the light-emission device 25 , and supplies a signal responsive to the intensity of the received light to the pulse generating circuit 22 . The pulse generating circuit 22 controls the generation of the pulses in response to the signal from the light-detection device 26 . This feedback control serves to adjust the voltage between the opposite ends of the smoothing condenser Cvs 0 to a predetermined voltage (i.e., to the sustain discharge voltage VS 0 ).
[0065] Since the voltage VS 0 to be controlled is used in the X-electrode drive circuit 34 A, it is preferable to perform the feedback control based on the voltage level that is detected on the X-electrode-drive circuit board 37 where the X-electrode drive circuit 34 A is implemented (i.e., where the controlled voltage is actually used). Through such feedback control, it becomes possible to set the voltage VS 0 more accurately. The resistors R 3 and R 4 described above are provided to detect the voltage level of the voltage VS 0 (or, more accurately, the divided voltage level) on the X-electrode-drive circuit board 37 .
[0066] The switching circuit 44 selects an input from the X-electrode-drive circuit board 37 during the normal operation in which the plasma display apparatus is used by a user, and the selected input is supplied to the optical coupling unit 27 . The setting of the switching circuit 44 may be changed in response to a control signal applied to the switching circuit 44 according to need, so that the voltage level divided by the resistors R 1 and R 2 is selected for provision to the optical coupling unit 27 . The resistors R 1 and R 2 are not necessary for the purpose of the normal operation in which the plasma display apparatus is used by a user. Unless the resistors R 1 and R 2 are provided, however, an operation test cannot be conducted with the AC/DC-power-supply circuit board 36 alone.
[0067] In the AC/DC power supply circuit 18 A of FIG. 8 , the resistors R 1 and R 2 are provided on the AC/DC-power-supply circuit board 36 , and provision is made such that the switching circuit 44 allows feedback control to be performed based on the voltage detected by the resistors R 1 and R 2 . With this provision, it is possible to perform an operation test for the AC/DC power supply circuit 18 A even if the AC/DC-power-supply circuit board 36 is provided alone without a connection to the X-electrode-drive circuit board 37 .
[0068] FIG. 9 is a block diagram showing a main portion of a second embodiment of the plasma display apparatus according to the present invention. A plasma display apparatus shown in FIG. 9 includes a plasma display panel 11 , an address-electrode drive circuit 12 , a Y-electrode drive circuit 33 , an X-electrode drive circuit 14 , a scan circuit 15 , a drive control circuit 16 , a signal processing circuit 17 , and an AC/DC power supply circuit 18 . In FIG. 9 , the same elements as those of FIG. 1 are referred to by the same numerals, and a description thereof will be omitted.
[0069] In the plasma display apparatus shown in FIG. 9 , a Y-electrode drive circuit 33 is provided in place of the Y-electrode drive circuit 13 , and the Y-electrode drive circuit 33 and the AC/DC power supply circuit 18 are implemented on the same circuit board (print circuit board) 38 . The provision of the Y-electrode drive circuit 33 and the AC/DC power supply circuit 18 on the same circuit board 38 eliminates the need to handle and store an electric cable that supplies the sustain discharge voltage VS 0 to the Y-electrode drive circuit 33 .
[0070] In the configuration shown in FIG. 1 , the voltage VS 0 is supplied from the AC/DC power supply circuit 18 to the X-electrode drive circuit 14 via the electric cable 18 a , and is further supplied from the X-electrode drive circuit 14 to the Y-electrode drive circuit 13 via the electric cable 18 b . In the configuration shown in FIG. 9 , the voltage VS 0 is first supplied from the AC/DC power supply circuit 18 to the Y-electrode drive circuit 33 , and is then supplied from the Y-electrode drive circuit 33 to the X-electrode drive circuit 14 via the electric cable 18 b.
[0071] The configuration and operation of the plasma display panel 11 , the address-electrode drive circuit 12 , the X-electrode drive circuit 14 , the scan circuit 15 , the drive control circuit 16 , and the signal processing circuit 17 shown in FIG. 9 are the same as the configuration and operation described in connection with FIG. 1 .
[0072] FIG. 10 is a drawing showing the Y-electrode drive circuit 33 and the AC/DC power supply circuit 18 implemented on the circuit board 38 . In FIG. 10 , the same elements as those of FIG. 4 are referred to by the same numerals, and a description thereof will be omitted.
[0073] Since the AC/DC power supply circuit 18 and the Y-electrode drive circuit 33 are implemented on the same circuit board 38 , the voltage VS 0 generated by the AC/DC power supply circuit 18 is supplied to the Y-electrode drive circuit 33 via printed wiring on the circuit board 38 . The length of the printed wiring is short, so that the voltage drop of the voltage VS 0 caused by an electric current running through the printed wiring can be ignored.
[0074] In the related-art configuration shown in FIG. 1 , the Y-electrode drive circuit 13 and the X-electrode drive circuit 14 have the same circuit configuration for their sustain circuit portions for performing sustain discharge. Namely, the circuit configuration shown in FIG. 3 that shows a portion corresponding to the sustain circuit for generating sustain discharge that is included in the X-electrode drive circuit 14 is identical to the configuration of the sustain circuit of the Y-electrode drive circuit 13 .
[0075] The Y-electrode drive circuit 33 shown in FIG. 10 according to the present invention has the same circuit configuration as the related-art Y-electrode drive circuit 13 , except that the energy-supply-purpose condenser Cvs 1 is removed. Since the voltage drop along the printed wiring can almost completely be ignored in this case, the condenser Cvs 0 provided in the AC/DC power supply circuit 18 can be utilized as an energy-supply-purpose condenser, so that there is no need to provide another energy-supply-purpose condenser in the Y-electrode drive circuit 33 .
[0076] The circuit configuration and operation of the AC/DC power supply circuit 18 are the same as the circuit configuration and operation described in connection with FIG. 2 . The circuit configuration and operation of the Y-electrode drive circuit 33 relating to the sustain discharge are the same as the circuit configuration and operation described in connection with FIG. 3 , except that the condenser Cvs 0 is used as an energy-supply-purpose condenser.
[0077] Further, the transformer 23 transmits an electric power from the primary side to the secondary side via changes in magnetic flux, so that the input side and output side of the transformer 23 are not electrically connected with each other (i.e., not directly connected through an electrical conductor). Also, the optical coupling unit 27 comprised of the light-emission device 25 and the light-detection device 26 transmits information from the input side to the output side via changes in light intensity, so that the input side and output side are not electrically connected with each other (i.e., not directly connected through an electrical conductor). In this manner, the primary side (hot side) and the secondary side (cold side) are electrically insulated from each other.
[0078] FIG. 11 is a drawing showing a variation of the second embodiment of the plasma display apparatus according to the present invention. In FIG. 11 , the same elements as those of FIG. 10 are referred to by the same numerals, and a description thereof will be omitted.
[0079] In the configuration shown in FIG. 9 and FIG. 10 , the Y-electrode drive circuit 33 and the AC/DC power supply circuit 18 are implemented on the same circuit board 38 , whereas in the variation shown in FIG. 11 , an AC/DC power supply circuit 18 A and a Y-electrode drive circuit 33 A are implemented separately on an AC/DC-power-supply circuit board 36 and a Y-electrode-drive circuit board 39 , respectively.
[0080] The AC/DC-power-supply circuit board 36 and the Y-electrode-drive circuit board 39 are placed side by side, and are connected with each other through a circuit-board connector 46 and a circuit-board connector 47 . The voltage VS 0 generated by the AC/DC power supply circuit 18 A is supplied to the Y-electrode drive circuit 33 A via the circuit-board connector 46 . The length of the circuit-board connector 46 is short, so that the voltage drop of the voltage VS 0 caused by an electric current running through the circuit-board connector 46 can be ignored.
[0081] The Y-electrode drive circuit 33 A has the same circuit configuration as the Y-electrode drive circuit 13 , except that the energy-supply-purpose condenser Cvs 1 is removed and that resistors R 3 and R 4 are additionally provided. Since the voltage drop along the circuit-board connector 46 can almost completely be ignored in this case, the condenser Cvs 0 provided in the AC/DC power supply circuit 18 A can be utilized as an energy-supply-purpose condenser, so that there is no need to provide another energy-supply-purpose condenser in the Y-electrode drive circuit 33 A.
[0082] The AC/DC power supply circuit 18 A is the same circuit as the AC/DC power supply circuit 18 A described in connection with FIG. 8 , and has the same circuit configuration as the related-art AC/DC power supply circuit 18 , except that the switching circuit 44 is provided. The basic circuit configuration and operation of the sustain circuit of the Y-electrode drive circuit 33 A are the same as the circuit configuration and operation described in connection with FIG. 3 , except that the condenser Cvs 0 is used as an energy-supply-purpose condenser.
[0083] In the configuration shown in FIG. 10 , the AC/DC power supply circuit 18 and the Y-electrode drive circuit 33 are implemented on the same circuit board 38 , whereas in the configuration shown in FIG. 11 , the AC/DC power supply circuit 18 A and the Y-electrode drive circuit 33 A are implemented separately on the AC/DC-power-supply circuit board 36 and the Y-electrode-drive circuit board 39 , respectively. Accordingly, the same merits as those described in connection with FIG. 8 are provided with respect to circuit modification and standard approvals.
[0084] Further, in the configuration shown in FIG. 11 , the resistors R 3 and R 4 are provided to detect the voltage level of the voltage VS 0 (or, more accurately, the divided voltage level) on the Y-electrode-drive circuit board 39 . The switching circuit 44 selects a voltage from the Y-electrode-drive circuit board 39 during the normal operation in which the plasma display apparatus is used by a user, and the selected voltage is supplied to the optical coupling unit 27 . On the other hand, the switching circuit 44 selects a voltage level from the resistors R 1 and R 2 in the situation in which the AC/DC-power-supply circuit board 36 is provided alone without a connection to the Y-electrode-drive circuit board 39 , thereby making it possible to perform an operation test on the AC/DC power supply circuit 18 A alone. These advantages are the same as the merits described with respect to the configuration shown in FIG. 8 .
[0085] Further, the present invention is not limited to these embodiments, but various variations and modifications may be made without departing from the scope of the present invention.
[0086] The present application is based on Japanese priority application No. 2006-187100 filed on Jul. 6, 2006, with the Japanese Patent Office, the entire contents of which are hereby incorporated by reference. | A plasma display apparatus includes a display panel in which display cells are constituted at least by a set of electrodes including first electrodes extending in a first direction, second electrodes extending in the first direction, and third electrodes extending in a second direction substantially perpendicular to the first direction, a first drive circuit configured to drive the first electrodes, a second drive circuit configured to drive the second electrodes, a third drive circuit configured to drive the third electrodes in conjunction with successive scanning of the first electrodes, and a power-supply circuit configured to generate a DC voltage based on an AC voltage and to supply the DC voltage to the first drive circuit and the second drive circuit, wherein the power-supply circuit and a given drive circuit that is one of the first drive circuit and the second drive circuit are implemented on a single print circuit board. | 6 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a method of forming an oxide substance dielectrode thin film, and more particularly a method of manufacturing a ferroelectric capacitor using an oxide ferroelectric material.
2. Description of the Related Art
Material by using SrBi 2 Ta 2 O 9 , which is Bi based layer compound (hereinafter, a material in which composition is changed and a series of compound groups to which an addition substance is added or replaced are referred to as SBT) or Pb(Zr 1−x Ti x )O 3 , which is titanic acid zirconate (hereinafter, a material in which composition of the compound is changed and a series of compound groups to which addition such as La or Ca is added are referred to as PZT) is currently put practical in use as a ferroelectric material used in a ferroelectric capacitor.
A memory using ferroelectric capacitors has an advantage in that an operation is available with 5V or below without an internal increase pressure circuit, which is essential for the above non volatile memory while the memory has the same function as a non volatile memory as represented in a flash memory or an EEPROM.
In particular, generally resistance of an electric field of a SBT lowers and the SBT is superior in a saturated characteristic for an electric filed of a residual polarization of the SBT compared with the resistance of the electric field and the saturated characteristic of a PZT as a ferroelectric material. Thereby, it is deemed that the SBT is suitable for a low voltage operation.
The residual polarization value of the PZT rapidly lowers with thinner film than film of 3000 Å. The PZT shows clearly film thickness independency as aforementioned. Therefore, the PZT has a drawback that practical in use of a device to operate with a voltage, which is below 5V is difficult. In contrast, since the film thickness dependency of the SBT lowers compared with the PZT, the SBT has an advantage that the SBT is easily applied to a device as purpose of low voltage operation.
In fact, when the film thickness is gradually thin as purpose of low voltage operation in the SBT, a big problem in which a resist pressure for an impressed voltage is rapidly decreased occurs. It is deemed that as this reason, a trough and peak on a surface of the SBT is greatly related as shown in FIG. 1 .
FIG. 1 is a SEM photo of a ferroelectric capacitor in a conventional art, which sandwiches a SBT film by Pt electrodes. The trough and peaks on the surface reflects the trough and peak of the SBT film and an upper Pt electrode film goes into a space of the SBT film. Due to the troughs and peaks on the surface of the SBT, an extreme thin portion of a local area appears in the SBT film and an electric field is concentrated on that portion. As a result of this, breakdown voltage of the film is greatly decreased.
Roughness of the trough and peak on the surface of the SBT film is a common feature of a crystal structure of Bi based layer compound and roughness is ascribed to anisotropy of a crystal growing speed. In a conventional formation method of the SBT film, generally coking solution is made by a sol-gel method or by an organometallic decomposition method (MOD method), coking solution is coated on a substrate by a spin coat method, and an anneal step is perform at crystallization temperature. When a film with thickness around 150 nm is formed by this method, a difference between the trough and the peak of the film reaches 100 nm or more.
In general, when a ferroelectric film with desired thickness of 100 nm to 300 nm is formed by the spin coat method, a ferroelectric characteristic is improved and thereby any steps from a coating step to a crystallization heating step are repeated from twice to sixth times. When steps from the coating step to an organic solvent drying step, which have been reported are repeated, multiple spaces occur in the ferroelectric film at a time of a ferroelectric crystallization heating process and, therefore, there is a problem that a high quality film can not be formed. A metal organic substance can not be decomposed sufficiently in the heating process around 250° C. of which purpose is dry of organic solvent and in the film, the metal organic substance remains as it is. In that state, when the film is stacked and becomes thick, it is difficult to eliminate the metal organic substance from the organic film at a time of crystallization anneal after the film becomes thick and multiple spaces occur in the film from anisotropy of film contraction at a time of crystallization. As a result, leak resist pressure of the ferroelectric capacitor is reduced and a residual polarization value also lowers. Japanese Patent Application Laid-Open No. H8-340084 discloses that steps from a coating step to a drying step are repeated and therefore the aforementioned problem is apprehended. Similarly, Japanese Patent Application Laid-Open No. H9-69614 discloses that the multilayered film is formed in steps from the coating step to the drying step. Japanese Patent Application Laid-Open No. H9-153597 has a similar problem and proposes that a reduction pressure anneal method is used. However, cost for an apparatus is extremely expensive with respect to reducing a pressure of oxide with high temperature of 700° C. to 800° C. and, thereby the method is not suitable for mass manufacture.
There is a problem that only anneal step in a short time of a few minutes using a rapid heating method (RTA) can not obtain the ferroelectric characteristic sufficiently in a method to repeat a series of steps from the coating step to the heating step to decompose the organic substance or a series of steps from the coating step to the crystallization heating step (Japanese Patent Application Laid-Open No. H10-270646 discloses this method).
Though it is possible to suppress the growing of a grain by accelerating temperature increase rate using the RTA in some ranges and by dense crystallization nucleation of the ferroelectric film, there is a problem that a sufficient characteristic of the ferroelectric film can not be obtained when a heating time to crystallize the film is short. When the heating time in the RTA is simplify long to improve the film's characteristic, throughput becomes greatly worsen from a characteristic of an apparatus, a single wafer process and thereby, the method is not suitable for mass manufacture.
SUMMARY OF THE INVENTION
Therefore, it is an object of the present invention to provide a method of forming a ferroelectric film, and more particular to provide a method of forming a thin film, with a high quality characteristic using Bi based material. According to the present invention, a ferroelectric characteristic included in the SBT film is sufficiently obtained, simultaneously, roughness of a trough and peak on a surface can be reduced. A resist pressure against a film's electric field can highly be improved by improving film's flatness. As a result, a thin film, of the ferroelectric film with thickness, of 100 nm or below can be obtained and a ferroelectric capacitor capable of low voltage operation with a voltage, which is 2V or below can be formed.
According to the present invention, a method of manufacturing a ferroelectric capacitor using a ferroelectric thin film, includes steps of: forming a lower conductive layer on a semiconductor substrate; coating solution of ferroelectric coking including organic solvent and organometallic complex on the lower conductive layer; performing a heating process for coated solution at temperature, to decompose the organometallic complex in solution of ferroelectric coking, or more and ferroelectric crystallization temperature or below to form the metal compound thin film; forming an upper conductive layer on the metal compound thin film; and performing a heating process for the metal compound thin film at ferroelectric crystallization temperature or more to form the ferroelectric thin film.
The summary of the invention does not necessarily describe all necessary features of the present invention. The present invention may also be a sub-combination of the features described above. The above and other features and advantages of the present invention will become more apparent from the following description of the embodiments taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a SEM photo of a surface of a capacitor in a conventional art.
FIG. 2 is a flowchart of a substantially step to explain a first embodiment.
FIG. 3 is the SEM photo of a surface of a capacitor to which the first embodiment is applied.
FIG. 4 is the SEM photo of a sectional face of the capacitor to which the first embodiment is applied.
FIG. 5 is a flowchart of a substantially step to explain a second embodiment.
FIG. 6 is a SEM photo of a sectional face of a capacitor to which the first embodiment is applied.
FIG. 7 is a flowchart of a substantially step to explain a third embodiment.
FIG. 8 is a SEM photo of a sectional face of a capacitor to which the third embodiment is applied.
FIG. 9 is a flowchart of a substantially step to explain a fourth embodiment.
DETAILED DESCRIPTION OF THE INVENTION
The invention will now be described based on preferred embodiments, which do not intend to limit the scope of the present invention, but rather to exemplify the invention. All of the features and the combinations thereof described in the embodiments are not necessarily essential to the invention.
(First Embodiment)
In a first embodiment, a method of manufacturing a ferroelectric capacitor to realize superior flatness will be described by a SBT, which a ferroelectric material as one example of a dielectric oxide material of a ferroelectric capacitor referring to a flowchart of a step in FIG. 2 . The method can similarly be applied to the other B i based materials other than the SBT (e.g., titanic acid bismuth, material to put addition, or a series of compound groups which one part of composition is replaced with a different element).
A Pt layer, which a lower electrode of a capacitor on a substrate is formed with a film of approximately 50 nm to 400 nm by a DC sputter method. SBT coking solution made by a MOD method or a sol-gel method is coated on the Pt layer by a spin coat method (S 10 in FIG. 2 ). With respect to a method of forming the SBT, a LSMCD (liquid source misted chemical deposition) method to use a mist coking instead of the spin coat method.
A rotational speed of a substrate at a time of spin coat is approximately 500 rpm to 4000 rpm and a ferroelectric's film is coated with a desired thickness. After the film is coated, a heating process is performed at 120° C. to 250° C. for 2 to 6 minutes to dry an organic solvent in solution of SBT coking with a hot plate etc. (S 11 in FIG. 2 ). It is necessary that temperature in this drying process is a temperature, to vaporize organic solvent in solution of SBT coking used to coat solution, or more. It is general that butyle acetate (vaporization temperature is 40° C. to 100° C.), 1-methoxy 2-propanol (vaporization temperature is 40° C. to 110° C.), or 2-methoxyethanol (vaporization temperature is 40° C. to 110° C.) is used as organic solvent.
The heating process is performed at 120° C. or more for a few minutes by which it is possible to completely dry organic solvent. After organic solvent is dried, sequentially, the heating process to decompose organic substances included in the film is performed at 450° C. to 550° C. for five minutes by the hot plate (electric furnace, lamp superheating, a RTA may be used) (S 12 in FIG. 2 ). It is preferable that this temperature is a suitable temperature according to organic substance decomposition temperature of coking solution. In most of cases, an included organic material is organometallic complex (or metallic alkoxide) and various materials can be applied. For example, decomposition temperature is around 340° C.±10° C. in carboxylate and decomposition of carboxylate is sufficiently available by the heating process at 450° C. or more for five minutes.
In this process (S 12 in FIG. 2 ), it is important that the heating process for a ferroelectric's thin film is performed at decomposition temperature of an organic substance or more and crystallization temperature of the ferroelectric or below. When the heating process for this thin film is performed at crystallization temperature or more, a difference between of a trough and peak on a film surface rapidly becomes large with the growing of the grain. Therefore, each level of the difference between the trough and peak on the surface of the film are changed depending on a type of the included organic substrate or a component of the ferroelectric material. In this case, heating process temperature and time can be set to a suitable condition by crystallization analysis using differential thermal analysis (DTA) or X-ray diffraction. A heating process to decompose the included organic substrate by the heating process at crystallization temperature or below is called as “preliminary anneal”.
In conventional manufacturing method, after preliminary anneal (S 12 in FIG. 2 ) is made or after the preliminary anneal step is omitted and a drying step (S 11 in FIG. 2 ) is made, the heating process to crystallize the SBT (s 14 in FIG. 2 ) is carried out in oxide at approximately 650° C. to 800° C. A series of steps from this coating step to the crystallization anneal step is repeated at several times and a thin layer of ferroelectric (SBT) with thickness of 50 nm to 300 nm is formed. After that, a Pt layer is formed as an upper electrode of the capacitor (S 13 in FIG. 2 ).
In a first embodiment, after steps from the coating step (S 10 in FIG. 2 ) to the preliminary anneal step (S 12 in FIG. 2 ) as aforementioned are repeated at twice to sixth times, the upper electrode is formed (S 13 in FIG. 2 ). The number of repeating times is adjusted according to a desired thickness. It is preferable that formation of a film of 100 nm is completed around fourth times when the film of 100 nm is formed.
As the upper electrode of the ferroelectric capacitor, the Pt layer with the film of 50 nm to 400 nm is formed in, for example, the DC sputtering method (S 13 in FIG. 2 ). Next, the upper electrode is worked by the known photolithography step and the etching step. Normally, after that, the ferroelectric film is worked and then the lower electrode is worked. The ferroelectric film and the lower electrode are worked by the known photolithography step and the etching step.
The upper electrode is worked. And then, it is possible to perform the crystallization anneal step of the ferroelectric film (S 14 in FIG. 2 ) after the ferroelectric film is worked or the electrode is worked. Preferably, the ferroelectric film is performed after the electrode is worked. This is because one part of the ferroelectric film is exposed after the upper electrode is worked, sufficient oxide can be supplied to the ferroelectric film at a time of the crystallization anneal, and characteristic inferior of the ferroelectric film is suppressed.
Although the crystallization anneal step (S 14 in FIG. 2 ) can be performed before the upper electrode is worked, in this case where there is probability the film on interfaces of the Pt film and the ferroelectric film come off. This tendency becomes sure according to thick of the Pt film, which is the upper electrode.
From a view of ensurance of a residual polarization in the ferroelectric film and prevention of coming off the upper electrode, it is preferable to perform the crystallization anneal step (S 14 in FIG. 2 ) after the upper electrode is worked (S 13 in FIG. 2 ). In the crystallization anneal step, the step is performed at 650° C. to 800° C. for 30 to 60 minutes by using the electric furnace.
FIG. 3 is the SEM photo of a ferroelectric capacitor formed in the first embodiment. As obvious from comparison the ferroelectric capacitor in FIG. 3 with the SBT film with thickness of 110 nm and the ferroelectric capacitor of 690000 um2 formed in the conventional manufacturing method shown in FIG. 1 , flatness of the SBT film is extremely improved. It is confirmed by the observation with AFM that the difference between the trough and peak is reduced to one-third or below in comparison a different step of 30 nm or below with a conventional different step of 100 nm.
As a result of this, in the ferroelectric capacitor of 690000 um2 with the SBT film of thickness of 110 nm formed by a conventional manufacturing method, a yield factor for resist pressure of 1V in 48 chips on a wafer face is 0%. In contrast, in the first embodiment, a result of 100%, the yield factor can be obtained in the ferroelectric capacitor of which the SBT film is thickness of 94 nm.
FIG. 4 is the SEM photo of a sectional face of the ferroelectric capacitor formed in the present. Flatness of the film in the upper electrode can be confirmed.
(Second Embodiment)
In the first embodiment, after the SBT film is stacked on the lower electrode at the several times in the preliminary anneal, the upper electrode is formed and crystallized. In a second embodiment, FIG. 5 is a flowchart of a step to explain the second embodiment.
In the second embodiment, two type's anneal steps are mixed and used. The steps are the same as steps in the first embodiment, that is, the steps are steps in which the lower electrode is formed on the substrate, solution of SBT coking is coated (S 20 in FIG. 5 ), and then coated solution is dried (S 21 in FIG. 5 ). In the first embodiment, “preliminary anneal” is carried out at crystallization temperature or below, which crystallization of the SBT film occurs. In contrast, “crystallization anneal” (S 22 in FIG. 5 ) is carried out at crystallization temperature or more in the second embodiment.
From the SBT coating step to the crystallization anneal step, when the coating step is repeated at fourth times, the crystallization anneal step (S 22 in FIG. 5 ) is carried out from once to third times and “preliminary anneal” is carried out at the last time.
Therefore, when the N number of coating times is repeated, the crystallization anneal step around 650° C. to 800° C. for 10 to 60 minutes by using electric furnace is performed for the coating step at the N−1 times. For the SBT layer formed in the last coating step “preliminary anneal” (S 23 in FIG. 5 ) of the same condition as condition in the first embodiment is performed at the last time. After that, the upper electrode is formed and the etching working of its upper electrode (S 24 in FIG. 5 ) is performed. Then, the crystallization anneal step (S 25 in FIG. 5 ) similar to the crystallization anneal step (S 14 in FIG. 2 ) in the first embodiment is performed.
In the first embodiment, since a status of the entire SBT layer is a status of “preliminary anneal”, there is possibility that the film is contracted at a time of the crystallization anneal step. In the present embodiment, rate of film thickness, in a “preliminary anneal” stage, for the SBT film's thickness can be reduced, a degree of film contraction can be reduced, as a result, a space at a center part of the SBT film can be prevented, and difference of rough density can be reduced.
FIG. 6 is a SEM photo of a sectional face a ferroelectric capacitor formed in the present embodiment. The space at the center part of the SBT film can be suppressed and difference of roughness over the entire film can be reduced.
With respect to a characteristic of the SBT film, flatness of the SBT film is the same as flatness in the first embodiment. A resist pressure of the ferroelectric capacitor is absolutely the same as the pressure in the first embodiment. With respect to the residual polarization characteristic in the ferroelectric capacitor, 2Pr value is 10.6 μC/cm2 (crystallization anneal temperature 750° C.) in the first embodiment. In contrast, the value is 13.8 μC/cm2 (crystallization anneal temperature 750° C.), that is, it is confirmed that 30% is increased.
(Third Embodiment)
In the first and second embodiments, there are features in the “preliminary anneal” step in formation of the ferroelectric. In the “preliminary anneal” step, flatness can highly be improved. In a third embodiment, a manufacturing method using an RTA is provided. According to this method, formation of the ferroelectric film becomes possible without formation of the space in the ferroelectric film.
The present embodiment is conceptually different from the first and second embodiments in the step of forming the ferroelectric film. In particular, they are different each other in a point in which the ferroelectric crystallization is performed before the upper electrode is formed. However, in the present embodiment, anneal step is stopped before a ferroelectric grain is grown and difference of height between the trough and peak exceeds 40% of thickness of the ferroelectric film.
Hereinafter, this step is referred to as “amorphous”. Below, a manufacturing method will be described referring to a flowchart of a step in FIG. 7 .
The steps in the third embodiment are the same as the steps in the first and second embodiments, that is, the steps are steps in which firstly the lower electrode of the ferroelectric capacitor is formed on the substrate, solution of SBT coking is coated (S 30 in FIG. 7 ) and next coated solution is dried (S 31 in FIG. 7 ). After that, “amorphous” heating process (S 32 in FIG. 7 ) of which temperature is around 700° C. to 750° C. and anneal is performed around 30 seconds to 3 minutes is performed. It is necessary to confirm crystallization of the SBT film by using XRD analysis. By SEM observation or AFM measurement, suitability of temperature and time for heating process of amorphous is important from view of flatness of the SBT film. The steps from coating step of solution of SBT coking (S 30 in FIG. 7 ) to an amorphous step (S 32 in FIG. 7 ) is repeated from twice to sixth times until film's thickness becomes desired thickness. The number of repeating times is not specially limited. After that, the Pt layer is formed as the upper electrode of the ferroelectric capacitor. Similar to the aforementioned embodiments, after the etching working of its upper electrode (S 33 in FIG. 7 ) is performed, the sufficient crystallization anneal step (S 34 in FIG. 7 ) is performed.
FIG. 8 is a SEM photo of a sectional face of a ferroelectric capacitor obtained in the third embodiment. The space in the SBT film, which occurs in the first and second embodiments is greatly suppressed. In addition, flatness is slightly inferior compared with the aforementioned embodiment. However, with respect to yield factor of resist pressure, it is confirmed that there is no problem specially even with film thickness is 94 nm. Further, 2Pr value of the ferroelectric capacitor obtained in the present embodiment is 14.0 μC/cm2 (crystallization anneal temperature 750° C.) and the more preferable result in the present embodiment than the result in the first and second embodiments is obtained.
(Fourth Embodiment)
The present embodiment is an embodiment to which modification is further added. In the third embodiment, the amorphous step is performed by the RTA in the step of forming the ferroelectric. An object in the third embodiment is mainly to miniaturize a grain's size of the SBT crystallization as much as possible. In the present embodiment, an object is to highly improve the ferroelectric characteristic such as residual polarization characteristic of the ferroelectric capacitor nevertheless flatness is slightly inferior compared with flatness in the third embodiment. Below, a manufacturing method in the present embodiment will be described referring to a flowchart of a step in FIG. 9 .
Steps in which the lower electrode is formed on the substrate, SBT solution is coated (S 40 in FIG. 9 ) and coated solution is dried (S 41 in FIG. 9 ) are the same as the steps in the first to third embodiments. After that, “amorphous” heating process (S 42 in FIG. 9 ) of which anneal is performed around 30 seconds to 3 minutes is performed around 650° C. to 750° C. by the RTA. Steps from the coating steps (S 40 in FIG. 9 ) to the amorphous step (S 42 in FIG. 9 ) are repeated from twice to sixth times until film's thickness becomes desired thickness. The above step's flow is the same as flow in the third embodiment. In the present embodiment, in the electric furnace, an oxide heating process (S 43 in FIG. 9 ) is added at 650° C. to 800° C. around 30 to 120 minutes.
After that, the Pt layer is formed as the upper electrode. Similar to the aforementioned embodiments, after the upper electrode is formed and the etching working (S 44 in FIG. 9 ) is performed, the crystallization anneal step (S 45 in FIG. 9 ) is again performed. In the present embodiment, the crystallization anneal step (S 45 in FIG. 9 ) after working of the upper electrode can be omitted.
In the third embodiment, only the oxide heating process (S 32 in FIG. 7 ) is performed around 30 seconds to 3 minutes. The heating process is not sufficient for the crystallization step of SBT crystallization and the oxide processes. After working of the upper electrode (S 33 in FIG. 7 ), crystallization anneal step (S 34 in FIG. 7 ) is performed. However, since the upper of the ferroelectric capacitor is covered with the Pt electrode layer, oxide reaction of the SBT proceeds by oxide which permeability diffusion of the Pt layer is performed. It is predicted that there is an oxide process inserted from the upper electrode end.
However, the longer the crystallization anneal time, the more the ferroelectric characteristic represented in the 2Pr value of the ferroelectric capacitor is improved. Such tendency appears. It is understood that efficiency of the oxide process by this method is terrible.
In this embodiment, a SBT film with high crystallization nucleation density is formed in a RTA processing (S 42 in FIG. 9 ) as a first stage. After that, oxide is directly supplied to a SBT surface by the electric furnace and efficient oxide reaction is facilitated (S 43 in FIG. 9 ). At this time, though the grain is grown, crystallization nucleation density is greatly high. Thereby, a degree to grow the grain is comparatively slow. This feature is paid attention in the present embodiment. Therefore, superior flatness is maintained, simultaneously, 16.4 μC/cm2 by the 2Pr value (crystallization anneal temperature 750° C.) can be obtained and the ferroelectric capacitor with the most preferable ferroelectric characteristic in the embodiments of the present invention can be obtained.
Although the present invention has been described by way of exemplary embodiments, it should be understood that those skilled in the art might make many changes and substitutions without departing from the spirit and the scope of the present invention which is defined only by the appended claims. | According to the present invention, a method of manufacturing a ferroelectric capacitor using a ferroelectric thin film, includes steps of: forming a lower conductive layer on a semiconductor substrate; coating solution of ferroelectric coking including organic solvent and organometallic complex on the lower conductive layer; performing a heating process for coated solution at temperature, to decompose said organometallic complex in solution of ferroelectric coking, or more and ferroelectric crystallization temperature or below to form said metal compound thin film; forming an upper conductive layer on said metal compound thin film; and performing a heating process for said metal compound thin film at ferroelectric crystallization temperature or more to form said ferroelectric thin film. | 8 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to a method for secure data transmission in wireless sensor network, and belongs to the wireless communication technology field.
[0003] 2. Description of the Prior Art
[0004] The wireless sensor network is a kind of the wireless communication system, and its basic unit is node. A node uses wireless transmitters/receivers to transmit the data through wireless channels. There are two types of nodes in the wireless sensor network: central node and device node.
[0005] A typical device node comprises a data pickup unit, a data processing unit, a data transmission unit and a power supply. The data pickup unit is usually a sensor, and its type is determined by physical form of the monitored signal. The data pickup unit collects information from its surroundings, and transmits the information to the central node via the data transmission unit under control of the data processing unit.
[0006] The central node is an interface interconnecting the wireless sensor network and other external communication system such as the internet. The central node transmits the data collected by the device nodes to the remote users via the internet, and likewise, the user can transmit control instructions to the central node via the internet. The central node forwards the instruction to the device node for the user to control the network. Compared to the device node, the central node generally has stronger computation ability and more system resources.
[0007] The wireless sensor network is widely used in environmental surveillance, space exploration, emergency service & disaster relief, smart home, etc. However, the node in the wireless sensor network usually has following characteristics: limited energy, limited computation ability and limited storage capacity. Firstly, energy is the main factor that limits the ability and duration of the node. A conventional sensor node generally uses batteries to provide the electricity, and cannot be recharged. Secondly, CPU of the node in the sensor network has only 8 bit and 4˜8 MHz capabilities. Moreover, the storage capacity of the node is also limited. Unlike the cable network using wire transmission from node to node, the wireless sensor network transmits signals by wirelessly broadcasting. Because of the openness of the wireless transmission medium, all nodes within the signal coverage can receive the signals, so the transmitted data is vulnerable to various security threats such as eavesdropping, data manipulation, and data replaying. Thus, it is crucial to adopt some methods to protect the security of the data transmission in the wireless sensor network, and the methods are generally related to authorization, encryption, and data integrity verification.
[0008] Authorization is a process of two nodes confirming the legal identification of each other, usually related to data interexchange between two nodes for verifying the legitimacy of each other. Only upon a successful authorization process, a trusted relationship between the two nodes can be established that allows a secured data communication to be initialized.
[0009] Encryption is a process of converting the data from plaintext into unrecognized ciphertext. Decryption is a process of converting ciphertext into plaintext. An encryption system generally comprises four parts: plaintext, the data to be encrypted; ciphertext, the data encrypted from the plaintext; an encryption algorithm; key, a string or digital series with specific length used together with the encryption algorithm for controlling the encryption and the decryption. While a sender transmits the ciphertext to a receiver via a transmission medium, the ciphertext may be intercepted or eavesdropped by a third party. Nevertheless, as long as the third party does not have the key, the ciphertext is just some meaningless codes that don't reveal any information. Therefore, the data transmission can be secured.
[0010] The integrity of data is verified to prevent the third party from either knowing or manipulating the data content to ensure the security of data transmission. Usually a one-way Hash function is used to verify the data integrity. To verify the data integrity, an ‘abstract’ with a fixed length has to be generated according to the plaintext to be verified, and the ‘abstract’ is referred to as message authentication code (MAC). Different MACs are definitely generated from Different plaintext, while MACs generated from the same plaintext would always be identical. Thus, it can be determined whether data is manipulated during the transmission according to the MAC. In the wireless sensor network, the MAC is usually generated by the one-way Hash function and attached to the data to be transmitted. After receiving the data, the data receiving party calculates the MAC and compares the MAC with the attached MAC. If the comparison is matched, the data is deemed integral; otherwise, it is deemed manipulated.
[0011] Due to the aforementioned characteristics of the wireless sensor network, the conventional security method has hit some bottlenecks when adapted in the wireless sensor network. Firstly, the consumption of computation resource is large, while the computation resource and ability in the node are limited, thus the security method that consumes significant computation resource is inadequate for the wireless sensor network. Secondly, in the conventional security method, significant amount of data exchange is required, inducing additional network communication and energy consumption that degrades the performance of network, so the conventional security method is also infeasible for the wireless sensor network. If the conventional security method is applied, the node may be overloaded with the security computation tasks while the performance of other tasks is affected. Thirdly, the excessive computation and the communication increase the power consumption of the node, so the energy of the node may be rapidly drained out and consequently the efficiency of the network is reduced. Restricted by the above disadvantages, the conventional security method is infeasible for the wireless sensor network, and the authorization between nodes remains as an unsolved issue.
SUMMARY OF THE INVENTION
[0012] An exemplary embodiment of the invention provides a method for secure data transmission in the wireless sensor network to work around with the difficulties caused by significant consumption of computation resource and the large overhead of the protocol communication in the conventional security method and to provide an authorization mechanism between the nodes, and further to secure data transmissions in the wireless sensor network with limited node resources.
[0013] The method for secure data transmission in the wireless sensor network includes following steps.
[0014] (1) The user of the wireless sensor network acquires a master key of a device node after purchasing the device node, and inputs the master key into a center node of the wireless sensor network;
[0015] (2) The central node and the device node performs authorizations on each other to verify mutual legitimacies;
[0016] (3) The central node periodically performs a Hash function using the master key and a random number to generate a session key;
[0017] (4) The central node generates a message authentication code (MAC) for the session key, encrypts the session key with the MAC using the master key to generate an encrypted session key, and sends the encrypted session key to the device node communicating with the central node;
[0018] (5) Upon reception of the encrypted session key, the device node decrypts and verifies the encrypted session key with the MAC using the master key, and replaces a previous session key used by the device node by the session key;
[0019] (6) The device node generates a MAC for a first data package to be transmitted, encrypts the first data package with the MAC into an encrypted first package using the session key, and then transmits the encrypted first data package to the central node; the central node decrypts the encrypted first data package and verifies the MAC to confirm integrity of the first data package; and
[0020] (7) The central node uses the session key generated in step (3) to encrypt a second data package to be transmitted with a MAC of the second data package, and sends the encrypted second data package to the device node communicating with the central node; the device node decrypts the encrypted second data package and verifies the MAC to confirm integrity of the second data package.
[0021] The authorization between the central node and the device node includes the following steps.
[0022] (1) The central node generates a MAC for a first random number, encrypts the first random number with the MAC using the master key, and sends them to the device node communicating with the central node; The device node decrypts the first random number and the MAC thereof, verifies the MAC of the first random number to obtain the first random number.
[0023] (2) The device node generates a MAC for a second random number, encrypts the second random number with the MAC using the master key, and sends them to the central node; the central node decrypts and verifies the encrypted second number with the MAC to confirm safe reception of the second random number.
[0024] (3) The central node generates a MAC for a central node identification (ID), encrypts the central node ID with the MAC using the master key, and sends the encrypted central node ID to the device node communicating with the central node; The device node decrypts and verifies the encrypted central node ID with the MAC to confirm safe reception of the central node ID.
[0025] (4) The device node generates a MAC for a device node ID, encrypts the device node ID with the MAC using the master key, and sends the encrypted device node ID to the central node; the central node decrypts and verifies the encrypted device node ID with the MAC to confirm safe reception of the device node ID.
[0026] (5) The central node generates a MAC for a first parameter S 1 , encrypts the first parameter S 1 with MAC using the master key, and then sends the encrypted first parameter S 1 with MAC to the device node, where the first parameter S 1 denotes certain information pre-shared by the central node and the device node including the following items sequentially appended one after another: the first data, the center node ID, the device node ID, the first random number and the second random number.
[0027] (6) The device node generates a MAC for a second parameter S 2 , encrypts the second parameter S 2 with MAC using to the master key, and sends the encrypted second parameter S 2 with MAC to the central node, where the second parameter S 2 denotes certain information pre-shared by the central node and the device node, including the following items sequentially appended one after another: the central node ID, the device node ID, the central node ID, the first random number, and the second random number.
[0028] (7) The central node decrypts the encrypted second parameter S 2 sent from the device node into a decrypted second parameter S 2 and a decrypted second MAC, Hashes the decrypted second parameter S 2 to generate a second local MAC, and verifies the validity the decrypted second parameter S 2 by comparing the second local MAC with the decrypted second MAC. If the comparison is matched, the authorization is deemed as passed. Otherwise the authorization is failed.
[0029] (8) The device node decrypts the encrypted first parameter S 1 sent from the central node into a decrypted first parameter S 1 and a decrypted first MAC, Hashes the decrypted first parameter S 1 to generate a first local MAC, and verifies the validity of the decrypted first parameter S 1 by comparing the first local MAC with the decrypted first MAC. If the comparison is matched, the authorization is deemed as passed. Otherwise, the authorization is failed.
[0030] The method for secure data transmission in wireless sensor network significantly reduces the computation resource consumption and the communication overhead without affecting the security performance of the network, and solves the difficulty of authorization between the nodes of the wireless sensor network. The methods for generating, transmitting, and updating the key are provided, and the data encryption and integrity verification greatly ensure the security of the data transmission in wireless sensor network.
BRIEF DESCRIPTION OF THE DRAWINGS
[0031] FIG. 1 is a flowchart of an embodiment of the data transmission method.
[0032] FIG. 2 is a flowchart of an embodiment of authorization between the central node and the device node.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0033] It is to be understood that other embodiments may be utilized and structural changes may be made without departing from the scope of the present invention. Also, it is to be understood that the phraseology and terminology used herein are for the purpose of description and should not be regarded as limiting. The use of “including,” “comprising,” or “having” and variations thereof herein is meant to encompass the items listed thereafter and equivalents thereof as well as additional items. Unless limited otherwise, the terms “connected,” and “coupled,” and variations thereof herein are used broadly and encompass direct and indirect connections, couplings, and mountings.
[0034] FIG. 1 shows an embodiment of a flowchart of the data transmission method. Firstly, the user of the wireless sensor network acquires a master key of a device node after purchasing the device node, and inputs the master key into a central node of the wireless sensor network. In step 101 , the central node and the device node perform authorizations with each other for verifying the legitimacy of both sides. In step 103 , the central node periodically performs a Hash function (e.g. one-way Hash function) using the master key and a random number to generate a session key. In step 105 , the central node generates a message authentication code (MAC) for the session key, encrypts the session key with the MAC to generate an encrypted session key using the master key, and sends the encrypted session key to the device node communicating with the central node. Upon reception of the encrypted session key, the device node decrypts the encrypted session key into an updated session key and a decrypted MAC using the master key, verifies the decrypted MAC to confirm integrity of the updated session key, and replaces an existing session key used by the device node with the updated session key. In step 109 , the central node uses the updated session key to encrypt a first data package to be transmitted with a MAC of the first data package, and sends the encrypted first data package to the device node communicating with the central node; the device node decrypts the encrypted first data package and verifies the MAC to confirm integrity of the first data package. In step 111 , upon acquisition of the updated session key, the device node generates a MAC for a second data package to be transmitted, encrypts the second data package with its MAC by the updated session key, and sends the encrypted first data package to the central node; the central node decrypts the encrypted first data package into a decrypted first data package and a decrypted MAC, verifies the decrypted MAC to confirm integrity of the decrypted first data package.
[0035] FIG. 2 is a flowchart of an embodiment of authorization between the central node and the device node.
[0036] (1) In step 201 , the central node generates a MAC for a first random number, encrypts the first random number with the MAC using the master key, and sends them to the device node communicating with the central node; the device node decrypts the first random number and the MAC thereof, verifies the MAC of the first random number and confirms the integrity of the first random number;
[0037] (2) In step 203 , the device node generates a MAC for a second random number, encrypts the second random number and the MAC thereof using the master key, and sends the encrypted second number and the MAC thereof to the central node; the central node decrypts the second number and the MAC thereof, verifies the MAC of the second random number to confirm integrity of the second random number;
[0038] (3) In step 205 , the central node generates a MAC for a central node identification (ID), encrypts the central node ID and the MAC thereof using the master key, and sends the encrypted central node ID and the MAC to the device node communicating with the central node; the device node decrypts the central node ID and the MAC, verifies the MAC of the central node ID to confirm integrity of the central node ID;
[0039] (4) In step 207 , the device node generates a MAC for a device node ID, encrypts the device node ID and the MAC thereof using the master key, and sends the encrypted device node ID and the MAC to the central node; the central node decrypts the device node ID and the MAC, verifies the MAC of the device node ID to confirm integrity of the device node ID;
[0040] (5) In step 209 , the central node uses the master key to compute a MAC of a first parameter S 1 , encrypts the MAC and sends it to the device node, where the first parameter S 1 =a first data pre-shared by the central node and the device node ∥ the central node ID ∥ the device node ID ∥ the first random number ∥ the second random number. The notation “M 1 ∥M 2 ”, denotes a relationship that the data M 2 is attached behind the data M 1 .
[0041] (6) In step 211 , the device node uses the master key to compute a MAC of a second parameter S 2 , encrypts the MAC and sends it to the central node, where S 2 =a second data pre-shared by the central node and the device node ∥ the central node ID ∥ the device node ID ∥ the first random number ∥ the second random number.
[0042] (7) In step 213 , the central node decrypts the encrypted second parameter S 2 sent from the device node into a decrypted second parameter S 2 and a decrypted MAC, Hashes the decrypted second parameter S 2 to generate a local MAC, and verifies the validity the decrypted second parameter S 2 by comparing the local MAC with the decrypted MAC. If the comparison is matched, the authorization is deemed as passed; otherwise the authorization is failed.
[0043] (8) In step 215 , the device node decrypts the encrypted first parameter S 1 sent from the central node into a decrypted first parameter S 1 and a decrypted first MAC, Hashes the decrypted first parameter S 1 to generate a first local MAC, and verifies the validity of the decrypted first parameter S 1 by comparing the first local MAC with the decrypted first MAC. If the comparison is matched, the authorization is deemed as passed. Otherwise, the authorization is failed.
[0044] The method uses two keys: the master key and the session key. The master key is used to generate, update, and transmit the session key. The session key is used to encrypt the data for transmission and verify the data integrity in the network.
[0045] In following text, the present method is described in details with reference to the accompanying drawings, which includes the following steps.
[0046] Firstly, the master key is shared by the central node and the device node, and this process is completed by the network user. The user selects a master key, and inputs the master key into the central node and the device node, each device node corresponding to one master key. The central node maintains a sheet for recording IDs of different device nodes corresponding with the master keys and the latest session keys. Thus, the secret value is set between the central node and the device node, and access controlling is realized to prevent unauthorized user accessing the network in the mean time.
[0047] Secondly, the central node and the device node are authorized by each other for confirming the legitimacy of both sides, and this process is completed by the central node and the device node automatically, as shown in FIG. 2 .
[0048] During the authorization, the central node and the device node each generates a random number, respectively called the first random number and the second random number. The first random number and the second random number are usually two strings with the same length to ensure generating different security information in each authorization process, which enhances the security of the authorization. The central node generates the first random number, attaches the MAC behind the first random number, uses the master key to encrypt the first random number and the MAC, and sends the encrypted first random number and MAC to the device node communicating with the central node; the device node encrypts the received data, verifies the MAC of the first random number, and gets the first random number of the central node.
[0049] The device node generates the second random number after receiving the first random number sent by the central node, attaches the MAC behind the second random number, uses the master key to encrypt the second random number and the MAC, and transmits the encrypted second random number and MAC to the central node; the central node decrypts the received data, verifies the MAC of the second random number, and gets the second random number of the device node.
[0050] Exchange of the random numbers between the central node and the device node in communication is completed as above. After the exchange of the random numbers, the central node and the device node exchange the node ID as follows:
[0051] The central node attaches the MAC behind the central node ID, uses the master key to encrypt the central node ID and the MAC, and transmits the encrypted central node ID and the MAC to the device node in communication; the device node decrypts the received data and verifies the MAC of the central node ID to get the central node ID.
[0052] After receiving the central node ID transmitted by the central node, the device node attaches the MAC behind the device node ID, uses the master key to encrypt the device node ID and the MAC, and sends the encrypted device node ID and the MAC to the central node; the central node decrypts the received data and verifies the MAC of the device node to get the device node ID. Thus, the ID exchange between the central node and the device node is completed.
[0053] After the exchange of the random numbers and the node IDs between the central node and the device node is completed, the central node and the device node both get the first random number, the second random number, and the IDs of the central node and the device node. The central node and the device node respectively compute the first parameter and the second parameter according to the following method, and compute the corresponding MACs of the first parameter and the second parameter.
[0054] The central node computes the first parameter, and the first parameter=data 1 shared in advance by the central node and the device node ∥ the central node ID ∥ the device node ID ∥ the first random number ∥ the second random number. The central node uses the master key to compute the MAC of the first parameter, encrypts the MAC, and sends it to the device node.
[0055] The device node computes the second parameter, and the second parameter=data 2 shared in advance by the central node and the device node ∥ the central node ID ∥ the device node ID ∥ the first random number ∥ the second random number. The device node uses the master key to compute the MAC of the second parameter, encrypts the MAC, and sends it to the central node.
[0056] The central node and the device node generate different random number in each authorization process, so the first parameter and the second parameter which are generated are also different according to the first random number, the second random number and the nodes ID.
[0057] The central device node decrypts the received data, gets the MAC of the second parameter, and compares it with the local computed MAC of the second parameter. If the two MACs are same, the device node and the central node have the same key and the device node is legal, and then the central node sends a confirmation to the device node, in which the device node is authorized by the central node; if the two MACs are different, the confirmation sent by the central node shows that the authorization fails.
[0058] The device node decrypts the received data, gets the MAC of the second parameter, and compares it with the local computed MAC of the first parameter. If the two MACs are same, the central node and the device node have the same key and the central node is legal, and then the device node sends a confirmation to the central node, in which the central node is authorized by the device node; if the two MACs are different, the confirmation sent by the device node shows that the authorization fails.
[0059] If one side confirms the authorization fails, then the authorization fails, and both nodes cannot proceed with data transmission. Only when two sides both confirm the authorization is passed, the central node and the device node can proceed with the data commission.
[0060] The session key is generated by the central node. After the central node and the device node are authorized by each other, the central node periodically performs Hash function to generate the session key according to the security information. The security information is composed by the master key corresponding to the device node and the random number with a certain length. The security information is used as the input of the one-way Hash function, and the output of the Hash function is the session key, that is, the session key=H (the master key ∥ random numbers),
[0061] Where H is the one-way Hash function, and the symbol “∥” represents that the random numbers are attached behind the master key.
[0062] The central node usually has high computation ability and system source, so the session key is generated by the central node, which not only increases the system speed, but also reduces the consumption of computation resource and the power consumption of the device node. After the same session key is used for a period of time, the security of the data encrypted by this session key will decrease, thus the session key used to encrypt data ought to be updated continuously and this problem can be solved by periodically generating and transmitting new session key by the central node.
[0063] After the new session key is generated, the central node searches the corresponding master key of the device node according to the device node ID. The central node attaches the MAC behind the new session key, uses the master key to encrypt the session key and the MAC and sends them to the device node. After successfully transmitting the session key to the device node, the central node updates corresponding items in the local sheet for the session key. Using the master key to encrypt the session key ensures the secure transmission of the session key.
[0064] After receiving the session key, the device node firstly uses the master key to decrypt the received data and verifies the MAC of the session key to get the new session key, and then replaces the existing session key of the device node with the new session key.
[0065] After the central node and the device node complete updating the session keys, the data begins to transmit between nodes in ciphertext. Before transmitting the data to the central node, the device node attaches the MAC behind the data, uses the latest session key to encrypt the data and the MAC thereof, and sends them to the central node. However, before transmitting the data to the device node, the central node firstly finds out the session key corresponding to the device node according to the device node ID, attaches the MAC behind the data for transmission, uses the latest session key to encrypt the data and the MAC thereof, and sends them to the device node. | A method for secure data transmission in wireless sensor network includes that: the network user determines a master key and inputs it into a central node and a device node; after the central node and the device node have authorized each other, the central node generates a new session key and sends it to the device node; while the central node and the device node communicate with each other, the data sending party uses the new session key to encrypt the data for transmission and verify the integrity of the data, and the data receiving party uses the session key to decrypt the data and verify the integrity of the data. The advantages of the present invention are that: the consumption of computation resource and the communication overhead are greatly reduced without affecting the security performance of the network, the problem of the authorization between the central node and the device node is solved, and the method for generating, transmitting and updating the key realizes the encryption of the data for transmission and the verification of the data integrity, and thus it ensures the security of the data transmission in wireless sensor network. | 7 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to an apparatus and method to actively reduce the magnitude of undesirable vibrations in a rotating roll. More particularly, the present invention relates to an apparatus and method to actively reduce undesirable vibration in a device for the treatment of a material web, specifically a paper or cardboard material web.
2. Description of the Related Art
A device to actively reduce the magnitude of undesirable vibrations in a rotating roll is described, for example, in German patent document no. DE 196 52 769 A1. In accordance with a first design alternative described therein, a vibration sensor is located at one bearing position, or at the bearing positions of the roll. In accordance with a second design alternative described in German Patent document no. DE 196 52 769 A1, it is suggested to locate the vibration sensor at the machine center. In an experimental arrangement, a capacitive sensor was located in the machine center, i.e., in the area of the longitudinal roll center, close to the substantially circular cylindrical roll shell. Positioning the vibration sensor in the area of the machine center offers the advantage that the amplitude of vibrations of a roll can be accurately measured due to the substantial distance of the sensor from the bearing positions of the roll, and from the significant “swings” of the roll resulting from the substantial distance separating the roll bearings (for example due to additional deflection vibration contributions). It is, however, a disadvantage that the capacitive sensor must be located in close proximity to the roll surface.
When utilizing the vibration weakening device in a machine for the production and/or coating of a material web, specifically a paper or cardboard web, there is an inherent risk of damage to the sensor in the event of a web break and the subsequently resulting “wrap-up” of the roll. There is also the danger that the ability of the sensor to function may be impaired due to contamination from coating medium, fiber components, etc. In addition, a sensor located in immediate proximity to the shell surface of the roll makes access to the roll shell more difficult for maintenance or operating personnel. It has, after all, proven difficult to precisely measure the vibration amplitude on coated surfaces, for example rubber coated surfaces and/or surfaces covered with a layer of coating medium.
Sensors which are located at the bearing positions of the roll do not exhibit the aforementioned disadvantages. However, due to the fact that the bearing positions coincide with the nodal points of the undesirable roll vibrations, it is considerably more difficult to measure the vibration amplitudes with the necessary precision at the bearing/mounting positions than it is in the area of the machine center.
Patent document no. WO 97/03832 describes a process and a device for the reduction of deflection vibrations in rotating systems which are designed for utilization with impression cylinders in rotogravure presses. However, the working width and running speed of material webs in rotogravure presses of this type are considerably different from that in a machine for the production and/or coating of material webs.
SUMMARY OF THE INVENTION
The present invention provides a method and apparatus that enable precise detection and measurement of the roll vibration amplitudes and is not susceptible to contamination and damage, and permits unhampered access to the shell surface of the roll by operating and/or maintenance personnel. A sensor arrangement having at least one sensor is located radially inside the substantially circular cylindrical outer shell surface of the roll relative to the rotational axis of the roll and/or at least one sensor is located remotely from the substantially circular cylindrical shell surface of the roll. The sensor arrangement measures the undesirable vibrations. A power unit device influences, dependent upon the measuring result, the roll in order to reduce the undesirable vibration. The apparatus and method of the present invention are intended for utilization in machinery for the production and/or treating of, and particularly for applying a coating to, a material web, specifically a paper or cardboard web.
A sensor device is located under the roll surface. In this location it is neither at risk from contamination through exposure to coating material, nor is the sensor device at risk of damage due to a web break. In addition, with the sensor located under the roll surface, free access to the roll surface is assured. Further, a sensor device is located in the area of the machine center, i.e., in the area of the longitudinal center of the roll, thereby enabling a high precision measurement of the amplitude of the roll vibration.
The sensor device includes at least one compression and/or tension sensitive element such as, for example, a wire strain gauge. Sensor elements of this type have proven themselves rugged, reliable and precise especially when applied for the purpose of detecting/measuring mechanical stress conditions. The compression and/or tension sensitive element may, for example, be located on the inside surface of the roll cylinder where it is protected by the roll shell (which may, for example, be manufactured from steel) from exterior influences caused by, for example, a web break. In the instance of internally cooled rolls, it must be ensured that the compression and/or tension sensitive element is resistant to the cooling medium, for example, water. In addition, or as an alternative, a compression and/or tension sensitive element is located on the outside surface of the roll cylinder underneath the roll surface cover layer which is, for example, formed of a protective layer of rubber, rubber-type material, synthetic material or other similar material. In such an arrangement, the compression and/or tension sensitive element is protected from exterior influences by the protective roll cover/layer. More particularly, the compression and/or tension sensitive element is protected from damage in the event of a web break and from contamination through exposure to coating medium when located under the protective roll cover/layer.
A sensor device is also located remotely from the roll surface. The distance between the sensor device and the roll surface is selected so that the sensor device is neither contaminated through exposure to coating medium splashes, nor damaged in the event of a web break. In addition, unhampered access to the roll surface is assured due to the distance between the sensor device and the roll surface. Again, location of the sensor device in the area of the machine center ensures precise detection/measurement of the roll vibration amplitude. In a machine equipped with two rolls which together form a “nip” through which the material web travels, signals can be detected/measured particularly effectively by placing a sensor device in the connecting plane of the axes of the two rolls. Remote vibration detection/measurement is provided simply and reliably by a sensor device that includes at least one optical sensor unit. In order to ensure free access to the shell surface of the roll, it is advantageous to locate the optical sensor unit at a distance of at least one meter from the roll surface.
Sensor units based on various principles of measurement can be utilized. The optical sensor device may, for example, be a laser-vibrometer, which may be purchased, for example, under the identification VH 300 from Ometron, Inc., Dulles, USA. This laser-vibrometer detects/measures the vibration of the roll as the component of the speed of the surface of the rotating roll that is progressing parallel to the laser bean conducting the measurement. In addition, or as an alternative, the sensor device can include an interferometrically operating sensor device that detects/measures mechanical tension/stress conditions of the roll surface. Such interferometric sensor devices are used in the area of non-destructive materials analysis. The interferometric sensor device detects/measures the mechanical tension/stress conditions, for example, at the substantially circular cylindrical shell surface of the roll.
In addition, or as an alternative, the interferometric sensor device measures the mechanical tension/stress conditions in the area of a header section of the roll, in which the roll surface tapers from the substantially circular cylindrical shell surface to the roll journals. The changes in the surface tension/stress of the roll caused by undesirable vibrations are especially pronounced and distinct in the transition area between the shell surface and the header section, as well as in the transition area between the header section and the roll journal. Measuring the mechanical tension/stress conditions of the roll in the area of the header section has the additional advantage that the interferometric sensor device may be located prior to, or after, the roll, viewed in direction of the roll axis, thereby not hampering free access to the shell surface of the roll. The tension/stress conditions in the header area may, however, also be detected/measured by other suitable sensors such as, for example, wire strain gauges.
The present invention also includes a control unit which, based on the detected/measured signals of the sensor device, determines actuating signals for the power unit device. The control unit, for the purpose of determining the actuating signals, combines the measured signals from a multitude of sensors additively and/or subractively and/or weighted and/or averaged and/or phase corrected. This allows for consideration of peculiarities in the vibration characteristics of the roll, depending upon prevailing operating parameters, and peculiarities of the utilized sensor devices, specifically with regard to their sensitivity to certain ranges of vibration frequencies. The control unit also considers the measured signals of at least one sensor device located at the bearings of the roll such as, for example, a compression and/or tension sensitive element, an acceleration sensor (for measuring radial accelerations), or the like.
In addition, the present invention provides a method to actively weaken undesirable vibrations of a rotating roll. The undesirable vibrations are detected/measured by use of a sensor. A power unit device influencing the roll is triggered dependent upon the detected/measured results, thereby weakening the undesirable vibrations.
As used herein, the terminology “in the area of the machine center” refers to a relatively wide area around the exact longitudinal center of the roll. The reason for this is that, in a good first approximation and with consideration of occurring centrifugal forces, the deformation of the roll due to vibration follows a parabola that progresses between the two side bearing positions and is substantially symmetric about the machine center. The value of a parabola changes only slightly in the maximum range. Thus, with regard to the precision of the measurement of the vibration swings of the roll, the “area of the machine center” can, therefore, be defined as the area between the two points in axis direction of the roll in which the vibration swing is approximately 75% of the maximum swing in the exact machine center.
BRIEF DESCRIPTION OF THE DRAWINGS
The above-mentioned and other features and advantages of this invention, and the manner of attaining them, will become more apparent and the invention will be better understood by reference to the following description of an embodiment of the invention taken in conjunction with the accompanying drawings, wherein:
FIG. 1 is a schematic illustration of an embodiment of an apparatus to actively reduce undesirable vibrations of a rotating roll of the present invention;
FIG. 2 is a sectional drawing along line II—II in FIG. 1; and
FIG. 3 is a perspective view of the applicator device of FIG. 1 .
Corresponding reference characters indicate corresponding parts throughout the several views. The exemplification set out herein illustrates one preferred embodiment of the invention, in one form, and such exemplification is not to be construed as limiting the scope of the invention in any manner.
DETAILED DESCRIPTION OF THE INVENTION
Referring now to the drawings and particularly to FIG. 1, there is shown a device to actively weaken vibration in accordance with the present invention generally designated 10 . In the embodiment shown, device 10 serves to weaken, compensate, reduce or dampen undesirable vibrations of roll 12 rotating around an axis A in a coating device 14 intended for indirect two-sided coating of a material web 16 with a liquid or viscous coating medium 18 . The material web 16 travels in flow direction L through a nip 15 which is formed between two neighboring rolls 12 and 13 .
It should, however, be pointed out that the device of the present invention can also be utilized advantageously with other rotating rolls of the type frequently used in machinery for the production and/or coating of material webs, specifically paper or cardboard webs.
Active weakening device 10 includes at least one power unit 20 which, through a positioning actuator 20 a, influences the journal 12 a of roll 12 . The influence occurs out-of-phase, preferably in phase opposition to the undesirable vibrations of roll 12 .
To detect/measure the vibrations of roll 12 , a series of different sensor devices are utilized which will be discussed in detail below. The sensor devices are positioned at locations where they are not exposed to the danger of contamination and/or damage, and where they do not hamper free access to the roll surface 12 by maintenance or operating personnel P.
Laser-vibrometer 22 is located at a distance d from the roll surface 12 b, whereby the laser jet 22 a is pointed onto the roll surface 12 b. Such laser-vibrometers available under product description VH 300 from Ometron Inc., Dulles, USA. Laser-vibrometers of the aforementioned type determine the vibrations of the roll 12 from the component of the speed of roll surface 12 b that is aligned parallel to the laser beam 22 a. In order to obtain a measurement precision that is as accurate as possible, the laser-vibrometer 22 is located preferably in plane E which connects the axes 12 a and 13 a of the two rolls 12 , 13 .
The detection/measurement signal of laser-vibrometer 22 is transmitted via a signal line 22 b to a control unit 24 which, utilizing the detection/measurement signal, determines actuating signals and then transmits the actuating signals via a signal line 24 a to power unit 20 .
The laser-vibrometer 22 has the advantage that it can be located at a very large distance d from roll surface 12 b, such as, for example, at a distance d of more than one meter. Such large distances ensure that there is sufficient room available for maintenance and/or operating personnel P in the area of roll 12 , and to permit unhampered access to roll surface 12 b. In addition, the large distance between roll surface 12 b and laser-vibrometer 22 ensures that, in the event of a break of material web 16 and the frequently resulting “wrap-up” of the roll 12 , the laser-vibrometer is not damaged by material web 16 . Additionally, laser-vibrometer 22 is protected from contamination due to splashes from the coating medium 18 . In a worst case scenario, a simple diaphragm system (not shown) may additionally be necessary. Due to the large distance from the roll surface 12 b, the laser-vibrometer 22 may be located without problem in the area of the machine center, that is in the area of the longitudinal center of roll 12 . In this area, the vibration of the roll 12 leads to very strong swings of the roll surface 12 b, thereby permitting a very precise measurement of the vibrations of roll 12 .
Another type of sensor for measuring the vibrations of roll 12 are the compression and/or tension sensitive elements 28 which are illustrated in FIG. 1 and which are located on the interior surface 12 c (FIG. 2) of the roll shell 12 d. The compression and/or tension sensitive elements 28 may, for example, take the embodiment of conventional wire strain gauges. It is, however, also possible to utilize any other type of compression and/or tension sensitive elements, films, or similar devices. Since a single one of these elements 28 is able to detect/measure the vibrations of the roll 12 only at a certain point of the roll, it is advantageous to place a multitude of these compression and/or tension sensitive elements 28 around the circumference of the roll 12 , as indicated in FIG. 1 over a section of the interior circumference of the roll 12 . The detection/measurement signals of the elements 28 are again transmitted to the control unit 24 via signal lines 28 a and/or radiometrically in order to avoid rotation compatible connections. These detection/measurement signals are used in determining the actuating signals for the power unit 20 .
Since the rolls utilized in machinery for the production and/or coating of material webs, specifically paper or cardboard webs, often must be and commonly are cooled, it is recommended that only such compression and/or tension sensitive elements 28 are utilized that are resistant to the cooling medium, for example, cooling water, or that these elements 28 are equipped with a protective layer or cover. Due to the location of the elements 28 on the interior 12 c of the roll shell 12 d, elements 28 are protected from damage by the material web 16 in the event of “wrap-up” of roll 12 and from contamination through splashes of coating medium 18 . In that location, elements 28 will not inhibit access to the roll surface 12 b by maintenance and/or operating personnel P.
In addition to the laser-vibrometer 22 and the compression and/or tension sensitive element 28 , additional sensor units measure the vibration of roll 12 . An example shows a compression and/or tension sensitive element 30 (FIG. 2) located on the outside of roll shell 12 d which is protected from damage and/or contamination by a layer 32 (i.e., a protective roll cover) of rubber or rubber-type material, synthetic or similar material. Based on the fact that element 30 is located underneath the actual roll surface 12 b, i.e., on the inner surface of layer 32 , it does not hamper access by the operator P to the roll surface 12 b. The measured signals of element 30 are transmitted via signal line 30 a to the control unit 24 and are considered in determining the actuating signals for the power unit 20 .
An additional sensor unit in the form of laser interferometer 34 detects/measures the mechanical stress/tension condition of the roll 12 and transmits a corresponding signal to the control unit 24 , via a signal line 34 a. Laser interferometers of this type are used, for example, in the field of non-destructive material analysis. Their utilization takes advantage of the fact that very high mechanical stresses/tensions occur in the roll 12 in the area of the machine center, i.e., in the longitudinal center of roll 12 , in the area of the header section 12 e of the roll 12 , i.e., between the roll shell 12 d and the roll journal 12 a, in the transition areas between the header section 12 e and the roll shell 12 d, and in the area of transition between the header section 12 e and the roll journal 12 a.
In the embodiment shown, the laser interferometer 34 is pointed to the transition between the roll shell 12 d and the roll header 12 e. This offers the advantage that the laser-interferometer 34 may be positioned next to the roll 12 , thereby permitting unhampered access to the roll surface 12 b. Alternatively, the laser interferometer 34 can be located at a great distance from the roll 12 .
Finally, in the embodiment shown, an acceleration sensor 38 is positioned in the area of bearing 36 of roll journal 12 a and detects/measures the vibration of roll 12 due to the radial acceleration of the roll journal 12 a. Acceleration sensors 38 of this type are, for example, utilized to verify the wear and tear condition of bearing 36 . Suitably sensitive and continuously-operable acceleration sensors 38 can be used for monitoring of wear and tear as well as for measuring the vibration of roll 12 . The measured signals of the acceleration sensors 38 are transmitted via signal lines 3 8 a to control unit 24 .
Since it is to be expected that the frequency spectrum of the vibrations of the roll 12 will change depending upon the prevailing operating conditions of the roll 12 or of the entire machine for the production and/or coating of the material web 16 , and since the sensitivity frequency spectrum of the sensors is firmly predetermined, the control unit 24 combines the measured signals of at least two of the sensors 22 , 28 , 30 , 34 and 38 in a suitable manner when determining the actuating signals for the power unit 20 . The measured signals of the sensor are combined by, for example, super-imposing additively and/or subtractively and/or averaged and/or weighted, depending upon the operating conditions, and/or phase corrected, depending on the arrangement along the circumference of the roll 12 . It must be added that movements, particularly self-vibrations, of the sensor devices mounted on machinery components, for example sensors mounted in the area of the machine center, must be considered when interpreting the measured signals of these sensors.
The present invention further provides a method and apparatus to determine the distribution of the forces or pressure prevailing in the nip of a device for treating a traveling material web, specifically a paper or cardboard web, that includes a pressure element, for example a press roll, and a backing element, for example a backing roll, whereby the pressure element and the backing element together form a nip therebetween through which the material web travels. The apparatus for determining the pressure/force distribution provides precise information regarding the forces or pressures being exerted in the nip upon the material web, so that countermeasures may be taken in the event of excessive variations of these forces or pressures across the working width of the material web. The countermeasures create essentially constant treating conditions across the entire working width of the material web.
The present invention may be utilized in a multitude of different treating processes for material webs, including, for example, the press section of machinery for the production of a material web, glazing units, coating units, or even in printing machines. However, in the interest of clarity, the present invention will be discussed below in detail only in connection with a device for the application of a liquid or viscous coating medium onto a material web.
Conventionally, specialty papers were fed into the nip in order to determine the pressure distribution therein. For example, a two-ply layer of carbon paper and a light illustrating sheet or papers containing ink-filled beads which burst under pressure and release the ink were used to determine pressure distribution in a nip. In addition, the company Stowe Woodward suggested a thin film encompassing a multitude of pressure sensors, which is fed into the nip in place of the specialty papers and which can be utilized to automatically measure the force or pressure distribution prevailing in the nip. All of these devices for determining the pressure distribution, however, have the disadvantage that they only permit measurement of the pressure distribution under stationary conditions. Therefore, dynamic influences of the machinery motion upon the forces and pressures prevailing in the nip cannot be detected with the conventional devices for determining the pressure distribution described above. In addition, a lengthy and laborious procedure is necessary in order to determine the variation in the pressure distribution in the circumferential direction of the roll.
German patent document no. DE 196 42 047 A1 describes an arrangement of a multitude of pressure sensors in a stationary press shoe. The disadvantage in this solution is that the measurement of the pressure distribution occurs only in the area of the press shoe, thereby rendering expensive and difficult an allocation to certain locations around the circumference of the cover element that is continuously wrapped around the press shoe. Another disadvantage is that not only the continuous cover element is located between the pressure sensors and the material web, but also a lubricant, which reduces the friction between the cover element and the press shoe, and a film, which protects the pressure sensors from the lubricant.
The present invention provides a method and apparatus which permit reliable determination of the pressure distribution prevailing in the nip even during operation of the treating/converting unit so that, when determining corrective control values, the dynamic effects are considered.
The present invention provides a treating unit in which at least one of the elements—pressure element or backing element—is a roll, and in which the device for determining the pressure distribution includes a sensor arrangement having a multitude of sensors arranged in circumferential direction and in axial direction of the roll. In this embodiment of the treating unit, it is ensured that the sensors of the aforementioned sensor arrangement are located in the immediate area of the surface that is in contact with the material web. Thus, the measured values possess a high degree of meaningfulness by reflecting the conditions to which the material web is subject. On the other hand, the sensors are not only arranged in the axial direction of the roll, thereby permitting the determination of the pressure distribution across the working width, but are also arranged in the circumferential direction of the roll, thereby enabling determination of the pressure distribution in the nip at any given rotational position of the roll. Therefore, the present invention provides for the determination of the prevailing pressure in the nip at all times, including when the treating unit is at a standstill and during full speed operation of the treating unit.
Preferably, the sensors are designed and/or provided for indirect or direct pressure/compression measurement. If there is no, or only negligible, danger of damaging the surface of the material web, the sensors for detecting/measuring the pressure can be located directly on the surface of the roll.
If a roll is equipped with a resilient elastomer-type protective cover layer, i.e., rubber, rubber-type material or synthetic material, it is suggested that at least some of the sensors within the sensor arrangement be located at the outside surface of the roll underneath this protective cover layer. In an applicator unit, this protective cover layer protects the pressure/compression sensors from the possibly detrimental consequences of exposure to the coating medium. The protective cover layer is the only layer between the material web and the sensors that influences the measured results. Therefore, placing the sensors under the protective cover layer permits meaningful measurements which correlate to the conditions to which the material web is exposed, together with a long life span of the sensor arrangement. The lines leading to the sensors, for example, the power supply lines and the signal transmission lines, are also routed underneath this protective cover layer.
In addition, or alternatively, to installing the sensors under the protective cover layer, at least some of the sensors of the sensor arrangement are embedded in the roll shell. This embedding may be accomplished during the manufacture of the roll, especially when the roll is manufactured from fiber reinforced synthetic material such as, for example, carbon fiber reinforced synthetic material. However, with both fiber reinforced synthetic rolls and steel rolls it is possible to embed the sensors after manufacture of the roll. Correspondingly, the lines leading to the sensors may also be embedded in the roll shell either during original manufacture or at a later date.
It is suggested that at least some of the sensors are grouped in a thin sensor plate or sensor foil. This arrangement offers the advantage of trouble free treating, particularly when the sensors are located underneath a protective cover layer.
The sensors convert the value of the measured pressure/compression into electric voltages which can easily be processed by an evaluation unit. With the use of suitable evaluation software it is, for example, possible to track on a screen exactly how the force distribution changes across a web width as the line pressure is influenced in the nip. A signal provided by the sensor arrangement is considered in the control function of a power unit controlling the pressure element and/or the backing element. The line pressure may be purposefully influenced during operation of the treating unit, and the changes in the force or pressure distribution resulting from this may be observed in real time. This enables optimization of the conditions prevailing in the nip automatically, if appropriate controls software is used, or manually through an operator, and ensures a high quality treating result.
The present invention also provides a roll fitted with a sensor arrangement which is utilized, for example, in the previously discussed treating line. Such “sensor-rolls” may, however, also be used advantageously in instances where pressure is exerted upon the roll merely through the effects of the traveling material web without the influence of a backing element. An example would be web guide rollers.
In this embodiment, an applicator device is generally identified with 510 (FIG. 3) that includes two rolls 512 and 513 which rotate around axes A and B (arrows P and P′) and which together form a nip 515 . The nip 515 is supplied by two applicator units (not shown) with liquid or viscous coating medium 518 . Coating medium 518 is supplied onto a material web 516 which is traveling through the nip 515 in the direction of arrow L.
Roll 512 determines the distribution of the pressures or forces prevailing in the nip 515 in cross direction Q. The roll 512 includes a rigid roll shell 550 which may, for example, be manufactured from steel or fiber reinforced synthetic material, and a cover layer 552 of resilient rubber-elastomer material such as, for example, rubber, rubber-type material or suitable resilient natural or synthetic material. Roll 512 , as shown in the area that is without the cover layer 552 , includes a multitude of pressure/compression sensors 554 located underneath cover layer 552 in circumferential direction U and in axial direction A. The power supply lines leading to these pressure/compression sensors, and the signal lines leading away from these sensors, (identified together as 556 in FIG. 3) are routed underneath the cover layer 552 .
In addition, or alternatively, to the compression sensors 554 , compression/pressure sensors 558 are embedded in the roll shell 550 , and arranged in both circumferential direction U and axial direction A. This permits determination/measurement of the pressure distribution in nip 515 in cross direction Q for any given rotational position of the roll 512 . The lines 560 to the sensors 558 are also embedded in the roll shell 550 .
In the embodiment shown, the sensors 554 are integrated in a pre-manufactured sensor arrangement including a thin backing foil 564 which simplifies their installation under the cover layer.
The measuring results obtained by the sensor arrangement 554 or the sensor arrangement 558 are transmitted to evaluation device 562 which, in accordance with a first embodiment, enables the operator to determine where and to what extent the line pressure in the nip 515 must be influenced through one or more power units (not shown) in order to ensure an essentially uniform pressure or force distribution in the nip 515 . In a second embodiment, the evaluating device 562 additionally determines the location and the magnitude of the influence over the line pressure and provides a corresponding signal to an appropriate power unit.
Sensor arrangements similar to the sensor arrangements 554 / 556 and 558 / 560 may also be provided in the roll 513 , resulting in a further improvement of the meaningfulness of the detected/measured results.
According to the aforementioned it is possible with the applicator device or the device for determining the pressure distribution of the present invention—even under dynamic conditions, i.e., in an applicator unit running at full production speed—to determine the distribution of the forces or pressures prevailing in the nip and to thereby create reproducible and uniform coating conditions in the nip, thus ensuring a uniform and high quality coating result.
While this invention has been described as having a preferred design, the present invention can be further 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 its general principles. 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 and which fall within the limits of the appended claims. | A device to actively reduce undesirable vibrations in a rotating roll includes at least one sensor arrangement to detect/measure the undesirable vibrations and at least one power unit device which, dependent upon the detecting/measuring result, influences the roll to reduce the undesirable vibration. The sensor arrangement includes at least one sensor which, relative to the rotational axis of the roll, is located radially inside the substantially circular cylindrical outer surface of the roll and/or at least one sensor which is located remotely from the substantially circular cylindrical outer surface of the roll. | 3 |
TECHNICAL FIELD
[0001] The present invention relates to an actuating and display plate for a flushing device, wherein the plate consists of a non-conductive transparent material, wherein the plate has at least one viewing window, and wherein behind the viewing are disposed: at least one infrared light source, at least one proximity sensor, which works on a light-reflection basis and is sensitive to the wavelength zone of the infrared light source and with which the flushing device can be triggered, and at least one display light source within the visible light zone.
PRIOR ART
[0002] From EP 1 961 876, a device for electrically triggering a toilet flushing system is known, wherein the actuating plate is a glass plate or a plate made of a non-conductive material. Behind the plate are sensor keys of capacitively working sensors, which contactlessly detect the approach of the hand of a user. The sensor system of the capacitive sensor keys is stuck on the rear side of the actuating plate.
[0003] EP 1 867 613 discloses, from the field of kitchens, a combined actuating and display plate which has, moreover, a rear, opaque coating that leaves a window open. This window is provided with a likewise rear precious metal coating, which in the visible light for the range of wavelengths from 400 nanometres to 750 nanometres is said to have a transmission in the range of 1 to 21% and a scatter of 0 to 1%.
[0004] In addition, in this viewing window region behind the glass ceramic plate, a lighting means is provided in order to be able to provide the user with a confirmation of the activation of the capacitive sensor likewise disposed behind the glass ceramic plate.
[0005] AT 009 069 U1 discloses an actuating and display plate of a flushing fitting having the features of the preamble of claim 1 , which actuating and display plate has a viewing window behind which is provided a proximity sensor, working on a light-reflection basis, with which the fitting can be triggered. The infrared sensor is said, on the one hand, to be capable of detecting the approach of a user to the fitting and, on the other hand, the sensor is capable of discerning when the fitting is due to be triggered. For this, the triggering is achieved via an infrared distance measurement. In addition, behind the viewing window is provided an optical lighting means, with which the operating state or the triggered function is displayed to the user of the fitting. The viewing window is in this case transparent, and symbols and signal fields provided for the display, which if need be are imprinted or stuck on the actuating and display plate, are likewise transparent.
REPRESENTATION OF THE INVENTION
[0006] Starting from this prior art, it is one object of the invention to define a combined actuating and display plate which ensures an improved optical display, whilst safeguarding the functional capability of the contactless triggering.
[0007] According to the invention is provided an actuating and display plate for a flushing device, wherein the plate consists of a non-conductive transparent material, wherein the plate has at least one viewing window, and wherein behind the viewing window are disposed: at least one infrared light source, at least one proximity sensor, which works on a light-reflection basis and is sensitive to the wavelength zone of the infrared light source and with which the flushing device can be triggered, and at least one display light source within the visible light zone, wherein a back coating of the plate, which has a transmission in the range between 1 percent and 15 percent for the visible light zone and a transmission of more than 60 percent for the near-infrared light zone, is provided.
[0008] The glass plate per se offers the foundation for contactless and hence hygienic triggering and is, in terms of its size, the basis of a wide variety of options for the display and the different triggering operations. By virtue of the fact that in this context a single back coating is provided, a homogeneous display, which safeguards the opaqueness of the sensor system hidden behind the glass plate and, at the same time, ensures the display by virtue of a display lighting means disposed behind the glass plate, can be realized.
[0009] A transmission of this coating in the range between 1 percent and 15 percent for the visible light zone allows a clearly visible display for a user even under adverse light conditions, without too high a transmission, as in a fully transparent glass plate without coating, showing details of the sensor system.
[0010] In the prior art of AT 009 069 U1, as in other embodiments of sensors in this field, the glass plates provided for this are kept very small in terms of their surface, which spatially precludes, for example, an arrangement of a plurality of sensors for the triggering or display of two different flush water quantities. As a result of the small surface area, the quantity of light which enters through the plate is automatically limited and it is difficult for the user to see through. The prior art according to EP 1 867 613 also then uses an opaque region to limit the incident scattered light.
[0011] Here an object of the invention is to define a large-area actuating and display plate which, nevertheless, allows no look-through onto electronics disposed behind it. For this, the coating is chosen in the said transmission range.
[0012] For the use of this actuating and display plate having a single coating for contactless detection by an optical contactless distance measurement, it is then a basic feature that the transmission of the coating in the region of the near-infrared wavelength zone is at least 60%, so that the transmittance of the coated plate for infrared light is sufficiently great for infrared distance measurement in both directions. The transmission takes place once for the emitted rays of the infrared light source in one direction, and then for the rays, reflected by the user, in the other direction through the plate.
[0013] The transmission behaviour of the actuating plate is crucial for the correct representation of the lighting elements and for the infrared sensor system. On the one hand, a maximum transparency in the IR-zone is realized, on the other hand the transmission in the visible zone must not exceed predetermined values in order to prevent components behind the actuating plate from becoming visible to the user.
[0014] Further embodiments are defined in the dependent claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] Preferred embodiments of the invention are described below with reference to the drawings, which serve merely for illustration and should not be interpreted in a restrictive sense. In the drawings:
[0016] FIG. 1 shows a transmission spectrum of a coating for use in an illustrative embodiment of the invention, and
[0017] FIG. 2 shows a schematic perspective view of an illustrative embodiment of an actuating and display plate according to the invention.
DESCRIPTION OF PREFERRED EMBODIMENTS
[0018] FIG. 1 shows a transmission spectrum of a coating for an actuating and display plate 100 according to the invention, represented in FIG. 2 .
[0019] The value of the transmission 10 in the thereto possible range between 0 and 100 percent is represented on the axis of ordinate relative to the wavelength 20 for a range from ultraviolet into infrared. The axis of abscissas is divided into five zones 21 , 22 , 23 , 24 and 25 .
[0020] According to the invention, in respect of the coating, two wavelength zones are essential, in which the transmission behaviour must lie within a specific range. This is the visible light zone 22 , this visible light zone being defined between 400 nanometres and 700 nanometres for the human eye. In the case of a restricted colour display, this zone can also be restricted to sub-zones, for example between 400 and 550 nanometres, from 500 to 700 nanometres, in order to utilize more blue or red displays, or having a restricted range from 500 to 600 nanometres.
[0021] The second essential wavelength zone is the infrared zone 24 of a wavelength from about 800 nanometres to 2000 nanometres, wherein the normally used infrared light sources deliver a radiation in the range between 850 nanometres and 920 nanometres. Furthermore, in FIG. 1 , the ultraviolet zone is provided with the reference numeral 21 , whilst the far infrared zone is provided with the reference numeral 25 . The transition zone between the visible light zone 22 and the infrared zone 24 is provided with the reference numeral 23 . The lower limit of this zone 23 can be altered according to the definition of the upper end of the visible light zone 22 . The zone 21 thus relates to the value of the transmission with a wavelength of less than 400 nanometres, or less than 500 nanometres according to the above illustrative embodiments. The far zone 25 thus relates to the value of the transmission with a wavelength of greater than 2000 nanometres, or greater than 920 nanometres according to the above illustrative embodiments. Finally, the transition zone 23 relates to the value of the transmission with a wavelength of greater than 700 nanometres, or greater than 550 or 600 nanometres, and less than 800 nanometres, or less than 850 nanometres according to the above illustrative embodiments. The combinations are fluid and dependent on the chosen coating.
[0022] In FIG. 1 , with the curve 39 , a curve modelled on the real transmission characteristic is plotted, which curve has been employed, in trials, in prototypes of the invention.
[0023] According to the invention, a transmission between 1 and 15% for the visible light zone 22 shall be provided in respect of the coating. This transmission is represented by the transmission band limited by the lower limit curve 31 and the upper limit curve 32 and is shaded. In particular, a transmission between 2 and 10% can be provided. Advantageously, transmissions of more than 5% are present only in small part-zones of the critical wavelength zone 22 . In the represented illustrative embodiment, a corresponding wavelength part-zone 38 with a higher transmission is found in the wavelength zone close to the ultraviolet. Such a part-zone 38 is a wavelength zone over no more than 150 nanometres in total, advantageously over no more than 100 nanometres in total, in which the transmission curve comprises between 5 and 15 percent. In the trials conducted by the Applicant, coatings were used which produce such zones 38 of up to 70 nanometres in the region of the short-wave visible zone and up to 70 nanometres in the region of the long-wave visible zone, i.e. for example between 400 and 450 nanometres and between 650 and 700 nanometres.
[0024] With this transmission in the zone 22 , the user of the inventive device is guaranteed to have sufficient perception of the light source, as a display means, disposed behind the actuating plate; conversely, the transmission, in turn, is not so high that the user can recognize, apart from the lighting means, other elements in the installation frame of the display and actuating plate. Preferably, the background of the installation frame is designed or coloured in particular as grey or black, at least not white. If there is no installation frame forming the background, but this is a wall part of a building, then this shall preferably be kept dark.
[0025] In the two boundary zones 21 and 25 of the ultraviolet and infrared, it is indicated with the shading between 0 percent and 100 percent that the transmission behaviour of the coating in these zones can be freely chosen; in particular, it can resemble the transmission behaviour of the adjoining zones.
[0026] In the transition zone 23 between the visible light zone 22 and the infrared zone 24 , a steady transition of the transmission behaviour is advantageously provided, although, here too, this transmission can in principle be freely chosen; in particular, it can be zero; this zone can also be relatively small and comprise just a few nanometres. A steep transition flank of this kind is preferred. In another, non-represented illustrative embodiment having a different coating, the zone 23 extends between 700 and 850 nanometres and steadily rises therein from about 10% transmission to 65% transmission. A zone 38 of enhanced transmission then exists at the upper wavelength zone end 22 .
[0027] The transmission behaviour in the infrared zone 24 is characterized by its lower limit of 60%. It is essential for a correct detection of the actuation that the infrared light emitted by the sensor light source and reflected back by the user is transmitted to the extent of no less than 60% in order to obtain an adequate response. The transmission in this zone 23 is upwardly open and can amount to up to 100% of the light entering the coating.
[0028] FIG. 2 shows in very schematic representation an actuating plate 100 , behind which a coating is here represented as a separate surface 101 , the thickness of the coating being negligible in relation to the thickness of the supporting actuating plate 100 . The coating 101 can comprise, in particular, a display window 102 and a sensor window 103 , which windows can be separated by a masking 104 . The masking signifies a light-impermeable coating, which in particular lets through neither visible light nor IR light.
[0029] Such a coating 104 further has the advantage that it is available as a very strongly adherent coating, which can simultaneously offer a base surface for fastening the actuating plate onto a mounting frame. For this, boundary regions, disposed on the margin of the plate, can be provided. In contrast to the representation of FIG. 2 , the opaque coating is not then disposed on a continuous coating 101 but directly on the glass plate 100 . Naturally it is possible to provide different arrangements of display windows 102 and sensor windows 103 as long as a light source in the visible light zone is provided as the display lighting, as well as a pair, comprising a sensor light source and sensor detector, which is designed to emit and detect infrared light.
[0030] The advantageously present, closed rear space of the actuating unit having the actuating plate according to the invention can easily be the rear space of a wall in which the display and actuating plate is installed, or a separate installation frame can be provided, the surface colour of which is then preferably dark.
[0031] It is further possible for the actuating and display plate to have a coating which has a mirroring effect for the viewer. This can be constituted by the said coating having the transmission behaviour of FIG. 1 . In other words, the feature that the further or the same coating shows a reflection shall be realized, of course, only for the wavelength zone 22 which is essential for the viewer; insofar as this reflection occurs only for incident light in part-zones of the wavelength zone 22 , a colour effect is obtained. The reflection can lie within the visible zone, in particular in the range from 30 to 50 percent, a reduced overall transmission being obtained if an additional coat is applied to the inventive coating. The values of the coating 101 should then be seen in total.
[0032] A combined coating of this kind can be an interference filter coating on Borofloat glass, which, given high reflection, produces a damping of 5% in the visible zone up to 700 nanometres and, from 800 nanometres, allows a transmission of over 60%.
[0033] The actuating plate can also be provided with a splinter protection film, which has no effect on the transmission and reflection behaviour.
REFERENCE SYMBOL LIST
[0000]
10 transmission
20 wavelength
21 ultraviolet zone
22 visible light zone
23 transition zone
24 near-IR zone
25 far IR-zone
31 lower limit curve
32 upper limit curve
38 zone of enhanced transmission
39 real transmission curve
100 actuating and display plate
101 coating
102 display window region
103 sensor window region
104 opaque coating | An actuating and display plate for a flushing device consists of a non-conductive transparent material, wherein the plate has at least one viewing window, behind which are disposed: an infrared light source, a proximity sensor, which works on a light-reflection basis and is sensitive to the wavelength zone and with which the flushing device can be triggered, and a display light source within the visible light zone. On the plate is provided a back coating, which has a transmission in the range between 2 percent and 15 percent for the visible light zone ( 22 ) and a transmission of more than 60 percent for the near-infrared light zone ( 24 ). | 4 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority from provisional application Ser. No. 61/546,079, entitled “Method And Apparatus For Interactive And Context Aware Television Experience Based On Closed Caption,” filed on Oct. 12, 2011. The contents of this provisional application are fully incorporated herein by reference.
BACKGROUND
[0002] 1. Field
[0003] The present subject matter relates to a method and apparatus for extracting data included in a video signal stream and generating options with which a user may interact based on contextual searching of the data.
[0004] 2. Background in the Art
[0005] Closed captioning data contains a continuously updated text resembling a transcript of a current television program. Closed captioning data was originally intended for use only by hearing impaired television viewers. The closed captioning data is transmitted during a vertical blanking period of a raster scan when video image data is not being received. During this period, the scan is prepared to define a next line of video data. New uses have been found for the closed captioning data signals separate from providing signals from which text display is derived.
[0006] Use of closed captioning information for a separate purpose is shown in United States Published Patent Application No. 20060215991. A television recorder reads a closed captioning data from a current program and stores it. The recorder also reads subsequent information. For comparison to the first set of data so that it can detect a duplicate program and avoid making a duplicate recording. This system does not provide information which is provided directly to a viewer.
SUMMARY
[0007] Briefly stated, in accordance with the present subject matter, an apparatus and method are provided in which text embodied in a closed captioning signal is decoded and read by a rules based processor in order to identify subject matter included in the closed captioning text. This subject matter is context-searched to derive search terms to access information relevant to the subject matter, generally from a remote location. Selections made from accessed information are made. The selections are the basis from which choices are constructed to present to a user via, e.g., a graphical user interface (GUI). The user may interact with the GUI to make a selection. Selections may include accessing a URL for information related to the subject matter or accessing an e-commerce site that offers goods related to the subject matter. The GUI facilitates further interaction in order to allow the user to select further options which are dependent from the initial selection.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] FIG. 1 is a block diagram of a system in which the present subject matter is employed;
[0009] FIG. 2 is a chart indicating content included in a nominal closed captioning data stream;
[0010] FIG. 3 is a chart of selected terms comprising data that may be derived from the content in FIG. 2 ;
[0011] FIG. 4 is a chart illustrating searching that may be performed on the data illustrated in FIG. 3 ;
[0012] FIG. 5 is a chart illustrating choices that may be provided to a user based on data obtained in response to searching;
[0013] FIG. 6 is a diagram illustrating a graphical user interface from which a user may make selections;
[0014] FIG. 7 is a diagram illustrating a response to a selection by a user of one alternative of the display in FIG. 6 ;
[0015] FIG. 8 is a flowchart illustrating operation of the content processor in the system of FIG. 1 ;
[0016] FIG. 9 is block diagram illustrating interaction of the remote control unit in greater detail; and
[0017] FIG. 10 is a block diagram illustrating a further implementation of the present subject matter.
DETAILED DESCRIPTION
[0018] The present subject matter comprises a method and apparatus which enable a user to interact with a communications system to produce results that are relevant to the subject matter of a current program. A system reads and analyzes closed captioning data in order to provide displays of data which may be presented via a graphical user interface (GUI) to a user on a screen on which the user is viewing a current program. The user may make various selections. Examples of selections available through the GUI include links to Internet sources. The screen display may also give the opportunity to the user to make choices. Links may link to websites in order to place an order to buy a product or service associated with program intelligence embodied in the closed captioning signals. The system and the GUI may allow further selections of options regarding an initial selection.
[0019] FIG. 1 is a block diagram of a system 1 which uses closed captioning signals included in a television signal. Television signals are provided from a source such as a cable provider 10 . The cable provider 10 transmits a video signal 11 . The video signal 11 includes a video data signal V and a closed captioning data signal CC. In standard television protocols, the signal CC is transmitted during the time period when video information is not transmitted. This time period is the vertical blanking interval when a raster scan moves from a first line to a next line. The video signal 11 is provided to a cable box 16 . In the present description, “cable box” is a term describing a device for decoding a video signal and providing it to a media device 12 . The term “cable box” is used since this describes an apparatus with a well-known function with many possible well-known structures. Alternative embodiments for providing a video signal to a media device 12 are further described below.
[0020] The media device 12 is a device for viewing of a program by a user 4 . The user 4 commonly comprises a person viewing the media device 12 . The media device 12 may comprise any of a number of various forms of receivers that exist today. With the convergence of communications devices and media devices, it is likely that there will be equivalent devices that do not yet exist. Examples of current media devices 12 include a television set 18 receiving signals directly from the cable box 16 . The television set 18 comprises a display 20 . As further described below, a graphical user interface 24 may selectively be provided on the display 20 . The cable box 16 preferably works in conjunction with a remote control unit 28 operated by the user 4 .
[0021] In accordance with the present subject matter, and interaction module 40 is provided for operation in conjunction with the cable box 16 . The interaction module 40 may comprise a separate set-top box. Alternatively, the interaction module 40 may be included as a component of a modified version of a conventional cable box 16 . The cable box 16 comprises a video decoder 50 , which provides signals to drive the display 20 and present the program via the television set 18 . In many common cases, the video decoder 50 may be included in the television set 18 . In FIG. 1 , the video decoder 50 is shown as being in the cable box 16 for convenience. Locating the video decoder 50 in a particular module is not essential. In the video decoder 50 , the video signal 11 is connected to a signal parser 52 , which separates the video components from the closed captioning component CC. The video signal V is connected to a video decompressor 54 , and the closed captioning signal CC is connected to a graphics overlay generator 56 . An output of the video decompressor 54 is connected to a second input of the graphics overlay generator 56 . The graphics overlay generator 56 translates the closed captioning signal CC and combines text with the video signal to provide an output at a terminal 58 coupled to drive the display 20 .
[0022] The signal parser 52 provides the closed captioning signal CC to the interaction module 40 as well. The cable box 16 includes a remote control decoder 60 for responding to signals from the user 4 's remote control unit 28 . The remote control decoder 60 provides an input to the interaction module 40 to indicate the channel to which the user 4 is tuned. The interaction module 40 provides a signal which is interpreted by a content processor 80 . The content processor 80 may receive signals from the interaction module 40 via a network 70 . In the present illustration, the network 70 comprises the Internet. The content processor contains components for interpreting data, following rules to make decisions based on data, obtain further information based on the data, and send information back to the interaction module 40 . The interaction module 40 further comprises a GUI generator 64 , which translates results received from operation of the content processor 80 , further described below, to the video display 20 .
[0023] In the content processor 80 , a data bus 82 communicates with a first rules-based processor 84 , a text decoder 86 , content analyzer 88 , a user profile memory 90 , a data register 92 , and a second rules-based processor 94 . A request processor 96 may send commands back to the network 70 in order to request further data from external networks 100 . The external networks 100 may comprise search engines and other data sources.
[0024] The first rules-based processor 84 contains rules for selecting terms from the content included in the signal CC. The text decoder 86 derives intelligence from the signal CC. The content analyzer 88 performs context searching in order to derive terms for use by the first and second rules based processors 84 and 94 . The user profile memory 90 contains demographic details and preferences of the user 4 . The data register 92 stores data to provide input data and store results from processing operations. The second rules-based processor 94 translates the data provided from the first rules-based processor 84 , namely significant data, into search request terms. The request processor 96 translates the search request terms into queries that can be set by the Internet, 70 to the external networks 100 . The request processor 96 may also be used to evaluate and select search results for provision to the GUI generator 64 . The above-described components of content processor 80 are illustrated as discrete modules only for explanatory purposes. Generally, the content processor 80 will comprise an integrated circuit having various locations performing the functions described above.
[0025] As further described below, the user 4 may interface with the content processor 80 to provide information to the user profile memory 90 . The user profile memory 90 will provide information to the content analyzer 88 to enable the request processor 96 to receive information that is sent back to the cable box 16 via the interaction module 40 and presented to the user 4 . The user 4 may use the remote control 28 to further interact via the cable box 16 with the information provided from the request processor 96 by the content processor 80 . A service company 110 may operate the content processor 80 and provide rules to the first and second rules based processors 84 and 94 . The user profile memory 90 may contain preferences of the user 4 and data regarding the user 4 so that selections to be provided are tailored to the user 4 . The user 4 may transmit preferences to the service company 110 or the user profile memory 90 directly via the Internet 70 from a personal computer 114 .
[0026] FIG. 2 is an illustration of a stream of text included in a nominal closed captioning data stream. For example, a program could include a review of Naifah and Smith, Van Gogh, the Life , Random House, 2011. A review from the Los Angeles Times said, “Vincent van Gogh is an extraordinary artist about whom everything seems to be known. His brilliant work and tragic life, combined with a paper trail of letters to his art-dealer brother, Theo, have made him an irresistible subject for art historians, biographers, journalists, filmmakers, media specialists and psychologists since his death from a gunshot wound in 1890.” This text would appear in the closed captioning transcript of a television signal including a narrator reading this passage.
[0027] FIG. 3 is an illustration of terms selected from the content in FIG. 2 . A number of different strategies may be used in order to select terms that will be used in the method steps. For example, a rules based processor may select the name “Vincent van Gogh.” This term is indicated as being a selected term by its emphasis in FIG. 3 . Another term that could be selected is “artist” Additionally, terms such as “filmmakers” can be used to derive terms such as “films.”
[0028] FIG. 4 is a chart illustrating searching that may be performed on the data illustrated in FIG. 3 . Search targets may be selected based on one or more objectives. For educational purposes, “Vincent van Gogh” and “biography” could be used to search for biographical information. For e-commerce, “Vincent van Gogh” could be used as a search term to find online marketplaces for books, movies, and reproduction prints. The search term could also be used to search for upcoming exhibitions featuring van Gogh or to identify museums with significant collections. The commercial search purposes can be extended. For example, a search would indicate a significant collection at the Rijksmuseum in Amsterdam, the Netherlands. The search could be arranged to seek travel packages to Amsterdam.
[0029] FIG. 5 is a chart illustrating choices that may be provided to a user based on data obtained in response to searching. For example, FIG. 5 illustrates URLs for biographical data that has been returned by a search. Results may be provided in the same manner for each set of the search terms illustrated in FIG. 4 . In FIG. 5 , the first four results are set out in full. The dots below the first four results are set out to demonstrate that a large number of results may be obtained. The request processor 80 ( FIG. 1 ) may select a particular number of results to provide to a rules based processor.
[0030] FIG. 6 is a diagram summarizing the complete concept of extracting context from the closed caption data and presenting the relevant results to the user. In FIG. 7 , the GUI is illustrated including the list of choices provided along with instructions on the screen to the user 4 . Each choice is contained in an option box 190 within the graphical user interface 24 . The user 4 employs the remote control unit 20 in order to select the link displayed in one of the option boxes 190 . Once the user 4 has made a selection, the GUI 24 displays a response.
[0031] FIG. 8 is a flowchart illustrating operation of the content processor in the system of FIG. 1 . At block 300 , a selected channel of closed captioning information is provided to the content processor 70 . The text parser 76 extracts the closed captioning data from the signal stream at block 302 and decodes data embodied therein at block 304 . The data is provided to the content analyzer 78 and compared to criteria set in the user profile memory 80 , at block 306 . At block 308 , the result of rules in the processor 70 provide search terms. At block 310 , the terms are sent to the request processor 86 . At block 312 the search processor 96 requests signals via the network 70 from the external network 100 . At block 314 results are received at the request processor 96 . At block 316 the request results are further compared to rules in the first request processor 84 . The selected results are provided to a graphical user interface register at block 318 . The system is allowed to respond at block 320 to inputs provided by the user 4 . At block 322 the response provided to the cable box 18 by the user 4 is coupled to local storage in order to invoke a response. At block 324 the system confirms the selection to the user 4 in a display. If there is another level of selection required, operation returns to block 322 . A next query is displayed to the user 4 , and another response is made. Once the user 4 has completed selections, a final, display is made at block 326 . The user 4 may provide a signal to positively terminate the interaction, or the system may provide the option to terminate the transaction mode after a “timeout” period.
[0032] FIG. 9 is a block diagram illustrating a further implementation of the present subject matter. In this embodiment, the media device 12 comprises an Internet television 400 receiving streaming signals via the Internet 70 . The Internet television 400 may comprise a “smart television,” which may run applications for facilitating interaction within the present system. The Internet television 400 may be coupled to the Internet 70 via a Wi-Fi interface 410 . The remote control device 28 may be provided in a form for interaction with the Internet television 400 . The Internet television 400 embodies a translation “app” for translating search results into signals viewable on a display.
[0033] In this manner, a great deal of flexibility may be provided in enriching the media experience for user 4 . The present system may greatly enhance educational capabilities that can be provided by a program. Additionally, expanded and varied e-commerce opportunities are provided.
[0034] While the foregoing written description of the present subject matter enables one of ordinary skill to make and use what is considered presently to be the best mode thereof, those of ordinary skill will understand and appreciate the existence of variations, combinations, and equivalents of the specific embodiment, method, and examples herein. The present subject matter should therefore not be limited by the above described embodiment, method, and examples, but by all embodiments and methods within the scope and spirit of the present subject matter. | An apparatus and method decode and read text embodied in a closed captioning signal. A rules based processor identifies subject matter included in the closed captioning text. This subject matter is context-searched to derive search terms to access information relevant to the subject matter, generally from a remote location. Selections made from accessed information are made. The selections are the basis from which choices are constructed to present to a user via, e.g., a graphical user interface (GUI). The user may interact with the GUI to make a selection. Selections may include accessing a URL for information related to the subject matter or accessing an e-commerce site that offers goods related to the subject matter. The GUI facilitates further interaction in order to allow the user to select further options which are dependent from the initial selection. | 7 |
BACKGROUND
In many cases, the precise location of a vehicle can be determined using a combination of a global positioning system (GPS) receiver and an inertial measurement unit (IMU). Images taken from a vehicle using such location systems may be registered to a location using the positioning measurements provided by the GPS and IMU.
However, signal distortions in urban canyons, mechanical tolerances, wear, etc. may cause the reported location of one or more image sensors to be different from the actual location of the sensor in an unpredictable manner.
An example of such a mismatch is illustrated in FIG. 1 , that shows a prior art result of an attempt to align building image data (e.g. photographic data) 50 with an existing three dimensional (3D) model 52 of the same building. As can be seen, the lack of accurate registration of the image source location to the geographic reference of the 3D model causes misalignment between the images 50 and the model 52 .
SUMMARY
A system and method use a combination of image and high resolution scanning to align street-level images to 3D building models by systematically adjusting the origin point of the image data until a best match between the image and building model occurs. By performing the origin adjustment (e.g. a camera location) for the set of images they can be satisfactorily aligned. Further accuracy may be provided when images are chosen for opposite sides of a street, providing greater diversity of data for the alignment process.
The images are aligned with 3D models of buildings that may be generated using another technique, such as airborne laser ranging (LIDAR). The street-level (i.e. less than 20 feet above ground) images may be supplemented by street-level LIDAR data for building feature identification.
The images and street-level LIDAR are processed to extract building edges and skylines which are then projected against the 3D models. A cost, or figure of merit, is generated based on the distance between the extracted image edges and skylines, the street-level edges and facade depths, and the corresponding features of the 3D model. The camera location is then iteratively displaced about its calculated location and the cost recalculated. The lowest cost, corresponding to the best match between extracted features and modeled features is then selected and the corresponding camera location may be stored. The process may incorporate images from along a run of images including images from opposite sides, e.g. both sides of a street. As the source location is displaced, the lowest overall cost for all considered images represents the more accurate absolute position for the camera. FIG. 2 illustrates alignment of image 54 and 3D model 56 as a result of this technique.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a prior art illustration of the result of incorrect origin location information on image and model alignment;
FIG. 2 is an illustration of alignment of image and model data as a result of accurate origin information;
FIG. 3 is a block diagram of a general purpose computing device suitable for use in image registration;
FIG. 4 is a block diagram illustrating skyline identification at one point in an image run;
FIG. 5 is a block diagram illustrating skyline identification at another point in an image run;
FIG. 6 is an illustration of skyline identification in a street-level image;
FIG. 7 is a block diagram illustrating origin location adjustment using skyline data;
FIG. 8 is an illustration of skyline matching in a street-level image;
FIG. 9 is a block diagram illustrating LIDAR facade and building edge identification; and
FIG. 10 is a flow chart of a method of image origin adjustment for image registration.
DETAILED DESCRIPTION
Although the following text sets forth a detailed description of numerous different embodiments, it should be understood that the legal scope of the description is defined by the words of the claims set forth at the end of this disclosure. The detailed description is to be construed as exemplary only and does not describe every possible embodiment since describing every possible embodiment would be impractical, if not impossible. Numerous alternative embodiments could be implemented, using either current technology or technology developed after the filing date of this patent, which would still fall within the scope of the claims.
It should also be understood that, unless a term is expressly defined in this patent using a sentence that begins “As used herein” and finishes with, “is hereby defined to mean . . . ” or a similar sentence that defines the use of a particular term, there is no intent to limit the meaning of that term, either expressly or by implication, beyond its plain or ordinary meaning, and such term should not be interpreted to be limited in scope based on any statement made in any section of this patent (other than the language of the claims). To the extent that any term recited in the claims at the end of this patent is referred to in this patent in a manner consistent with a single meaning, that is done for sake of clarity only so as to not confuse the reader, and it is not intended that such claim term by limited, by implication or otherwise, to that single meaning. Finally, unless a claim element is defined by reciting the word “means” and a function without the recital of any structure, it is not intended that the scope of any claim element be interpreted based on the application of 35 U.S.C. §112, sixth paragraph.
Much of the inventive functionality and many of the inventive principles are best implemented with or in software programs or instructions and integrated circuits (ICs) such as application specific ICs. It is expected that one of ordinary skill, notwithstanding possibly significant effort and many design choices motivated by, for example, available time, current technology, and economic considerations, when guided by the concepts and principles disclosed herein will be readily capable of generating such software instructions and programs and ICs with minimal experimentation. Therefore, in the interest of brevity and minimization of any risk of obscuring the principles and concepts in accordance to the present invention, further discussion of such software and ICs, if any, will be limited to the essentials with respect to the principles and concepts of the preferred embodiments.
With reference to FIG. 3 , an exemplary system for implementing the claimed method and apparatus includes a general purpose computing device in the form of a computer 110 . Components shown in dashed outline are not technically part of the computer 110 , but are used to illustrate the exemplary embodiment of FIG. 3 . Components of computer 110 may include, but are not limited to, a processor 120 , a system memory 130 , a memory/graphics interface 121 , also known as a Northbridge chip, and an I/O interface 122 , also known as a Southbridge chip. The system memory 130 and a graphics processor 190 may be coupled to the memory/graphics interface 121 . A monitor 191 or other graphic output device may be coupled to the graphics processor 190 .
A series of system busses may couple various system components including a high speed system bus 123 between the processor 120 , the memory/graphics interface 121 and the I/O interface 122 , a front-side bus 124 between the memory/graphics interface 121 and the system memory 130 , and an advanced graphics processing (AGP) bus 125 between the memory/graphics interface 121 and the graphics processor 190 . The system bus 123 may be any of several types of bus structures including, by way of example, and not limitation, such architectures include Industry Standard Architecture (ISA) bus, Micro Channel Architecture (MCA) bus and Enhanced ISA (EISA) bus. As system architectures evolve, other bus architectures and chip sets may be used but often generally follow this pattern. For example, companies such as Intel and AMD support the Intel Hub Architecture (IHA) and the Hypertransport™ architecture, respectively.
The computer 110 typically includes a variety of computer readable media. Computer readable media can be any available media that can be accessed by computer 110 and includes both volatile and nonvolatile media, removable and non-removable media. By way of example, and not limitation, computer readable media may comprise computer storage media and communication media. Computer storage media includes both volatile and nonvolatile, removable and non-removable media implemented in any method or technology for storage of information such as computer readable instructions, data structures, program modules or other data. Computer storage media includes, but is not limited to, RAM, ROM, EEPROM, flash memory or other memory technology, CD-ROM, digital versatile disks (DVD) or other optical disk storage, magnetic cassettes, magnetic tape, magnetic disk storage or other magnetic storage devices, or any other medium which can be used to store the desired information and which can accessed by computer 110 .
The system memory 130 includes computer storage media in the form of volatile and/or nonvolatile memory such as read only memory (ROM) 131 and random access memory (RAM) 132 . The system ROM 131 may contain permanent system data 143 , such as identifying and manufacturing information. In some embodiments, a basic input/output system (BIOS) may also be stored in system ROM 131 . RAM 132 typically contains data and/or program modules that are immediately accessible to and/or presently being operated on by processor 120 . By way of example, and not limitation, FIG. 3 illustrates operating system 134 , application programs 135 , other program modules 136 , and program data 137 .
The I/O interface 122 may couple the system bus 123 with a number of other busses 126 , 127 and 128 that couple a variety of internal and external devices to the computer 110 . A serial peripheral interface (SPI) bus 126 may connect to a basic input/output system (BIOS) memory 133 containing the basic routines that help to transfer information between elements within computer 110 , such as during start-up.
A super input/output chip 160 may be used to connect to a number of ‘legacy’ peripherals, such as floppy disk 152 , keyboard/mouse 162 , and printer 196 , as examples. The super I/O chip 160 may be connected to the I/O interface 122 with a bus 127 , such as a low pin count (LPC) bus, in some embodiments. Various embodiments of the super I/O chip 160 are widely available in the commercial marketplace.
In one embodiment, bus 128 may be a Peripheral Component Interconnect (PCI) bus, or a variation thereof, may be used to connect higher speed peripherals to the I/O interface 122 . A PCI bus may also be known as a Mezzanine bus. Variations of the PCI bus include the Peripheral Component Interconnect-Express (PCI-E) and the Peripheral Component Interconnect-Extended (PCI-X) busses, the former having a serial interface and the latter being a backward compatible parallel interface. In other embodiments, bus 128 may be an advanced technology attachment (ATA) bus, in the form of a serial ATA bus (SATA) or parallel ATA (PATA).
The computer 110 may also include other removable/non-removable, volatile/nonvolatile computer storage media. By way of example only, FIG. 3 illustrates a hard disk drive 140 that reads from or writes to non-removable, nonvolatile magnetic media.
Removable media, such as a universal serial bus (USB) memory 153 , firewire (IEEE 1394), or CD/DVD drive 156 may be connected to the PCI bus 128 directly or through an interface 150 . A storage media 154 may coupled through interface 150 . Other removable/non-removable, volatile/nonvolatile computer storage media that can be used in the exemplary operating environment include, but are not limited to, magnetic tape cassettes, flash memory cards, digital versatile disks, digital video tape, solid state RAM, solid state ROM, and the like.
The drives and their associated computer storage media discussed above, provide storage of computer readable instructions, data structures, program modules and other data for the computer 110 . In FIG. 3 , for example, hard disk drive 140 is illustrated as storing operating system 144 , application programs 145 , other program modules 146 , and program data 147 . Note that these components can either be the same as or different from operating system 134 , application programs 135 , other program modules 136 , and program data 137 . Operating system 144 , application programs 145 , other program modules 146 , and program data 147 are given different numbers here to illustrate that, at a minimum, they are different copies. A user may enter commands and information into the computer 20 through input devices such as a mouse/keyboard 162 or other input device combination. Other input devices (not shown) may include a microphone, joystick, game pad, satellite dish, scanner, or the like. These and other input devices are often connected to the processor 120 through one of the I/O interface busses, such as the SPI 126 , the LPC 127 , or the PCI 128 , but other busses may be used. In some embodiments, other devices may be coupled to parallel ports, infrared interfaces, game ports, and the like (not depicted), via the super I/O chip 160 .
The computer 110 may operate in a networked environment using logical connections to one or more remote computers, such as a remote computer 180 via a network interface controller (NIC) 170 . The remote computer 180 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 relative to the computer 110 . The logical connection between the NIC 170 and the remote computer 180 depicted in FIG. 3 may include a local area network (LAN), a wide area network (WAN), or both, but may also include other networks. Such networking environments are commonplace in offices, enterprise-wide computer networks, intranets, and the Internet. The remote computer 180 may also represent a web server supporting interactive sessions with the computer 110 .
In some embodiments, the network interface may use a modem (not depicted) when a broadband connection is not available or is not used. It will be appreciated that the network connection shown is exemplary and other means of establishing a communications link between the computers may be used.
FIGS. 4-8 illustrate how image data can be interpreted in view of a 3D model of the same scene to refine the accuracy of a camera location in geographic terms. In one embodiment utilizing this technique, a precision scanner, for example, light detection and ranging (LIDAR) equipment may be airplane mounted and used to capture geometry data for a geographic region, such as an urban area. From this LIDAR data, three dimensional models of the region including buildings may generated with accuracies on the order of 10 centimeters. While such as geographic model provides a valuable resource, breathing life into a scene may require that color and texture data be added to the 3D models. Street-level photographs can provide the desired realism, but, as shown in FIG. 1 , when the photographic data is not aligned properly with the 3D model, an unintelligible jumble may result. Street-based LIDAR data can place the source location of the photographic data with respect to the object of the photograph (e.g. a building) within one centimeter, but location of the camera with respect to geographic coordinates, as used by the 3D model may be off by as much as a meter or more. When projecting photographic data on a 3D model of a building hundreds of meters in height, this source location inaccuracy can easily result in the mismatch of FIG. 1 .
To address the geographic location inaccuracy of the camera, the more accurate airborne and street-level LIDAR data may be used to mathematically change the camera location coordinates until the images and street-level LIDAR data best fit the 3D models of the same scene. Once two points along a run of images, particularly near the ends of the run, are correctly located, images from other intervals along the run can use IMU data to accurately locate the intervening points.
FIG. 4 is a block diagram illustrating skyline identification at one point in an image run. A street 402 and representative buildings 404 , 406 , and 408 are shown representing a typical street environment. A track 410 illustrates a run path used in capturing image data along the track 410 . Images may be captured at periodic intervals along the track. A representative first location 412 , near the beginning of the track 410 , shows representative skylines 416 , 418 , and 420 of the buildings from the perspective of the first location 412 .
One embodiment uses a skyline detection algorithm based on an optimal path algorithm known in the art. The algorithm is dependent on edges, gradient magnitude and direction, as well as sky classification edges and vanishing point information. For example, a combination of edge and vanishing point may use a percentage of the sky classified pixels on the line joining the considered pixel to the vanishing point. Another skyline detection attribute may use an apriori estimated skyline based on existing building models, that is, the 3D model itself may be used to help determine the skyline in the image data.
The skyline data 416 , 418 , and 420 extracted for the buildings 404 , 406 , 408 respectively, may be used later when determining the source location as part of the comparison with the 3D model.
The depiction of the first and second locations 412 and 414 , respectively, as cubes illustrates that the exact location of the source of the image at that point in the track 410 is an estimate in three dimensional space that may be more or less accurate, depending on the nature of the environment for GPS reception and IMU accuracy.
FIG. 5 is a block diagram illustrating skyline identification at another point in an image run, such as the image run shown in FIG. 4 . As above, a street 502 and buildings 504 , 506 , and 508 are shown. A track 510 shows the image run progression along the street, with images taken at intervals along the track 510 , including representative first location 512 near the beginning and a representative second location 514 , near the end of the track 510 . In some embodiments, other images along the run may be used when calculating the best-fit actual position of the camera.
As shown, skyline detection may be used to determine the skyline 516 , 518 , 520 of each respective building 504 , 506 , 508 from the street-level perspective of the second location 514 .
This information may then be combined with 3D model data to determine a correction factor for the geographic location of the camera from which the original street-level image was obtained.
FIG. 6 is a street-level image 602 depicting several buildings and their associated skyline. The detected skyline 604 is shown with the white line. The black line 606 represents the projected skyline of the 3D model if the camera were actually at its reported location.
FIG. 7 shows a representative building 702 with a detected skyline edge 704 . A range over which an image source may be located is represented by cube 706 . The cube 706 may be centered on the location of the camera as recorded by the GPS and IMU equipment.
As depicted in FIG. 7 , projected skylines based on 3D model data may be compared to the detected skyline of the image. For example, a first projection 708 may be located from a top left corner of cube 706 , a second projection 710 may be made with a camera location of top middle, and a third projection 712 may be made from a bottom right corner of the cube. In operation, camera locations over a 3×3×3 matrix around the measured location may be made. The distance between the extracted and projected skylines may be calculated as the e sum of absolute distance in x and y dimensions in image coordinates (abs(x 1 −x 2 )+abs(y 1 −y 2 )). In some embodiments, the distances beyond 100 pixels may not be considered to account for falsely detected parts of the skyline. The projection location associated with the closest match between detected and projected skylines may be selected and stored, in this example, projection 710 represents the best match. Because IMU data is extremely accurate along the run of a given track, performing the location operation using data from along the given track can be used to re-orient the entire track in one calculation.
FIG. 8 , depicts a street-level image 802 illustrating a plurality of projected skylines 804 representing different camera locations for generating the projected skylines 804 .
FIG. 9 illustrates use of street-level LIDAR data to supplement skyline data for image matching. A building 902 may be captured in image data from camera location 904 . Edge data 906 and 908 , and facade depth 910 may be recorded at the same time the image data is captured. As with detected and projected skylines above, edge 912 , 914 and facade depth 916 information can be compared to projected edge and facade information extracted from a 3D model of the building 902 . LIDAR depth data may be more robust than detected skyline information and may be given more weight when combining all sources information related to actual camera location.
Calculation of LIDAR depth, for a given a run segment, may first obtain 3D models of one or more nearby buildings. For each building, the building facades which are facing the run segment and have large area and width may be considered. The start and stop positions of the edges of each facade (in local coordinate system) system are computed based on the 3D building model. The start and stop trigger events corresponding to the edges, and the projections of the facade edges onto the run segment are computed. Based on this information the facade depth from the run segment may be obtained.
The start and stop trigger events are passed to a LIDAR depth detection module. The depths of the dominant planes found are passed back. The dominant plane which is closest to the facade of interest (in the centroid sense) is selected and the disparity computed.
The difference of the LIDAR based depth and the existing building model-facade based depth is considered if it is within a given tolerance. This is referred to as the building facade-LIDAR depth based disparity. The average of all the building facade-LIDAR depth based disparities for the entire broadside building facades surrounding the run segment is the LIDAR depth-based figure of merit.
Calculation of LIDAR edges may also begin by obtaining 3D building models for buildings in the vicinity of a given a run segment. For each building the edges may be computed using the building geometry model in local coordinate system. The start and stop positions of the building and the trigger events corresponding to the building are computed.
These start and stop trigger events along with the Lidar unit (left or right broadside) are individually passed to a LIDAR edge detection module. Also, the side of the building in the LIDAR depth image may be provided. The LIDAR edge detection module detects the dominant plane around the building edge and finds the edge depending on the side of the building.
The centroids of the LIDAR detected edges are projected back to the building corner-looking images. Similarly the points (using the same height as a camera, corresponds to building corner position in Local coordinate system) corresponding to building edges from the existing model are projected back. The difference in the column number of these projections (in pixels) is considered for edge based cost or figure of merit. This is an approximate cost based on the assumption that the image frame is perfectly vertical. This is reasonable enough for resolutions typically used in an exemplary geolocation module.
An average of these differences for all the buildings surrounding the run segments is considered as LIDAR edge based cost, or figure of merit, (in pixels).
FIG. 10 depicts a method 1000 of determining a displacement value for a source location of image data. At block 1002 a first displacement value of the source location may be loaded. At block 1004 , a figure of merit for skyline displacement between a skyline extracted from a source image and a skyline calculated from a corresponding 3D model. A number of source images may be used for skyline figure of merit calculation for each source image displacement being tested.
At block 1006 , a figure of merit for LIDAR edge and facade data may be calculated by comparing the LIDAR data and 3D model data.
At block 1008 , the skyline and LIDAR figures of merit may be calculated. In one embodiment, the figures of merit are simply added. In another embodiment, one figure of merit, for example, LIDAR data, may be weighted more heavily if its associated data is considered to be more accurate.
At block 1010 , the result of block 1008 may be compared to a previously stored minimum value, if any. If the new figure of merit value is lower than the previous minimum, execution may follow the ‘yes’ branch to block 1012 . If the new figure of merit is equal to or greater than the current minimum, execution may follow the ‘no’ branch, and if more displacement values are to be tested, execution may continue at block 1002 .
If the ‘yes’ branch from block 1010 is taken, at block 1012 , the new low value for figure of merit may be stored, as well as the displacement value that resulted in the new low value. If more displacement values need to be tested, execution may continue at block 1002 .
When all displacement values have been tested, the displacement value associated with the lowest figure of merit may be used to correct run data.
The ability to use actual images for facades of modeled buildings lends a new level of realism to 3D imagery and geolocation applications. The use of the techniques described above allow automation of what would be a staggering task of image-to-model matching for large amount of geolocation data. As a result, casual users, business application developers, gamers, etc., can enjoy the accuracy and realism of large scale geographic modeling.
Although the foregoing text sets forth a detailed description of numerous different embodiments of the invention, it should be understood that the scope of the invention is defined by the words of the claims set forth at the end of this patent. The detailed description is to be construed as exemplary only and does not describe every possibly embodiment of the invention because describing every possible embodiment would be impractical, if not impossible. Numerous alternative embodiments could be implemented, using either current technology or technology developed after the filing date of this patent, which would still fall within the scope of the claims defining the invention.
Thus, many modifications and variations may be made in the techniques and structures described and illustrated herein without departing from the spirit and scope of the present invention. Accordingly, it should be understood that the methods and apparatus described herein are illustrative only and are not limiting upon the scope of the invention. | Point of origin information for image data may be inaccurately registered against a geographic location absolute. A process for aligning image and highly accurate model data adjusts a point of origin of the image data by matching elements in the image with corresponding elements of the model. In a street-level image, building skylines can be extracted and corresponding skylines from the building model can be placed over the image-based skyline. By adjusting the point of origin of the image, the respective skylines can be aligned. Building edge and facade depth information can similarly be matched by adjusting the image point of origin of the image. The adjusted point of origin of the image can be used to then automatically place images on the models for a long run of images. | 6 |
FIELD OF INVENTION
[0001] The present invention describes improved methods of reinforcing concrete structures. Specifically the invention describes a method of reinforcing concrete structures by combining an externally bonded FRP (fibre reinforced plastic) configuration with the mechanical fastening of cover plates on a concrete structure.
BACKGROUND
[0002] There is a need for a dependable mechanism for increasing the shear and flexural strengths of in-service concrete structures. This need is especially acute in ageing buildings, highways having heavy traffic, railroad bridges, and other transport related structures.
[0003] Adhesively attaching FRP sheets, laminates or strips to concrete is the most common and effective method for the strengthening of concrete structures (this is commonly referred to as externally bonded FRP, or EB-FRP). Using this method, the strength of the FRP materials is transmitted into the concrete members through adhesive bonding, however the relatively weak interface by surface adhesion between the FRPs and the concrete limits the efficacy of the method. As a result, tension failure is usually a premature, sudden and brittle detachment of the FRP from a concrete substate (unless small quantities of FRP are used).
[0004] Mechanical fastening is another technology used to bond reinforcing materials to concrete structures. Mechanical fastening relies on the bearing of the attaching material on the fasteners to transmit the interface shear, for example in steel plating the interface shear that causes the tension force in the steel plate is transmitted into the concrete substrate through the bearing of the plate holes on the bolts that are anchored into the concrete. However, mechanical fastening is not easily used with FRP materials, because FRPs do not have sufficient bearing strength. Mechanical anchors often cut through the FRP sheet and cause longitudinal splitting of FRP sheets under loading.
[0005] It is an object of the invention to provide an improved or alternative method of reinforcing concrete structures using fiber reinforced plastic.
SUMMARY OF THE INVENTION
[0006] In a first aspect the invention broadly describes a method of reinforcing a concrete structure comprising
[0007] Attaching an amount of reinforcing material onto a concrete or masonry substrate; and
[0008] Attaching at least one cover plate on top of the reinforcing material onto the substrate.
[0009] In a preferred embodiment more than one cover plate is attached to the external surface of the concrete substrate.
[0010] Preferably the reinforcing material is attached to the concrete substrate by means of an adhesive, more preferably an epoxy resin.
[0011] In a preferred embodiment, the cover plate is a metal cover plate, preferably a steel cover plate.
[0012] Preferably the plane of the reinforcing material and the plane of the at least one cover plates are parallel, or are substantially parallel.
[0013] In a particularly preferred embodiment at least one cover plate is anchored into the substrate. Preferably each cover plate is nailed, or otherwise anchored to the substrate. In a preferred embodiment each cover plate is anchored to the substrate by two or more nails. Holes may be are drilled into the substrate prior to the attachment the cover plate(s); alternatively the nails could be forced into the substrate without the prior drilling of holes (for example using a Ramset™ gun. Concrete nails are preferred.
[0014] In a second aspect the invention broadly describes a method of reinforcing a concrete structure comprising
[0015] Attaching an amount of reinforcing material onto a substrate; and
[0016] Mechanically reinforcing the bond strength of the reinforcing material to the substrate.
[0017] According to any aspect of the invention, the reinforcing material is preferably a fiber reinforced plastic.
[0018] According to any aspect of the invention, the reinforcing material is adhesively attached to the substrate material.
[0019] According to any aspect of the invention, the substrate material is preferably concrete.
[0020] According to any aspect of the invention, the cover plate is mechanically attached to the substrate.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] FIG. 1 is a photograph of an externally bonded FRP debonding from the bottom of a concrete beam.
[0022] FIG. 2( a ) is a photograph of a preferred embodiment of a reinforcing fastener (cover plate) useful in the present invention. FIG. 2( b ) shows a number of cover plates attached to a concrete structure according to a preferred embodiment of the invention. The dark part under the cover plates is the FRP sheet.
[0023] FIG. 3 shows a concrete structure prepared according to the present invention, about to be tested for collapse strength.
[0024] FIG. 4 is a graph comparing the loads applied to different concrete structures before failing. “HB-FRP” (hybrid bonding of FRP) indicates that the concrete structure was reinforced according to the present invention, while “EB-FRP” indicates that the concrete structure was reinforced using known external FRP adhesive bonding techniques.
[0025] FIG. 5 is a photograph of a concrete structure failure after load testing. It can be seen that the HB-FRP strip itself ruptured in the 2-ply and 4-ply tests.
[0026] FIG. 6 is a photograph of a concrete structure failure after load testing. It can be seen that the 6-ply test failed due to the debonding of the HB-FRP strip, rather than the rupture of the FRP strip.
[0027] FIG. 7 is a photograph of a conventional mechanical fastener after failure in load testing. It can be seen that the bearing of the reinforcing steel plate on the bolt has led to the deformation of the fastener.
[0028] FIG. 8 is a photograph of an embodiment of the invention after failure in load testing. The fastener itself is not deformed, indicating that little or no bearing of the FRP strip on the anchor has taken place.
DETAILED DESCRIPTION OF THE INVENTION
[0029] The present invention involves increasing the interfacial bond of an FRP strip or plate (or strips or plates of other reinforcing materials) with a concrete substrate (or masonry or other suitable substrates). The invention combines externally bonded FRPs (EB-FRPs) with a variation on traditional mechanically fastened FRPs (MF-FRPs). No bearing resistance in the FRP is required and the invention can be used with commercially available FRP strips, plates, laminates or sheets.
[0030] The process comprises of two main steps. The first step involves adhesively attaching an FRP onto the surface of the substrate concrete. While the FRP may be applied directly to the surface of the concrete structure, near-surface mounting may also be used to attach the FRP to the concrete structure (near-surface mounting involves cutting a groove into the concrete structure, and inlaying the FRP into the groove).
[0031] A skilled artisan would know which adhesives would be appropriate for use with specific FRPs or other reinforcing materials, but a commonly used adhesive for bonding FRPs to concrete is an epoxy adhesive. Alternative adhesives that would be suitable are matrices of vinylester, polyester, and other similar compounds.
[0032] The second step involves the attachment of mechanical fasteners along the concrete structure using predetermined spacing. In a particularly preferred embodiment, the mechanical fasteners consist of metal cover plates that are attached to the concrete structure in a configuration whereby each plate is placed along the line of the reinforcing strip or plate strip, but is rotated around 90 degrees (this is best illustrated in FIG. 2( b )). Preferably each cover plate is positioned on top of the reinforcing strip. For wide reinforcing sheets or plates that cover a wide surface area, several rows of cover plates along the direction of the tensile stress may be required.
[0033] Externally bonded reinforcing techniques (EB-FRP) have traditionally encountered problems such as premature debonding, leading to an inability to mobilize the full tensile strength of FRP materials. This results in EB-FRPs having a suboptimal strengthening ability. In addition, EB-FRP systems without mechanical fastening are susceptible to acts of vandalism.
[0034] The present invention is useful for the structural retrofitting, strengthening, and repairing of reinforced concrete structures. The methods described are capable of mobilising the full tensile strength of FRP materials. Since the preferred mechanical fasteners are relatively thin pieces of steel plate attached to the concrete structure with two normal concrete nails (or other bolts), the additional cost of implementing the new applicant's method is low.
[0035] Below are a number of working examples of the invention. These are intended to illustrate to a skilled reader how to effectively implement the method of the invention, and are not intended to limit the scope of the invention in any way. Where particular technical features have been described, equivalents of those features not specifically mentioned (but that would be evident to a skilled artisan) are also intended to be encompassed by the present application.
EXAMPLES
[0036] An Mbrace sheet system including a CFRP (carbon FRP) sheet and two parts Saturant manufactured by MBT (Singapore) Pte Ltd was used in the following tests. The Mbrace CF130W CFRP fibre sheet was unidirectional with a nominal thickness of 0.165 mm. The impregnation resin was prepared by mixing Mbrace Saturant Part A and B in a volume ratio of 3:1. The CFRP sheet was first attached to the concrete structure by the traditional EB-FRP method.
[0037] In this particular test the mechanical fasteners used were 3 mm thick steel plates having the dimensions of 30 mm by 70 mm.
[0038] To install the cover plates, two small holes for each cover plate were drilled alongside the FRP strip in the concrete structure, with the hole just big enough to house a concrete nail securely. The cover plates were spaced along the length of the FRP strips, approximately 100 mm apart. The test concrete structure after the installation of the FRP and cover plates is shown in FIG. 2( b ). The specimens were tested using the setup shown in FIG. 3 to investigate the effectiveness of the applicant's system.
[0039] The effect of the applicant's fastening system was measured, with the results shown in FIG. 4 . The lowest curve in FIG. 4 shows the response of the beam strengthened by a conventional EB-FRP method, with 2 plies (layers) of 0.165 mm thick CFRP fabric. The EB-FRP system increased the beam strength from the un-strengthened strength of about 8 kN to 17 kN. The failure of the beam occurred when the FRP strip debonded from the bottom of the beam, as shown in FIG. 1 . This indicates that the bond strength was less than that of the tensile break strength of the 2-ply CFRP strip.
[0040] The other three responses in FIG. 4 are for beams strengthened with the applicant's system, with 2, 4 and 6 plies of CFRP fabric, respectively. Both the beams with 2 and 4 plies of CFRP failed due to the rupture of the CFRP strip. FIG. 5 is a photograph of a ruptured CFRP strip. This shows that the bond strength with the applicant's system was greater than that of the material tensile strength of the 4-ply CFRP strip and caused the breaking of the CFRP strip itself. The beam with 6-ply CFRP strip failed due to debonding of the strip as shown in FIG. 6 . In this case, the bond strength of the applicant's system reached the maximum value, indicating that the tensile strength of the 6-ply CFRP strip was greater than that of the bond strength.
[0041] From the testing of the EB-FRP strengthened beam, it was observed that the strength increment of the beam due to EB-FRP system was about 9 kN (from 8 to 17 kN), which means that the bond of the EB-FRP system contributed 9 kN of the beam strength. The highest recorded strength of the applicant's system was 70 kN. Taking away 17 kN contributed by the steel bar and the EB-FRP system, the additional strength due to the applicant's system was therefore 53 kN, which is approximately six times that contributed by the conventional EB-FRP system. It is clear from these results that the applicant's system produces surprising results, which demonstrate that synergism is observed when a concrete structure has an externally bonded FRP in combination with the new mechanical fastening system described. | A method of reinforcing a concrete structure includes attaching an amount of reinforcing material onto a concrete or masonry substrate and attaching at least one cover plate on top of the reinforcing material onto the substrate. | 4 |
FIELD OF THE INVENTION
The present invention relates to computing networks in general and, in particular, to a secure network extension device and method.
BACKGROUND
Enterprise networks are commonly overseen at remote sites by an Information Technology (IT) administrator placed on-site to deploy and maintain the remote network's functionality, availability, and security. Means of remotely administering network functionality and availability are known, but they do not handle security adequately to maintain the posture required for high value information systems without local security administration. Assigning IT administrator resources to remote sites presents a significant cost, and security depends greatly on the particular administrator's expertise and prioritization of security. This issue can be pronounced for some organizations (e.g., DoD, Financial, Medical, Government) that may need significant networked resources at remote sites, but require high network security and data confidentiality; the issue is compounded where the remote sites may be prone to degradation, reduction, or loss of network communications.
SUMMARY OF THE INVENTION
The present invention permits robust centralized IT administration of remote network extensions from the central enterprise network, through means including the attestation of trusted operation, allowing personnel at a remote location to operate securely. A network extension device according to an embodiment of the present invention may comprise a CPU, a memory connected to the CPU, a protected I/O connected to the CPU and connectable to one or more local controls and to one or more local peripherals, an external communications port connected to the CPU and connectable to a known external network, a trusted device connected to the CPU such that the trusted device can provide attestation of trusted operation of the network extension device to a known external network to which the external communications port is connected, and a protected interface connected to the CPU and to at least one network extension module that includes a local network communications port. In a preferred embodiment, a traffic encryption module is also connected to the CPU and to the trusted device such that the trusted device can communicate attestation of trusted operation of the traffic encryption module to a connected known external network, such as with the trusted device checking the traffic encryption module's encryption algorithm. The network extension device's communications and security functions may be embodied within a single module (e.g., a trusted controller module) to further enhance security and remote verifiability, and the network extension device also may include tamper-proofing such as sensors.
A method of secure computing using a network extension device according to an embodiment of the present invention comprises providing a network extension device (having a CPU, a memory connected to the CPU, a protected I/O connected to the CPU and connectable to one or more local controls and one or more local peripherals, a trusted device connected to the CPU, and an external communications port connectable to a known external network, connecting the external communications port to the external network, after making the connection performing an operating mode check, after making the operating mode check causing the network extension device to operate in a mode corresponding to its results and performing a security check corresponding to its results, after making the connection causing the trusted device to attest the trusted operation of the network extension device to the external network, and after sending acceptable attestation causing the CPU to function fully and permitting the network extension device to access the external network. A high assurance level of trust for the remote site network (i.e., network extension) preferably is afforded throughout different modes of operation (e.g., different communication conditions such as full bandwidth, partial bandwidth, or no network connectivity), and different security checks may be performed depending on the mode of operation. In an embodiment adapted for modes that correspond to different levels of external network bandwidth, local (i.e., on the network extension device) backing up of data and/or execution of applications may be implemented during modes that are less than full bandwidth.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram of a network extension device according to an embodiment of the invention.
FIG. 2 is a flowchart of a process of communication failover according to an embodiment of the present invention.
DETAILED DESCRIPTION OF EMBODIMENTS
Referring to FIG. 1 , a block diagram of a network extension device 100 according to an embodiment of the present invention is shown. In a preferred embodiment, the network extension device 100 is in a sealed enclosure that is physically secured by a tamper security boundary 119 , and primarily comprises a trusted controller module 120 (embodied, e.g., on a printed circuit board) and one or more (N) network extension modules 150 (embodied, e.g., in commercial off-the-shelf servers such as the HP ProLiant® DL320 Generation 6 with Trusted Platform Module). The trusted controller module 120 receives power from power control 121 , which can be connected to external power 110 . Power control 121 then also controls network extension power 151 , via power switch 131 to which network extension devices 100 are connected. Network extension module 150 includes a CPU 153 , memory 154 , a communication port 159 , an input/output 152 , and a trusted device 155 . The trusted controller module 120 includes a CPU 123 , memory 124 , a protected interface 132 , an input/output 142 connecting the module 120 to internal storage 143 (e.g., a hard drive) and other internal devices 144 , a security monitor 136 connected to on-master security sensors 137 and internal security sensors 138 , a trusted device 125 connected to a cryptographic key store 126 , a traffic encryption module 127 , a network security module 128 , and a communication port 129 . Communication port 129 can connect to an external network 99 such as through one or more (N) COM devices 102 , and communication port 159 can connect to a local client network 199 . In addition to controlling communication port 129 , network security module 128 also may have switch and route control over communication port 159 's local network connection. Encrypted communication with the local client network 199 (e.g., an office, temporary work site, etc.) may also be supported, preferably with any wires connecting to the communication port 159 being physically secured from tampering. Additionally, protected I/O 122 (which provides the trusted controller module 120 protection by only admitting authorized I/O, and checking the authorized I/O for viruses, malware, black/white list information, etc.) can connect to local peripheral devices 111 , a local control 112 (e.g., a keyboard, mouse, etc.), and an out-of-band remote control 113 to which might be connected one or more COM devices 114 (of which the system would preferably require pre-configured credentials or the like that would have to be authenticated, e.g., by the external network 99 , before a COM device 114 would be allowed to change settings etc.).
The trusted controller module 120 protects communications and ensures secure computing by utilizing the trusted device 125 to ensure that various functions are operating in a known configuration. In a preferred embodiment, the trusted controller module 120 provides network traffic encryption, network security, protected interfaces, security monitoring and control, communications failover, and general computing resources needed for the network extension, described further below. The number of network extension modules 150 may be scalable, to extend the general computing resources needed to support a larger client network extension.
The protected interface 132 buffers data passed into the trusted controller module 120 from the network extension module(s) 150 , and is preferably a high-speed, low-level interface that can be configured to provide functions such as confirmation of message types, malware detection, and other facilities to preclude receiving data that might affect the security (e.g., modify security settings or protocols) of the trusted controller module 120 through the network extension module 150 from a local user or attached local network. Message type checking and malware detection could be based on multiple well-known techniques and software available from commercial vendors such as Symantec and McAfee.
Traffic encryption module 127 encrypts data traversing the network between the remote site (where the network extension device 100 is) and the enterprise network (external network 99 ), using algorithms and key management schemes chosen based on the application and the sensitivity of its data. In a preferred embodiment, the National Security Agency's Suite B cryptographic algorithms can be used, which include Advanced Encryption Standard (AES) used with the Galois/Counter Mode (GCM) for traffic encryption and Elliptic-Curve Diffie-Hellman (ECDH) key agreement. Optionally, the trusted controller module 120 can handle more than one level of encryption, such as in a secure sockets layer-encrypted browser session sent through a virtual private network.
The security monitor 136 controls the system's response to a perceived physical attack that may compromise the data and/or trust of the system, enhancing security as an additional layer of defense to network and application security mechanisms (which could otherwise be circumvented when physical access is granted to the hardware, e.g., by active probing, forced data remanence, and/or malicious hardware replacement). A tamper security boundary 119 can be provided with a sealed container housing the hardware and one or more internal sensors 138 and/or on-master sensors 137 , such as tamper switches provided to detect access to the sealed container, active tamper wrappers around sensitive components, temperature monitors, and voltage detectors. If a breach is detected, the security monitor 136 can cause various responses including erasure of all sensitive unencrypted data and some security parameters that will prevent the system from operating until the appropriate security controls and initialization parameters have been restored by a trusted source.
The network security module 128 can include a firewall (e.g., with “white lists” of authorized network resources), intrusion detection and prevention system (e.g., a commercial IPS security appliance from a commercial vendor such as Juniper Networks or CISCO), and malware/antivirus system (e.g., off-the-shelf software from a commercial vendor such as Symantec), so that the network infrastructure, policies enforced (remotely) by the network administrator, and the trust of the network remain intact as deployed, preserving confidentiality, integrity, and availability of the network.
The trusted device 125 serves as the root of trust for the network extension device 100 , with the trusted device 155 providing an additional layer of security (e.g., verifying the boot up sequence, and then monitoring the application stack of the network extension module 150 to ensure the configuration has not been altered from what is expected); each can be based on the trusted platform module (TPM) of the trusted computing standard developed by the Trusted Computing Group. The trusted device 125 manages cryptographic functions such as cryptographic key management, certificate validation (either directly or by monitoring the software that performs validation), and non-traffic-related encryption. An embodiment of these functions could be extensions of the cryptographic functions found with a trusted device 125 such as hashing and key generation. The trusted device 125 also preferably provides remote attestation, preferably including of traffic encryption operation (including the algorithm), which can be implemented similarly to the remote attestation taught by U.S. Pat. No. 7,254,707 to Herbert et al., the teachings of which are incorporated by reference. For example, information can be captured in an audit log for the trusted device 125 , and then digitally signed and provided to the external network 99 via a protected communications path for attestation of the network extension device 100 . The trusted device 125 can be paired with hardware-based trusted processor extensions (such as Intel's trusted execution technology) to create and verify processor environments that run only approved software and can be correctly measured to verify system properties, providing superior assurance of trust over software-based techniques. A remote control function, for example via an out-of-band remote control 113 , could be enabled through a standard communications protocol (e.g., a later version of SNMP that provides facilities for confidentiality, message integrity, and authentication) that works with the trusted device 125 to verify that any remotely commanded configuration changes are executed correctly.
In a preferred embodiment of the invention, the network extension device 100 can have its security attested to an external network 99 (which network is ‘known,’ such as by the trusted device 125 being deployed to the remote site with cryptographic information corresponding to the external network 99 ) throughout multiple operational modes, such as throughout differing levels of communicativity as is outlined in the flowchart of FIG. 2 . (Instead of differing communicativity levels, other types of operational modes could be used in other embodiments; for example, the operational modes could be differing network architectures, such as client/server, thin client, standalone workstation, cloud computing). In such a communication failover process 200 , trusted functionality of the network extension device 100 is retained even when communication is restricted (e.g., communication conditions degrade the bandwidth of a connection, or a reduced-bandwidth alternative communication mode is used) or lost. The process preferably automatically detects when failovers are necessary, and may be accompanied by one or more alternative modes of communication. Failover to POTS, satellite, etc., can be provided, such as with commercially available solutions by NETRIX including their Nx2200 series switches, and/or to a secondary interface using routing daemons such as disclosed in U.S. Patent Application Publication No. 2010/0097925 to Bell, such teachings of which are incorporated by reference.
With reference to FIG. 2 , in such a failover process 200 the network extension device commences in full bandwidth mode 210 after startup 201 , immediately performing a security check 216 . (Preferably, data mirroring, which can utilize or be functionally similar to database software sold by several commercial vendors such as Microsoft and Oracle, also commences, preferably creating and maintaining a local copy of important data and applications that is complete enough to support subsequent operation in no bandwidth mode with at least a selected subset of applications. Various known failover computing and backup techniques can be employed as appropriate for a given embodiment, such as those taught in U.S. Pat. No. 7,707,457 to Marchand and U.S. Patent Application Publication No. 2010/0057789 to Kawaguchi, the disclosures of which in that regard are incorporated by reference.). Failure of the security check causes the network extension device 100 to enter recover mode 219 (whereupon an alert to the failure is provided, and depending on the perceived severity of the failure, an automated response to the failure may be initiated); otherwise, a bandwidth connectivity check 211 is performed to determine if full, partial, or no bandwidth communication is present (e.g., ‘full’ if the bandwidth is sufficient for the external network 99 to perform the computational processing required for the nodes connected to the network extension device 100 to operate as thin clients, ‘partial’ if the bandwidth tests at a level falling below support for thin client processing but sufficient to allow the network extension device 100 to process the applications while the data is exchanged with the external network 99 , and ‘no’ for a bandwidth that tests below a threshold to support even shared computational processing). The outcome at that step causes the network extension device 100 to enter the associated bandwidth mode (i.e., full bandwidth mode 210 , partial bandwidth mode 212 , no bandwidth mode 214 ) and then perform another security check 216 , 217 , or 218 , and so on. In partial bandwidth mode 212 , the network extension device 100 performs a security check 217 , which if passed leads to a bandwidth connectivity check 211 . The outcome of the check again causes the network extension device 100 to enter the associated resultant bandwidth mode of the bandwidth connectivity check 212 . This same cycle is repeated when the network extension device 100 is in no bandwidth mode 214 , but with security check 218 .
In a preferred embodiment, the trusted device 125 changes what is monitored depending on the mode of communication. In full bandwidth mode 210 , the trusted device 125 performs security check 216 and monitors the functions that provide access to network applications and data that reside on the external network 99 for unauthorized changes (and also, e.g., for inappropriately addressed TCP/IP data packets when compared to the “white list” of approved recipients). In a ‘thin client embodiment,’ network extension module 150 preferably just passes data through without any significant processing during full bandwidth mode 210 .
After a communications failover to partial bandwidth mode 212 , local hosting of processing begins (preferably based on data mirrored during full bandwidth mode 210 ) such as running the web browser server locally (optionally, ‘locked down’) on the network extension module 150 (preferably using a secure system virtual machine), to leave the restricted communications bandwidth more available for data transport. The trusted device 125 preferably adapts its monitoring techniques and security check 217 to incorporate the adjusted operation of the network extension device 100 . In addition to monitoring the web browser server, the protocol of communications may be changed resulting in a different method by which monitoring must take place.
Finally, in the no bandwidth mode 214 , all applications and data are retained and executed locally until connectivity is re-established back to the external network 99 . (In this embodiment, that is the most complex local computing allowed by the architecture and system-enforced policy, and is specified to be within the monitoring capability of the trusted device 125 ). The techniques of monitoring and security check 218 by the trusted device 125 are preferably adapted to allow trust of the network extension device 100 to be retained and then attested back to the external network 99 when connectivity is restored. (Preferably, local mirror and external databases are re-synchronized if and when network connectivity is restored).
One skilled in the art will appreciate that other variations, modifications, and applications are also within the scope of the present invention. Thus, the foregoing detailed description is not intended to limit the invention in any way, which is limited only by the following claims and their legal equivalents. | A network extension device comprising a CPU, memory, protected I/O connectable to local controls and peripherals, external communications port, a trusted device connected to the CPU such that it can provide attestation of the network extension device's trusted operation to a connected known external network, and a protected interface connected to at least one network extension module that includes a local network communications port. Optionally, a traffic encryption module may be provided, and the trusted device's attestation may include a check of its operation. Also, a method comprising connecting the network extension device to an external network, performing an operating mode check, causing the network extension device to operate in a mode and perform a security check that correspond to the result, causing the trusted device to attest trusted operation to the external network and thereafter causing the CPU to function fully and permitting access to the external network. | 7 |
CROSS-REFERENCE TO RELATED APPLICATION
[0001] The present application is related to and claims priority from prior provisional application Ser. No. 61/708,420 filed Oct. 1, 2012 which application is incorporated herein by reference.
COPYRIGHT NOTICE
[0002] A portion of the disclosure of this patent document contains material which is subject to copyright protection. The copyright owner has no objection to the facsimile reproduction by anyone of the patent document or the patent disclosure, as it appears in the Patent and Trademark Office patent file or records, but otherwise reserves all copyright rights whatsoever. 37 CFR 1.71(d).
BACKGROUND OF THE INVENTION
[0003] The following includes information that may be useful in understanding the present invention(s). It is not an admission that any of the information provided herein is prior art, or material, to the presently described or claimed inventions, or that any publication or document that is specifically or implicitly referenced is prior art.
[0004] 1. Field of the Invention
[0005] The present invention relates generally to the field of comestibles and more specifically relates to ready to eat cold cereal cakes.
[0006] 2. Description of the Related Art
[0007] It is desirable to offer nutritious comestibles for consumption. Nutrition, if maintained, may help individuals avoid serious health problems. Cereals are a healthy food choice; however they may not typically be offered in a conveniently readily edible form. For example many individuals eat cereal in some form for breakfast; however cereal in this traditional manner is not conducive to portability and is thus often eaten in the home before leaving for the day. Cereals are an important source of protein and carbohydrates and are widely available for consumption. Further, cereals have significant amounts of fiber and soluble fiber, with one cup of cooked cereals providing between nine and thirteen grams of fiber. Soluble fiber can help lower blood cholesterol. Since people's schedules are busy, convenience may outweigh nutrition which is not desirable in the long-term. It is desirable to have foods such as cereals that are nutritious and also convenient to eat. A more efficient option is needed wherein cereals can be produced in such a form.
[0008] Various attempts have been made to solve the above-mentioned problems such as those found in U.S. Pat. Nos. and Pub. Nos. 2003/0147999; 5,871,793; 6,248,379; 2005/0142262; 2009/0053379; and 2012/0269939. This art is representative of comestibles relating to cereals. None of the above inventions and patents, taken either singly or in combination, is seen to describe the invention as claimed.
[0009] Ideally, ready to eat cold cereal cakes should provide nutrition and convenience to consumers and, yet would be manufactured at a modest expense. Thus, a need exists for ready to eat cold cereal cakes to avoid the above-mentioned problems.
BRIEF SUMMARY OF THE INVENTION
[0010] In view of the foregoing disadvantages inherent in the known cereal-related comestibles art, the present invention provides novel ready to eat cold cereal cakes. The general purpose of the present invention, which will be described subsequently in greater detail is to provide ready to eat cold cereal cakes with a variety of ingredients. The invention is to provide people who shop for cereals grains for food the option of getting processed and cooked cereal cakes, cold and ready to eat.
[0011] A ready to eat cold cereal cake product comprising ingredients is disclosed herein combined in proportions substantially including: at least one cereal; milk; a binding agent; additives; and flavorings. The cereal, milk, binding agent, additives and flavorings are stirred, mixed as an admixture and cooked to form cereal cakes as a ready to eat cold cereal cake product. The binding agent causes the admixture to congeal (after being cooked) when the admixture is cooled using refrigeration. The flavorings cause the cereal cakes to be flavored (as per consumer preference) for consumption; the cereal cakes are high in nutrition and suitable for readily consuming Various flavored versions of the cereal cakes may be produced. Kits may be packaged with ingredients and sold for home cooking.
[0012] A method of preparing ready to eat cold cereal cakes comprises the steps of: stirring and mixing cereal grains with ingredients, seasonings, and a binding agent as an admixture; boiling until texture of admixture is soft and smooth; removing remaining solid residues; forming cereal cakes; storing the cereal cakes in a refrigerator to congeal and solidify; and optionally packaging to preserve freshness once solidified (before consumption).
[0013] The present invention holds significant improvements and serves as a ready to eat cold cereal cakes system. For purposes of summarizing the invention, certain aspects, advantages, and novel features of the invention have been described herein. It is to be understood that not necessarily all such advantages may be achieved in accordance with any one particular embodiment of the invention. Thus, the invention may be embodied or carried out in a manner that achieves or optimizes one advantage or group of advantages as taught herein without necessarily achieving other advantages as may be taught or suggested herein. The features of the invention which are believed to be novel are particularly pointed out and distinctly claimed in the concluding portion of the specification. These and other features, aspects, and advantages of the present invention will become better understood with reference to the following drawings and detailed description.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] The figures which accompany the written portion of this specification illustrate embodiments and method(s) of use for the present invention, ready to eat cold cakes, constructed and operative according to the teachings of the present invention.
[0015] FIG. 1 shows a perspective view illustrating ready to eat cold cereal cakes according to an embodiment of the present invention.
[0016] FIG. 2 is a perspective view illustrating the ready to eat cold cereal cakes according to an embodiment of the present invention of FIG. 1 .
[0017] FIG. 3 is a flowchart illustrating a method of preparing the ready to eat cold cereal cakes according to an embodiment of the present invention of FIGS. 1-2 .
[0018] The various embodiments of the present invention will hereinafter be described in conjunction with the appended drawings, wherein like designations denote like elements.
DETAILED DESCRIPTION
[0019] As discussed above, embodiments of the present invention relate to a comestible and more particularly to ready to eat cold cereal cakes as used to improve the health of consumers. The purpose as previously mentioned is to create healthy comestibles; ready to eat cold cereal cakes, and with a variety of ingredients.
[0020] Generally speaking, the cereal grains used herein can include corn, wheat, oat, barley, rye, rice, buckwheat, millet, sorghum, and the like; other cereals may be used in alternate embodiments. The cereal grains are stirred and mixed with the ingredients, seasonings, and binding agent, and boiled until the texture is soft and smooth, and any remaining solid residues can be removed. When the binding agent is a starch component and/or egg white instead of gelatin, the cereal cakes and cereal cakes can be reheated in the microwave oven or conventional oven.
[0021] The cereal cakes are stored in the refrigerator to congeal or solidify, and are ready to eat. The cereal cakes may be cooked and eaten or packaged into air-tight containers to preserve freshness for storage or shipping. The containers can be made of paper, plastic, glass, metal. The serving size can be a single serving, or a six pack of servings. Each serving can be contained in a cubical shaped (or other shaped) container, with each side of the container about 3 to 4 inches in length.
[0022] Cold and ready to eat cereal cakes save people the time and energy of preparing and cooking of the food. They can be served as food for breakfast, lunch, snack, or dinner. Cold and ready to eat cereal cakes offer the consumers an easy and convenient way to obtain an affordable, nutritious and delicious meal.
[0023] Referring to the drawings by numerals of reference there is shown in FIGS. 1-2 , perspective views illustrating ready to eat cold cereal cakes 110 according to embodiments of the present invention.
[0024] Ready to eat cold cereal cake product 102 comprises ingredients combined in proportions substantially including: at least one cereal 120 ; milk 130 ; binding agent 140 ; additives 150 ; and flavorings 160 ; wherein at least one cereal 120 ; milk 130 ; binding agent 140 ; additives 150 ; and flavorings 160 are stirred, mixed as an admixture and cooked to form cereal cakes 112 as ready to eat cold cereal cake product 102 .
[0025] Cereals 120 are preferably selected from the group consisting of corn, wheat, oat, barley, rye, rice, buckwheat, millet, and sorghum, as previously mentioned. Milk 130 , when used is preferably selected from the group consisting of whole milk, lowfat milk, nonfat milk, soy milk, coconut milk, almond milk, and vanilla milk. Other suitably flavored milk 130 may be used.
[0026] Binding agent 140 causes admixture to congeal after being cooked when the admixture is cooled using refrigeration means. Binding agent 140 is an edible binder and may comprise gelatin and/or egg white since it is high in protein. The binding agent 140 as an edible binder may alternately comprise a starch component. Binding agent 140 may be selected from the group consisting of gelatin, egg white, corn starch, potato starch, sago, and tapioca.
[0027] Flavorings 160 cause cereal cakes 112 to be appropriately flavored for consumption. Flavorings 160 are preferably selected from the group consisting of salt, pepper, garlic, ginger, onion, chili, curry, vinegar, lemon, lime, basil, thyme, rosemary, parsley, peppermint, and soup stock. Cereal cakes 112 are high in nutrition due to their high cereal content and suitable for readily consuming Ready to eat cold cereal cake product 102 may further comprise fruit juice to make fruity flavored versions of cereal cakes 112 ; wherein fruit juices are selected from the group consisting of apple juice, orange juice, lemon juice, lime juice, grapefruit juice, grape juice, pear juice, cranberry juice, blueberry juice, pineapple juice, pomegranate juice, and coconut juice.
[0028] Ready to eat cold cereal cake product 102 may comprise additives 150 which are preferably selected from the group consisting of coffee, tea, chocolate, caramel, butterscotch, raisin, fruit, nut, vegetable oil, cream, butter, peanut butter, cheese, and egg.
[0029] Ready to eat cold cereal cake product 102 , as disclosed herein, may further comprise at least one topping; wherein the topping(s) may be selected from the group consisting of chocolate, caramel, butterscotch, apple sauce, fruit, nut, cheese, and cream. The toppings generally produce a sweet version of ready to eat cold cereal cake product 102 . Alternately, ready to eat cold cereal cake product 102 may further comprise a salt source, which can make up of ingredients that are cooked and seasoned. When used, the salt source is preferably selected from the group consisting of vegetables, seafood, meat, cheese, and egg; the salt source cut into small pieces. This provides a salty version that may suit the individual taste of the consumer.
[0030] Vegetables, when used are preferably selected from the group consisting of onion, garlic, mushroom, spinach, carrot, pea, corn, beet, radish, turnip, pepper, tomato, asparagus, cucumber, zucchini, eggplant, and squash. Other vegetables and salt sources may be used. In this way the present invention is very versatile in taste and preparation.
[0031] In yet other embodiments, ready to eat cold cereal cake product 102 may further comprise at least one seafood; wherein the seafood is selected from the group consisting of squid, cuttle fish, shrimp, crab, crayfish, octopus, clam, oyster, scallop, lobster, abalone, conch, jellyfish, shrimp roe, fish roe, and fish. Other fish and seafood(s) may be included. Meat may also be included within the present recipe. In these embodiments meat is preferably selected from the group consisting of chicken, pork, beef, lamb, bacon, and sausage; however other meats or combinations thereof may be used.
[0032] Examples: an example of cereal cake is made with oat, milk and gelatin. Another example of cereal cake is made with rice, almond milk and gelatin. Yet another example of cereal cake is made with wheat, milk, pea, carrot and gelatin. An example of sweet cereal cake is made with corn, soy milk, honey, ginger, lime juice and gelatin. Another example of sweet cereal cake is made with rice, coconut milk, sugar, butter, gelatin, and egg white. An example of fruity cereal cake is made with oat, milk, apple juice, sago, and gelatin. An example of salty cereal cake is made with rye, milk, bacon, onion, salt, garlic, olive oil, gelatin, and corn starch. An example of salty and spicy cereal cake is made with barley, milk, shrimp, salt, ginger, chili, vinegar, flaxseed oil and gelatin. Many other examples can be produced; however these provide a general exemplary means for preparing the present invention.
[0033] Referring now to FIG. 3 , a flowchart 350 illustrating method of preparing 300 ready to eat cold cereal cakes 110 according to an embodiment of the present invention of FIGS. 1-2 .
[0034] Method of preparing 300 ready to eat cold cereal cakes 102 comprises the steps of: step one 301 stirring and mixing cereal grains 120 with milk or water; step two 302 boiling until the texture of the admixture is soft and smooth; step three 303 removing remaining solid residues; step four 304 adding ingredients, seasonings, and binding agent 140 as an admixture; step five 305 forming cereal cakes 112 ; step six 306 storing cereal cakes 112 in a refrigerator to congeal and solidify; and optionally step seven 307 packaging to preserve freshness once solidified.
[0035] It should be noted that step 307 is an optional step and may not be implemented in all cases. Optional steps of method 300 are illustrated using dotted lines in FIG. 3 so as to distinguish them from the other steps of method 300 .
[0036] It should be noted that the steps described in the method of use can be carried out in many different orders according to user preference. The use of “step of” should not be interpreted as “step for”, in the claims herein and is not intended to invoke the provisions of 35 U.S.C. §112, ¶6. Upon reading this specification, it should be appreciated that, under appropriate circumstances, considering such issues as design preference, user preferences, marketing preferences, cost, structural requirements, available materials, technological advances, etc., other methods of use arrangements such as, for example, different orders within above-mentioned list, elimination or addition of certain steps, including or excluding certain maintenance steps, etc., may be sufficient.
[0037] The embodiments of the invention described herein are exemplary and numerous modifications, variations and rearrangements can be readily envisioned to achieve substantially equivalent results, all of which are intended to be embraced within the spirit and scope of the invention. Further, the purpose of the foregoing abstract is to enable the U.S. Patent and Trademark Office and the public generally, and especially the scientist, engineers and practitioners in the art who are not familiar with patent or legal terms or phraseology, to determine quickly from a cursory inspection the nature and essence of the technical disclosure of the application. | Cold and ready to eat cereal cakes, with a variety of ingredient combinations suitable for healthy consumption. Serving size can be a single serving, or a six pack of servings for convenience such that the inherent nutritional aspects of cereals are able to be included in consumer's diets. | 0 |
CROSS REFERENCE TO RELATED APPLICATION
This application is a continuation-in-part of my application Ser. No. 648,140, filed Jan. 12, 1976, and now U.S. Pat. No. 4,007,946.
BACKGROUND OF THE INVENTION
1. Field of the Invention:
The rearwardly controlled snow ski of the present invention relates to a relatively short ski which enables the skier to practice a novel skiing technique accommodating turns wherein the ski is essentially pivoted about the rear extremity of the ski.
2. Description of the Prior Art:
As described in my aforementioned patent, the evolution of skiing has led to current day parallel skiing wherein turns are accomplished in a number of different styles, one of which involves shifting of the weight abruptly forwardly on the skis in order to swing the tails of the skis to one side about the more forward portion of the skis, thus accommodating the turn to the side opposite such one side. Other styles emphasize merely sliding the tails of the skis away from the direction of the turn and further styles even emphasize unweighting of the tips of the skis in what is known as a "jet turn". Skis commonly used in these various styles of skiing generally incorporate a ski constructed of metal, fiber glass or the like to assume a camber wherein the central portion of the ski is self-biased to a raised position elevated slightly from the opposite ends of the ski and having mounted thereon bindings for receiving the skier's boots. Efforts have been made to simplify the teaching of skiing by a technique known as a graduated length method (GLM) wherein a skier initially begins on shorter skis, as for instance skis in the neighborhood of 100 centimeters long and even shorter, and then advances to longer skis as his skills develop, such GLM skis being conventionally shaped and of conventional flexibility throughout their length. While all of the aforedescribed skis offer great enjoyment for the skier, they are all characterized by central location of the ski binding in a forward-aft direction on the ski and by the fact that they are all formed with tails projecting rearwardly of the binding and having a length nearly equal to the leading portion of the ski projecting forwardly of the binding, with both such tail and leading portions having substantially the same flexibility. Such design characteristics extremely limit the ski performance, thus preventing the skier from performing styles of turns wherein the ski itself essentially pivots about the tail of the ski and requiring the tail to always be shifted to one side or the other relative to the remainder of the ski while a turn is being accommodated. Further, such prior art skis provide substantially equal balance between the front and rear of the skis and fail to mount the skier rearwardly on the ski to enable the flexibility of the leading ski portion to lead the way over irregularities and obstacles without the resistance normally offered by the leverage exhibited the ski tail.
SUMMARY OF THE INVENTION
The rearwardly controlled snow ski of the present invention is characterized by a configuration mounting the ski binding rearwardly on the ski over a relatively rigid weight-bearing portion for receipt thereon of the skier's boot and having a flexible leading portion projecting forwardly therefrom to turn rather abruptly upwardly at its forward extremity to form a ski shovel. A short trailing portion may extend rearwardly of the weight-bearing portion but in no instance should extend rearwardly from the skier's heel a distance greater than 20% of the length of the planing portion projecting forwardly of the skier's toe. The forward planing portion may curve gradually forwardly and upwardly from the weight-bearing portion to the abruptly upturned shovel to provide a camber which is reversed in comparison to conventional ski cambers to enable such planing portion to project forwardly and upwardly with respect to the weight-bearing portion to thereby prevent hooking thereof and give excellent tracking characteristics.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side elevational view of a ski embodying the present invention;
FIG. 2 is a side elevational view similar to FIG. 1 but showing a heel-elevated binding mounting on such ski;
FIG. 3 is a top plan view, in enlarged scale, of the ski shown in FIG. 1;
FIG. 4 is an elevational view of a second embodiment of the ski of the present invention;
FIG. 5 is a partial end view, in enlarged scale, of the trailing portion of the ski shown in FIG. 4;
FIG. 6 is a bottom view of the trailing portion shown in FIG. 5;
FIG. 7 is a perspective view of the trailing portion of a third embodiment of the ski of present invention;
FIG. 8 is a force distribution diagram associated with the operation of a conventional ski; and
FIG. 9 is an elevational view of the ski shown in FIG. 1 and force distribution diagram associated therewith.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIG. 1, the rearwardly controlled ski of the present invention has an overall appearance somewhat similar to conventional skis except that the ski which is intended for use by both children and adults is only about 106 centimeters long and about 10 centimeters wide and is formed with a medial rigid weight-bearing portion 11 having a conventional ski binding 13 mounted directly thereover and normally spanning approximately 32% of the overall length of the entire ski to receive a ski boot 141. Projecting forwardly from the weight-bearing portion 11 is a relatively flexible leading portion 15 which curves upwardly slightly for approximately 32% of the overall length then curves abruptly upwardly to form within about 17% of the forwardmost portion a conventionally shaped shovel 17. Projecting rearwardly from the rear end of the medial weight-bearing portion 11 is a trailing portion 19 which is also relatively rigid and constitutes approximately 17% of the overall ski length terminating at its rear end in a trailing edge 21. Consequently, the skier's weight is positioned rearwardly on the ski itself thus enabling the flexible leading portion 15 to ridge above the snow surface and act to negotiate various undulations and obstacles appearing over the ski course and the skier himself may initiate a turn by merely rolling his knees in the direction of the turn thus causing the rear edge 21 to dig into the snow on the side of the skis toward which his knees have rolled thus causing the leading portion 15 of the ski to be drawn sideways in the direction of the turn thereby causing the ski to, in essence, pivot about the heel of the skier with very little, if any, resistance thereto being offered by the trailing portion 19 or the front portion 15.
Typically, adult skis are on the order of 185 centimeters long and longer with a maximum width of about 8 to 9 centimeters and are formed with a self-biasing camber causing the longitudinal medial portion thereto to be raised slightly with respect to the leading and trailing ends of the ski. The weight-bearing portion of the ski is conventionally located medially along the fore-aft length of the ski with the tail of the ski being only slightly less flexible than the leading portion thereof. Consequently, typical skiing techniques on such conventional skis result in the ski itself being rotated either about the median portion thereof during a turn or about a portion somewhat forwardly of the ski binding. These skiing techniques have led to many teaching methods emphasizing a skier keeping his weight forward on the ski and even tending to shift his weight abruptly upwardly and forwardly when coming into a turn in order to raise the tails of the skis momentarily off the ski trail while simultaneously shifting the tails to one side in a direction opposite the direction of the turn in order to facilitate such pivoting of the ski about a forward portion thereof. Heretofore, there have been no efforts to provide a snow ski which essentially pivots about the trailing extremity thereof and provides for the weight of the skier being borne rearwardly of the ski median leaving the flexible leading portion of the ski free to plane over the ski terrain thus leading the weight-bearing portion gradually over obstacles and undulations encountered on the ski trail.
While the particular ski shown in FIG. 1 is 106 centimeters long, it will be understood that the length of such ski, while being shorter than conventional adult skis, will vary in length from approximately 90 centimeters to approximately 110 centimeters. It is only important that the weight-bearing portion 11 be formed rearwardly on the ski, that the trailing portion 19 not exceed 20% of the overall ski length and that the leading portion 15 and be relatively flexible to enable upward and downward flexing thereof as the ski maneuvers over the ski trail.
In order to support an adult skier's weight on the 106 centimeter ski, the ski is formed with a width approximately 10% greater than that of conventional skis and to enhance tracking and the planing effect of the leading portion 15 to the widest portion thereof, immediately behind the shovel 17, is approximately 10 centimeters wide and tapers rearwardly and inwardly therefrom to the trailing portion 19 which is approximately 8.5 centimeters wide. The widest section of the planing portion 15 must be approximately 10 centimeters wide for adult skiers.
The weight-bearing and trailing portions 11 and 19 are substantially rigid for 40.5% of the overall ski length to maintain their straight planar configuration when weight is applied thereto and commence curving gradually upwardly and forwardly from the horizontal plane thereof at a gradually decreasing radius of curvature from a point directly beneath the ball of the boot 14 and continue such upward curvature for 42.5% of the ski length to form a planing portion, generally designated 22, which is, in essence, reverse cambered to be raised in its unflexed condition, to 0.5 centimeters about the plane of the weight-bearing portion 11 at the base of the shovel 17. While the reverse camber of such planing portion 22 may be sufficient to raise the front thereof several centimeters off the snow it should be sufficient to raise it at least 0.3 centimeters and preferably 0.5 centimeters. Such planing portion 22 becomes gradually more flexible as it projects forwardly and incorporates the leading portion 15. Such planing portion 22 must exceed 35% of the overall ski length for proper ski performance. In skiing steep slopes the entire weight of the skier may at times be borne by such trailing edge 21 so it is important from a performance standpoint that the trailing portion be relatively short, not exceeding 20% of the ski length and preferably no more than 17% of the overall ski length. Also since the trailing edge 21 acts as a third edge it should incorporate a metallic edge or other wear resistant covering to be discussed hereinafter.
The ski may be constructed as set forth in my aforementioned parent application to incorporate longitudinally extending spaced apart I-beams of extruded polystyrene and wrapped with layers of various different weaves of fiber cloth pre-impregnated with resin with the space between such I-beams being filled with expanded urethane foam. The sides of the ski are closed by adhering plastic strips to the ends of the impregnated fiber cloth and elongated steel strips are secured to the opposite sides of the ski to form edges 25. The longitudinal I-beams may gradually decrease-in-cross section toward the forward extremity of the planing portion 15 to thereby gradually increase the flexibility of such planing portion thus providing the greater relative flexibility with respect to the weight-bearing and trailing portions 11 and 19.
In operation, the ski binding 13 may be of conventional construction and is mounted over the weight-bearing portion 11 with the toe thereof being positioned approximately medially in a fore-aft direction on the ski. The skier's boot will then be received in such binding and in standing on such ski his weight will be positioned rearwardly on the ski thus distributing his weight in a gradually increasing magnitude toward the rear of the ski as depicted by the broken line force diagram shown in FIG. 9.
This weight distribution should be contrasted with that for a conventional ski as shown in FIG. 8 wherein the weight-bearing portion is located centrally in a fore-aft direction and the ski is formed with a conventional camber raising the central portion thereof relative to the shovel and tail. Consequently, as the skier skis down the ski slope, the relatively unweighted shovel 17 and planing portion 22 will encounter various obstacles and unevenness in the terrain and will flex upwardly and downwardly in response to such encounter, thus leading the weight-bearing portion over the obstacles. It will be appreciated that such flexing of the planing portion 22 will not only absorb shock and forces resulting from consequent changes in direction as dictated by such obstacles, but will essentially telegraph forces applied thereto to the skier's foot, thus providing advance notice of the expected encounter with such obstacles by the weight-bearing portion 11 thereby giving the skier an opportunity to anticipate sudden changes in direction, speed and the like.
It will be appreciated that with the weight positioned rearwardly on the ski, there is no necessity for the skier to make extra effort to manipulate his body in such a manner as to unweight the tails of the ski during turning maneuvers, thus enabling the skier to utilize an entirely new skiing technique in negotiating a turn. Surprisingly, a mere rolling to one side of the skier's knees will cause the edges of the skis on such one side to be weighted and with the weights positioned rearwardly on the ski, the rear corner of the trailing edge 21 on such one side will dig into the snow, thus tending to draw the planing portion 15 of the ski to such one side thereby causing the ski itself to pivot about the skier's heel, thereby negotiating such turn. This turning maneuver can be further facilitated by the skier shifting his weight even further rearwardly on the skis, as by assuming a nearly sitting position, thus applying even more weight to the trailing edge 21 as depicted by the solid line force distribution diagram shown in FIG. 9 to thereby exaggerate the braking effect of the corner digging into the snow and further sharpening the curvature of the turn.
It has been found that in normal skiing over relatively hard-packed snow, the planing portion 22 may project upwardly from the plane of the snow at an angle of approximately seven degrees, thus causing the forwardmost portion thereof to only encounter rises in the terrain itself and to normally be elevated from the snow surface. However, when the skier is skiing down an extremely steep slope or skiing through soft powder, the planing portion 22 may project from the snow surface at an angle of 80° or more, as shown in FIG. 4.
The flexibility of the planing portion 22 enables the leading extremity thereof to flex upwardly to facilitate plowing through soft powder while the rigid trailing portion 19 enables the skier to dig the trailing edge 21 into either hard or loose snow on a steep slope to thus act as a highly effective brake enabling the skier to maneuver essentially straight down an extremely steep slope, even up to an 80° incline, without making significant contact of the underside of the planing portion 22 with the snow. Consequently, the combination of the rigid weight-bearing and trailing portions 11 and 19 with the flexible planing portion 22 exhibits an entirely new ski performance heretofore unknown.
Because of the nature of the skis being rearwardly controlled, the skier normally assumes a position leaning further rearwardly from the vertical than for normal skis in order to apply greater pressure on the third edge of the ski. This position may lead to early fatigue or eventual discomfort so it is desirable to provide a new ski binding, generally designated 30, which incorporates a support wedge 31 which acts to elevate the heel of the boot relative to the toe itself, thus enabling the skier to maintain his weight rearwardly on the trailing portion without assuming a skiing position angling his body excessively rearwardly of the vertical. It will be appreciated that the angular binding support may take many different forms, as shown in my aforementioned co-pending application, and the wedge type support 31 is merely shown as a representative embodiment.
Referring to FIGS. 4, 5 and 6, the trailing edge 21 may be formed by the rear edge of a pressure plate, generally designated 37, which is received in a relief formed in the underside of the trailing portion 19 and is removably secured thereto by means of screws 39 so the pressure plate may be removed and replaced with different pressure plates having other configurations and characteristics for different snow conditions and intended use.
Referring to FIG. 7, the pressure plate may be formed with one or more longitudinal downwardly projecting skegs 41 to enhance maneuverability and facilitate control, it being appreciated that in many instances the longitudinal edges 25 of the ski may have little contact with the snow, thus placing great emphasis on such pressure plate for control.
From the foregoing, it will be apparent that the ski of present invention exhibits characteristics enabling a skier to ski a totally new style of skiing whereby a relatively unaccomplished skier may accommodate what were heretofore considered extremely challenging slopes and adverse snow conditions. A relatively unaccomplished skier will not be plagued by the feeling of awkwardness normally accompanying the learning to master skis having rather lengthy tails projecting substantial distances rearwardly of the binding and offering resistance to turning of the ski. Because of the rearward control a ski in the 100 centimeter range will be suitable for use by both male and female adults thus eliminating the necessity of carefully selecting the ski length in accordance with the physical size of the skier.
Various modifications and changes may be made with regard to the foregoing detailed description without departing from the spirit of the invention. | A pair of rearwardly controlled snow skis including a relatively rigid weight-bearing rear portion for mounting of ski boots thereon and projecting rearwardly from the boot heel to form a trailing portion terminating in a trailing edge. The skis project forwardly of the boot and have the top and bottom surfaces tapering inwardly toward one another to form a relatively flexible planing portion. The skis also taper outwardly along their opposite edges to form a relatively wide upturned shovel at the front extremity thereof. | 0 |
DESCRIPTION
1. Technical Field
This invention pertains to flooring units or panels, either in the form of elongated planks or in smaller rectangular or square parquet, and more particularly, to interconnecting adjacent such units together by a simple snap-together locking system.
2. Background of the Invention
Flooring in the form of elongated planks or strips and rectangular or square parquet panels are well known. Generally it is desirable to be able to inter-fit the flooring so that it has a tight inter-fit and an outer appearance devoid of large gaps or cracks. In general, it is also desirable that the flooring be easily and quickly assembled, to reduce installation costs.
Various techniques in the past have been proposed for providing such flooring and flooring systems. U.S. Pat. No. 3,310,919 shows a flooring system in which interlocking flooring units are engaged by tongue and grooves with interlocking screws locking a groove to a tongue. U.S. Pat. No. 3,657,852 shows interlocking tongue and grooves with the panels or units having to be overlaid and tilted to allow the tongue to fit within the groove.
While the known prior art systems have been adequate in many cases, they are not adequate in locations where speed of installation is of the essence, and the interlock must be tight.
SUMMARY OF THE INVENTION
It is an object of this invention to provide a flooring that can be interconnected one to another to make up a flooring system in which each of the individual flooring or flooring units is interlocked by a mechanical interlock system that can be quickly snapped together at the installation site without the need for tools.
Furthermore, it is another object of this invention to provide a versatile flooring system in which individual flooring units such as planks or parquet squares or other shapes can be inter-fitted together in various different patterns simply by snapping together the flooring to make the total system.
In one embodiment, the flooring has base members, each with four outer peripheral edges. A tongue connector is attached to one outer edge and a groove connector is attached to another of the outer edges. The groove connector has an outer opening of a reduced width, and an inner opening with a width greater than the width of the outer opening. The tongue has a forward end with forwardly converging opposed elastically flexible sidewalls. The sidewalls can be compressed toward one another to form a transverse width smaller than the outer opening of the groove. The expanded width of the sidewalls of the tongue, however, is greater than the outer opening of the groove, so that once the tongue is inserted into a groove the tongue can expand in the inner opening of the groove and provide positive interlocking abutting surface between the tongue and the groove to hold the two base members together. Preferably, the connectors are attached to the base members in recesses in the outer edges by additional tongues and grooves. The connectors are preferably attached to the base members at the factory during manufacture.
As is readily apparent, the flooring can be interconnected together quickly and positively locks in a variety of patterns to enable rapid construction of the flooring system in the dwelling or other structure.
The base member generally will have a top side covered by a wood veneer or other attractive wear surface, and an underside which may be covered by a rubber cushion layer.
The flooring units when assembled can have various different arrangements of their outer peripheral edges connected to one another, and in the case of the elongated planks the planks may be laid side-by-side, end-for-end, or with an end abutting a side.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a flooring unit of the invention locked together with another flooring unit to form the flooring system.
FIG. 2 is a fragmentary vertical cross section through two interconnected flooring units.
FIG. 3 is a plan view of an elongated plank of one embodiment of the invention.
FIG. 4 is a plan view of a second embodiment of an elongated plank with grooves and tongues running the full length of the side edges of the plank.
FIG. 5 is a fragmentary isometric exploded view of the invention.
DETAILED DESCRIPTION OF THE INVENTION
As best shown in FIG. 1, a typical flooring unit 10 can be rectangular or square of the parquet type or an elongated plank. A second flooring unit 11, identical to flooring unit 10, can be interconnected to flooring unit 10. The arrangement of units connected can be different lengths and widths to fit the size of the room in which the flooring is to be laid.
As best shown in FIG. 2, a flooring unit includes a base member 12. The base member of each flooring unit except for its dimensions is identical, so only one will be described. Preferably, the base member is plywood or other solid, durable material. The base member for flooring unit 10 has a tongue connector 14 attached to it. A groove connector 16 is attached to flooring unit 11. All connectors are preferably made from plastic having some flexibility. The tongue connector has a forwardly protruding tongue 18. The groove connector has a forwardly protruding groove 20.
The tongue is provided with a pair of forwardly diverging sidewalls 22 and 24 separated by an elongated groove 26. The sidewalls terminate rearwardly at transverse rear locking surfaces 28. The sidewalls can be compressed together to a narrower width, and are made of elastic or resilient plastic to naturally expand outwardly into an enlarged width as shown in FIG. 2.
The groove 20 has an outer opening 30 with inwardly converging sidewalls 32 which terminate at substantially transverse intermediate locking surfaces 36. The intermediate locking surfaces 36 partly form an enlarged inner opening 38 of a size slightly larger than the periphery of the sides of the sidewalls of the tongue when in its expanded position. The outer opening 30, however, is smaller in cross-section than the width of the inner sidewalls of the tongue, so that the transverse rear locking surfaces 28 of the tongue overlay and abut against the intermediate locking surfaces 36 of the groove.
As is readily apparent, by forcing the tongue into the groove the sidewalls of the tongue compress into the center groove or slot 26, allowing the sidewalls to pass beyond the outer opening of the groove 30. Once past the outer opening, the sidewalls of the tongue expand into the position in FIG. 2 to positively interlock the two connectors together.
Each connector is provided with additional tongues or ribs in the shape of barbs 40 having enlarged heads 42 that fit into elongated grooves 44 in the base member. Two such tongues 40 and grooves 44 are provided for each connector. The grooves 44 and the tongues 40 run the entire length of an outer edge of the base member. Preferably the base member is cut away or recessed with a flat surface 50, a sloping surface 52, and a bottom flat surface 54 substantially parallel to the surface 50.
Preferably each base member has its underside covered by a cushioning layer 60 and its top surface covered by a wood veneer or other hard finish decorative surface 62.
Normally the peripheral outer edges of the planking or of a square or rectangular parquet unit will be as in FIG. 4 and in a circumferential direction around the unit will have one edge with a groove connector 16, the next edge with a tongue connector 14, the next edge with another tongue connector 14 and the final edge around the periphery being another groove connector 16. Also, the arrangement of alternating tongue and groove connectors around the circumference of the flooring unit is also feasible.
In the embodiment shown in FIG. 3, a planking 82 will have a tongue connector 14 at one end, a groove connector 16 at the opposite end, but will have a groove connector 16 for one half of an elongated side and a tongue connector 14 for the remaining half. Likewise on the opposite elongated side, a tongue connector 14 will be for one half and a groove connector 16 will extend for the other half. In this arrangement, the end 86 of one plank can be inserted against a sidewall 87 with the tongue connector 14 fitting in the groove connector 16. A second plank can then be fitted against the remainder of the sidewall 88 with a groove connector 16 of that plank fitted into the tongue connector 14 of the side 88. Alternatively, the planks 82 can be interconnected side-by-side.
As is readily apparent, installation of the planking or parquet units is quite quick and simple. A supply of the units is delivered to the job site. The workman needs only begin snapping the units together quickly, until the entire room is made up. No special tools of any kind are needed.
While the preferred embodiments of the invention have been illustrated and described, it should be apparent that variations will be apparent to one of ordinary skill in the art without departing from the principles herein. Accordingly, the invention is not to be limited to the specific embodiments shown in the drawing. | A flooring system having a base member having a top side, an underside, and four circumferentially spaced outer edges, a tongue connector secured to one outer edge by an interlocking rib and groove, a groove connector secured to another outer edge by an interlocking rib and groove, the tongue connector having forwardly converging compressible sidewalls terminating in rear transverse locking surfaces, the groove connector having an enlarged inner opening and a smaller outer opening, the tongue sidewalls in a compressed position being smaller than said groove outer opening to pass through the outer opening but elastically expandable to be larger than said outer opening to lock a tongue in a groove. | 4 |
BACKGROUND OF THE INVENTION
Due to material fatigue, material breakage or other aging processes, a plurality of changes in the foundation of the fixed railroad track may occur and, as far as possible, should be monitored constantly and, if necessary, corrected.
SUMMARY OF THE INVENTION
In order to be able to carry out such monitoring as simply as possible and at regular intervals, a device is provided pursuant to the invention, which is characterized by a height sensor system, which is installed in a measuring vehicle and preferably constructed as a laser scanning system, for determining the height position of an anchor clamp and/or of the base of the rail and/or of a railroad tie.
Such a sensor monitoring system is configured most easily for detecting loosened anchor clamps. In a further development of the invention, provisions are made for this purpose so that the height-scanning system, disposed above the central loop of the anchor clamps, detects the difference in height between the central loop and the surface of the angle guiding plate, which can be achieved in the simplest case with one and the same height-scanning sensor. If the locking screw is loose, the central loop of the anchor clamp springs upwards, so that, during the scanning height of this central loop, there is an appreciable deviation in height from the nominal value, which enables such a loosened anchor clamp to be detected rapidly and reliably.
In order to monitor the rigidity of the elastic intermediate layer of the rail support or to detect loosened railroad ties, a device is provided pursuant to the invention, for which the height-scanning system has two scanning sensors, which are disposed next to one another in the region of a an axle, which is under load, and an axle, which is not under load, of the measuring vehicle. In order to monitor the rigidity of the elastic intermediate layers of the rail support, one of these scanning sensors of each scanning sensor pair, disposed at separate axles, detects the base of the rail and the other detects the surface of the railroad tie. In each case, the difference in the height values, measured by each sensor pair, is determined, the difference for the axial under load obviously being greater than the difference for the axles not under load. The magnitude of this deviation is a measure of the still existing rigidity of the elastic intermediate layers.
In order to detect loosened railroad ties, the sensors of each sensor pair of an axle detect once the surface of the railroad tie and once the surface of the concrete supporting plate. In contrast to fixed railroad ties, the height of the surface of a loosened (and, with that, a moving) railroad tie above the concrete supporting plate varies, so that here also once again such loosened railroad ties can be detected easily merely by driving over a segment with a measuring vehicle.
Further advantages, distinguishing features and details of the invention arise out of the following description of an example of an embodiment, as well as from the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a partial cross section through a fixed railroad track parallel to the axis of the railroad ties,
FIG. 2 shows a plan view of the railroad tie section of FIG. 1 , the different scanning lines being drawn, along which height-measuring sensors at a measuring carriage can be moved, and
FIG. 3 shows a section along the line III—III of FIG. 1 .
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The railroad ties (in the present case, one half 2 of a two-block railroad tie with protruding lattice support reinforcement 3 ) is cemented into a fixed railroad track plate, the rail 4 being mounted on the rail support 6 over intermediate layers 5 and held by means of railroad tie clips 7 and locking screws 8 , which pass through these railroad tie clips 7 . The anchor clamp 7 is supported, on the one hand, on the base 9 of the rail and, on the other, on the angle guiding plates 10 . In order to monitor the rigidity of the elastic intermediate layers 5 , height-scanning sensors, preferably a laser scanning system, extend along the line A—A as well as along the line B—B. In each case, two adjacent height-scanning sensors are provided at an axle, which is under load, and at an axle, which is not under load, of a measuring vehicle, so that the one runs along the line A and the other along the line B. The sensor at the axle, which is under load, provides values for determining the surface height of the base 7 of the rail under load, relative to the height position of the surface of the railroad tie, unchanged by the load, along the line B—B.
The second pair of sensors at an axle, which is not under load, once again determines the distance between the base 7 of the rail and the surface of the railroad tie and, from this, especially the difference between these height values, since this difference is different for axles, which are under a load, then for axles, for which the intermediate layers 5 are not compressed as much. This difference provides a measure of the compressibility of the intermediate layers, from which the rigidity can be determined and monitored.
In order to detect loosened anchor clamps, a height-scanning sensor runs along the scanning line C—C, determining, on the one hand, the height of the surface of the anchor clamp, especially of the center loop of the anchor clamp, relative to the height of the surface of the angle guiding plate 10 . If the locking screw 8 has become loose, the center loop springs upwards, so that the distance from the angle guiding plate is much larger. This can be recognized by a corresponding change in the difference between the scanned height values of the anchor clamp and the angle guiding plate. In this case, the measurement range should be about 30 mm and the resolution 0.2 mm or better. In the case of this detection of loosened anchor clamps, it is generally not necessary to differentiate between axles under load and axles not under load.
For detecting loosened railroad ties, a scanning device is used, which is similar to that already used to monitor the rigidity of the elastic intermediate layers. In this case, however, the scanning sensors run along the line B on the one hand and along the line D on the other. By pressing down the loosened railroad tie into the railroad track plate 1 , the sensors at the axle, which is under load, determine a lesser height difference between the surface of the railroad tie and in the surface of the railroad track plate than do the sensors at the railroad tie, which is not under load. At the railroad tie, which is not under load, the loosened railroad tie protrudes more from the railroad track plate 1 , so that the corresponding height differences are greater. The measurement range in this case should be about 100 mm and the resolution once again about 0.2 mm. | A device for monitoring the superstructure state especially of fixed railroad tracks, with a height sensor system, which is installed in a measuring vehicle, preferably constructed as a laser scanning system, for determining the height position of an anchor clamp and/or of the base of a rail and/or of a railroad tie. | 4 |
This invention was made with U.S. government support under contract number F33615-88-C-5448 (Program Name MMST) awarded by the United States Air Force. The U.S. government may have certain rights in this invention.
This is a continuation of application Ser. No. 07/870,446, filed Apr. 16, 1992, now U.S. Pat. No. 5,268,989.
CROSS-REFERENCE TO RELATED APPLICATIONS
The following co-assigned patent applications are hereby
______________________________________Serial No. Filing Date TI Case No.______________________________________690,426 4/14/91 TI-15255702,646 5/17/91 TI-15188702,792 5/17/91 TI-15844785,386 10/30/91 TI-15734702,798 05/17/91 TI-15843______________________________________
FIELD OF THE INVENTION
This invention generally relates to semiconductor device processing and more particularly to a multi-zone illuminator with embedded real-time process control sensors for uniform wafer processing in rapid thermal processing reactors.
BACKGROUND OF THE INVENTION
Without limiting the scope of the invention, its background is described in connection with single-wafer rapid thermal processing of semiconductors wafers, as an example.
Single-wafer rapid thermal processing (RTP) of semiconductors is a powerful and versatile technique for fabrication of very-large-scale-integrated (VLSI) and ultra-large-scale-integrated (ULSI) electronic devices. It combines low thermal mass photon-assisted rapid wafer heating with inert or reactive ambient semiconductor wafer processing. Both the wafer temperature and the process environment can be quickly changed and, as a result, each fabrication step can be independently optimized in order to improve the overall electrical performance of the fabricated devices.
Rapid thermal processing (RTP) of semiconductor wafers provides a capability for improved wafer-to-wafer process repeatability in a single-wafer lamp-heated thermal processing reactor. In prior art RTP systems, equipment manufacturers have spent significant design resources to provide uniform wafer heating during the steady-state heating, conditions. These prior art systems are designed with illuminators which provide single-zone or very limited asymmetrical multi-zone control capability. Thus, with an increase or decrease of power to the illuminator, the entire wafer temperature distribution is affected. As a result, there are insufficient real-time adjustment and control capabilities to adjust or optimize wafer temperature uniformity during the steady-state and dynamic transient heat-up and cool-down cycles. As a result, the transient heat-up or cool-down process segments can produce slip dislocations as well as process non-uniformities. Various process parameters can influence and degrade the RTP uniformity. Prior art RTP systems are optimized to provide steady-state temperature uniformity at a fixed pressure. Thus a change in pressure or gas flow rates may also degrade the RTP uniformity.
SUMMARY OF THE INVENTION
Generally, and in one form of the invention, a multi-zone illuminator used in processing of semiconductor wafers is described which comprises a plurality of individual source lamps embedded in the reflector side of a lamp housing. The source lamps are arranged in a plurality of concentric circular zones for generating and directing optical energy. The illuminator also comprises a light interference elimination circuit (LIEC) having a plurality of dummy lamps not used for actual wafer heating. There is at least one dummy lamp for each circular zone which contains a light pipe for receiving a fiber-optic radiance sensor. This fiber-optic radiance sensor measures the radiation from the dummy lamps. It is also possible to use a single dummy lamp for all zones. However, the use of one dedicated dummy lamp for each zone is preferred. A gold-plated reflector plate is attached to the bottom side of the lamp housing for reflecting and directing optical energy. The distance between the reflector plate and the wafer and the lamps and the wafer may be adjusted with the use of an adjustable elevator (for lamp-to-wafer spacing and an adjustable adaptor between the lamp housing and the process chamber.
An advantage of the invention is uniform wafer heating over a wide range of gas pressures and flow rates using the concentric multi-zone configuration.
A further advantage of the invention is the use of adjustable reflector-to-wafer and lamp-to-wafer spacings.
A further advantage of the invention is providing the means for implementation of multi-point temperature sensors and light interference elimination components with minimum space and packaging complexity.
BRIEF DESCRIPTION OF THE DRAWINGS
In the drawings:
FIG. 1 is a schematic diagram of a single-wafer rapid thermal processing reactor for processing semiconductor devices using the present invention;
FIG. 2 is a partially cut-away schematic diagram of a preferred embodiment of the present invention in association with the processing chamber of FIG. 1;
FIG. 3 shows a simplified view of a preferred embodiment of the multi-zone illuminator of the present invention;
FIG. 4 is a schematic diagram of a front view of a multi-zone illuminator in accordance with the present invention;
FIG. 5 is a schematic diagram of a bottom view of a multi-zone illuminator according to the present invention;
FIG. 6 is schematic diagram of a side view of a multi-zone illuminator according to the present invention;
FIG. 7a-d are a schematic diagram of the power distribution system according to the present invention;
FIG. 8 is a block diagram showing the operation of the light interference elimination circuit (LIEC) in accordance with the present invention.
Corresponding numerals and symbols in the different figures refer to corresponding parts unless otherwise indicated.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
The continuing down scaling of device dimensions in VLSI/ULSI circuits places increasingly challenging demands on the manufacturing tools and technologies required to manufacture complex microelectronic devices. Rapid technology advancements have reduced the minimum feature sizes of digital integrated circuits into the submicron regime. As a result, short-time and or activated low temperature processes are considered to be essential for minimizing the dopant distribution problems, increasing the device fabrication yield, and achieving enhanced process control during the device fabrication sequence.
RTP operates based on the single-wafer processing methodology which is considered desirable for flexible fast turn-around integrated circuit manufacturing.
FIG. 1 is a schematic representation of a semiconductor processing reactor 100 that establishes the environment of the present invention. Within a single-wafer RTP reactor 100 such as the Texas Instruments' advanced automated vacuum processor (AVP), may reside semiconductor wafer 60. Beginning at the may reside semiconductor wafer 60. Beginning at the bottom right-hand corner of FIG. 1, gas distribution network 102 may comprise two gas manifolds: a non-plasma process gas manifold and a plasma manifold. Non-plasma gas manifold penetrates through reactor wall 108 via gas line 104 and process chamber wall 110 to proceed through ground electrode 112 and into gas injector 114. Plasma manifold connects into discharge cavity 118 via gas line 106 for generating process plasma. Process plasma activated species pass within plasma discharge tube 120 through reactor casing 108 and process chamber wall 110, through ground electrode 112 and into plasma injector 122 near nonplasma gas injector assembly 114. Above gas injector assembly 114 and supported by low thermal mass pins 124 appears semiconductor wafer 60. Low thermal mass pins 124 are supported by ground electrode 112 (or a liner, not shown) within process chamber 126. Wafer processing may be conducted with only thermal activation or with a combination of thermal and plasma process activation.
Process chamber 126 includes optical quartz window 128 which separates semiconductor wafer 60 from multi-zone illuminator 130 of the present invention. In association with multi-zone illuminator 130 may be multi-point temperature sensor 132 (not shown) as described in U.S. Pat. application Ser. No. 702,646 by M. Moslehi, et al. filed on Apr. 24, 1991 and assigned to Texas Instruments Incorporated. Vacuum pump connection 134 removes flowing process gas and plasma from process chamber 126 and into pumping package 136. Additionally, isolation gate 138 permits passage of semiconductor wafer 60 from vacuum load-lock chamber 140 into RTP process chamber 126. To permit movement of semiconductor wafer 60 into process chamber 126, chamber collar lift mechanism 142 supports process chamber collar 110.
Within vacuum load-lock chamber 140 appears cassette 144 of semiconductor wafers 60 from which wafer handling robot 146 removes a single semiconductor wafer 60 for processing. To maintain load-lock chamber 140 under vacuum, load-lock chamber 140 also includes vacuum pump connection 148.
Process control computer 150 controls the processing of semiconductor wafer 60 in RTP reactor 100. Control signals from process control computer 150 include signals to multi-zone controller 152. Controller (or multi-zone controller) 152 provides various signals to multi-zone lamp module power supply 154. Illuminator power supply 154 responsively provides power settings to multi-zone illuminator 130.
Process control computer 150 also directs pressure set points to pumping package 136 as well as gas and plasma inlet flow signals to mass-flow controllers in the gas distribution network 102. To provide proper activation of plasma species at discharge cavity 118, process control computer 150 provides a control signal to microwave source 156 which, in the preferred embodiment, operates at a frequency of 2450 MHZ.
Process control computer 150 checks the status of multi-zone illuminator 130 via line 158 for diagnosis/prognosis purposes and provides multiple temperature control signals to multi-zone controller 152 in response to temperature readings of multi-point sensors (not shown). The multi-zone controller receives measured multi-point temperature sensor outputs (not shown) as well as the desired wafer temperature setpoint (from computer) and delivers power setpoints to the lamp zone power supplies. Sensing lines 159 between process control computer 150 and multi-zone illuminator 130 of the present invention include signals from multi-point temperature sensor (not shown) for real-time semiconductor wafer 60 temperature measurements as well as the status of the zone lamps to monitor aging and failure of the lamps.
FIG. 2 shows a perspective view of the Texas Instruments AVP or advanced/automated vacuum processor operating as an RTP reactor 100 for purposes of the present invention. Process chamber 126 is mounted on reactor frame 136. Process chamber 126 rigidly supports multi-zone illuminator 130. Adjacent to process chamber 126 is vacuum load-lock chamber 140 within which appears cassette 160 for holding semiconductor wafers 144. Adjacent to vacuum load-lock chamber 140 is process control computer 150 which controls the operation of the various elements associated processing reactor 100.
FIG. 3 shows a schematic view of the main components of a multi-zone illuminator 130 of this invention (components shown separate from each other). The main components include a water-cooled lamp housing/reflector 200, an array of multi-zone heating lamps 328, a lamp socket base plate 322, and a power wiring module 320. The power wiring module 320 provides electrical connections between the lamp zones and external electrical power supplies (not shown). The base plate 322 holds all the lamp sockets. The multi-zone heating lamps 328 penetrate through the water-cooled lamp tubes 329 within the water-cooled lamp housing/reflector assembly 200. Additional water-cooled tubes 326 with a smaller diameter are included for insertion of a multi-point temperature sensor system for multi-zone lamp and temperature control. These sensors are inserted into the multi-zone illuminator assembly 130 through various holes 325, 324, 210, which are aligned between the power wiring module 320, lamp base plate 322, and water-cooled lamp housing/reflector 200.
The preferred embodiment of the invention is shown more in detail in FIG. 4. The multi-zone illuminator 130 consists of a lamp housing 200 which has a series of open spaces or tubes through which an array of heating lamps 220 and dummy lamps 222 protrude. Dummy lamps 222 are shown in the periphery of housing 200 but they may be located elsewhere. On the bottom of housing 200 is a gold-plated reflector plate 230. Lamp housing 200 is water-cooled to prevent heating of the reflector 230 and the pyrometer light pipes 210. Referring to FIG. 5, the lamps 220 are arranged vertically as point sources along the axis of the illuminator, distributed over several concentric rings. The preferred embodiment uses four concentric rings, wherein each ring forms one heating zone. The number of rings (or zones) may be more or less than four. Zone 1 consists of 5 heating lamps 240 and a peripheral dummy lamp 242 located on the periphery of housing 200. Zone 2 consists of 11 heating lamps 250 and a dummy lamp 252 located on the periphery of housing 200. Zone 3 consists of 20 lamps 260 and four dummy lamps 262, 264, 266, and 268 located on the periphery of housing 200. Zone 4 consists of 29 lamps 270 and a dummy lamp 272 located on the periphery of housing 200. In the preferred embodiment lamps 220 are each 1 KW tungsten-halogen lamps. However, it should be noted that lamp ratings of 500 watts, 750 watts, 2 kw or even more may also be used. Other types of lamps different from the tungsten-halogen type may also be used.
Referring to FIG. 4, housing 200 is located above and separate from wafer 60 by optical window 290. Optical window 290 may be made of quartz or another transparent material. On the peripheral bottom edge of optical window 290 is a reflective film coating 295. The reflective film 295 may be of, for example chromium and may be used to prevent direct exposure of the vacuum O-ring seals to lamp light. The distance between reflector plate 230 and wafer 60 and the distance between heating lamps 220 and wafer 60 is adjusted by adjustable elevator 300 and an adaptor ring placed between the lamp housing 200 and the quartz window 290. Motor 350 drives lead screw 330 which itself drives (raises or lowers) nut 370. Nut 370 is connected to carriage 202. Carriage 202 is connected to wiring module 320 and lamp support. This mechanism raises or lowers the lamp array with respect to the main lamp housing 200 (reflector 230). A separate mechanism (not shown) is provided to adjust the spacing between the lamp reflector 230 and the quartz window 290. The elevator mechanism 300 can be used for two purposes: (i) to adjust the relative spacing between the lamp array and the quartz window 290 (with a given reflector-to-quartz spacing); and (ii) to raise the entire lamp array and associated wiring module 320 out of the main lamp housing 200 (water-cooled reflector 230). The latter will allow rotating the lamp array in order to replace lamps. As a result, the overall optical flux of the illuminator and its distribution pattern can be optimized for a wide range of process parameters, including chamber pressure and total gas flow rate. FIG. 4 shows lamp housing 200 at a typical position near optical window 290. FIG. 6, shows illuminator 130 from a side view, indicating the radial positions of various lamps in four concentric zones, as well as the pivot for rotation of the illuminator assembly for maintenance.
Power supplies 340 through 370 are three phase power supplies. Referring to FIG. 7, Zone 1 is powered by power supply 340. Lamps 240 may be connected as follows: Lamps 240a and 240b connected in series between phase 1 and phase 2, lamps 240c and 240d connected in series between phase 2 and phase 3, lamp 240e and dummy lamp 242 connected in series between phase 1 and phase 3.
Referring to FIG. 7, zone 2 is powered by power supply 350. Between phases 1 and 2 lamps 250a and 250b are connected in series, and lamps 250c and 250d are connected in series. Between phases 2 and 3 lamps 250e and 250f are connected in series and lamps 250g and 250h are connected in series. Between phases 1 and 3 lamps 250i and 250j are connected in series, and lamp 250k and dummy lamp 252 are connected in series.
Referring to FIG. 7, zone 3 is powered by power supply 360. Between phases 1 and 2 the following pairs of lamps may be connected in series: 260a and 260b, 260c and 260d, 260e and 260f, 260g and dummy lamp 262. Between phases 2 and 3 the following pairs of lamps may be connected in series: 260h and 260i, 260j and 260k, 2601 and 260m, 260n and dummy lamp 264. Between phases 1 and 3 the following pairs of lamps may be connected in series: 260o and 260p, 260q and 260r, 260s and dummy lamp 266, 260t and dummy lamp 268.
Referring to FIG. 7, zone 4 is powered by power supply 370. Between phases 1 and 2 the following pairs of lamps may be connected in series: 270a and 270b, 270c and 270d, 270e and 270f, 270g and 270h, 270i and dummy lamp 272. Between phases 2 and 3 the following pairs of lamps may be connected in series: 270j and 270k, 2701 and 270m, 270n and 270o, 270p and 270q, 270r and 270s. Between phases 1 and 3 the following pairs of lamps may be connected in series: 270t and 270u, 270v and 270w, 270x and 270y, 270z and 270aa, 270ab and 270ac. The above described connection is an example only. As will be apparent to those skilled in the art, other combinations are possible (depending on the power supply and lamp voltage ratings).
Lamps 220 may, for example, be tungsten-halogen or plasma arc lamps and are used to heat the semiconductor wafer 60 during processing. The concentric rings of lamps 220 in the preferred embodiment provide as much as 58 kw of power for RTP. Because of the multiple lamp sources in each zone and their proximity to one another, each zone provides a continuous photon radiation ring at the surface of wafer 200 and results in uniform wafer heating. Using multiple independent point source lamps in a zone and connecting them to one power supply is significantly less complicated and more economical and practical than providing a single ring shaped lamp.
Dummy lamps 222 are identical to lamps 220 except that they are placed in housing 200 such that their output radiation is isolated from the wafer 60. The isolation is accomplished by blocking the end sections of the dummy light pipes with a cap 224 as shown in FIG. 4. The purpose of dummy lamps 242, 252, 262, 264, 266, 268, and 272 is to measure the light modulation depth as is described below, for the purpose of precise pyrometry-based temperature measurement.
Multi-point temperature sensors, such as those described in U.S. Pat. application Ser. No. 702,646 filed Apr. 24, 1991, can be used to perform real-time temperature measurement and uniformity control during transient and steady-state thermal cycles. However, lamps producing radiance with infrared wavelengths of less than 3.5 microns are desired because the quartz window 290 is transparent at those wavelengths. At wavelengths of less than 3.5 microns, pyrometry measurements are, however, subject to lamp interference effects which can cause significant temperature measurement errors and process repeatability problems. Thus, a light interference elimination circuit (LIEC) is desired.
Each dummy lamp includes a light interference eliminator circuit (LIEC) pyrometer insert light pipe 205 for LIEC modulation depth measurement and control for their respective zones. Radiance pyrometers 206 (shown in FIG. 8) associated with light pipes 205 measure the radiation from the dummy lamps 222. Multiple pyrometer insert light pipes 210 are also embedded in housing 200 for up to 5 or more radial wafer temperature measurements. Wafer pyrometers 211 associated with light pipes 210 measure radiation from both the lamps 220 (due to their interference) and wafer 60. A power modulation source (not shown) is provided for modulating the electrical power source to a selected modulation depth such that the output radiation of the dummy lamps 222 varies with the selected AC modulation but the temperature of the wafer 60 remains substantially constant. Circuitry is provided for determining the fraction of total radiation collected by pyrometers associated with light pipes 210 which is emitted by the wafer heating lamps 220 and calculating the true temperature of wafer 60. Referring now to FIG. 8, a sample or portion of the spectral power of the lamp radiation is measured by a lamp pyrometer 206. The spectral power includes an AC component ΔI (for reference, ΔI is the peak-to-peak AC signal) and the DC component I. The dummy lamp pyrometers 206 operate in the same spectral band Δλ, and therefore the same center wavelength, as the wafer pyrometers. As an example, λ 0 may be 3.3 μm and Δλ may be 0.4 μm.
A lamp pyrometer output signal is provided to a low-pass filter 428 which outputs the DC component I. The dummy lamp pyrometer 206 output is also provided to a high-pass filter 430 and a peak-to-peak to DC converter 432 which in turn outputs the AC portion of the lamp intensity ΔI. (Note: If desired, both blocks 430 and 432 can be bypassed without affecting the functionality of LIEC).
The lamp radiation modulation depth M L is determined by dividing the peak-to-peak value of the AC component ΔI of the lamp pyrometer 206 by its DC component I in divider 434.
At the same time, the AC component ΔI' of a wafer pyrometer 211 is determined from high-pass filter 436 and peak-to-peak to DC converter 438. The AC component ΔI' of the wafer pyrometer 211 is then divided by the measured lamp modulation depth M L in dividing circuit 440. The output Y 2 of the divider is the amount of DC lamp interference, i.e., the main source of measurement error in the wafer temperature sensor or wafer pyrometer 211. Again, blocks 436 and 438 are eliminated/bypassed if blocks 430 and 432 are eliminated/bypassed.
The lamp interference effect or Y 2 may be subtracted from the DC component I' from the wafer pyrometer 211 (obtained from low-pass filter 442) in difference or differential amplifier circuity 444. The output Y 3 of the difference circuit 444 is based on the true wafer temperature and substantially all lamp interference portion has been eliminated.
This technique also provides real-time data on spectral wafer reflectance (or emissivity) in the spectral band of the pyrometer. This information can be used for real-time correction/compensation of wafer temperature measurement using pyrometry. The spectral reflectance is essentially proportional to the ratio of the AC signal level ΔI' detected by the wafer pyrometer 211 to the AC signal level ΔI detected by the lamp pyrometer 206. The emissivity is proportional to the output of divider 452, labeled as Y 4 in FIG. 5. Y 4 is a measure of the wafer spectral emissivity at the same center wavelength as the pyrometers. A more detailed description of the operation of a LIEC (without embedded dummy lamps) is described in co-pending patent application Ser. No. 785,386, filed Oct. 30, 1991 and assigned to Texas Instruments, Inc and is hereby incorporated by reference.
A few preferred embodiments have been described in detail hereinabove. It is to be understood that the scope of the invention also comprehends embodiments different from those described, yet within the scope of the claims.
While this invention has been described with reference to illustrative embodiments, this description is not intended to be construed in a limiting sense. Various modifications and combinations of the illustrative embodiments, as well as other embodiments of the invention, will be apparent to persons skilled in the art upon reference to the description. It is therefore intended that the appended claims encompass any such modifications or embodiments. | A multi-zone illuminator for processing semiconductor wafers is described which comprises a plurality of source lamps and dummy lamps embedded in the reflector side of a lamp housing. The source lamps are arranged in a plurality of concentric circular zones. The illuminator also comprises plurality of light pipes for receiving multi-point temperature sensors to measure the semiconductor wafer temperature and its distribution uniformity. A gold-plated reflector plate is attached to the bottom side of the lamp housing for reflecting and directing optical energy toward the wafer surface. The distance between the reflector plate and the wafer and the lamps and the wafer may be adjusted with the use of a spacial elevator and adaptor assembly. The multi-zone illuminator allows uniform wafer heating during both transient and steady-state wafer heating cycles. | 7 |
FIELD OF THE INVENTION
The present invention is directed generally to a device for connecting paper webs. More particularly, the present invention is directed to a device for connecting two paper webs in an automatic roll changer. Most specifically, the present invention is directed to a device for connecting two paper webs in an automatic roll changer of a web-fed rotary printing press with means for compensating for web length changes during a paper web splice. The device utilizes a pivotable support frame which carries a compensation device at one end. The compensation device utilizes two spaced double armed levers that have upper and lower web engaging rollers supported between the upper and lower ends of the levers. As the upper of these rollers exerts a force on the web during a web change, the lower roller exerts a reduced force on the web thereby lessening possible web length changes.
DESCRIPTION OF THE PRIOR ART
It is generally well known in the art to utilize paper rolls on roll supports in web-fed rotary presses. Typically two paper web rolls are supported by a roll support with one web being used while the second roll is in a standby or waiting position. As the first roll becomes exhausted, the supply of paper to the press is changed to the standby roll during a so-called flying web change. Various different assemblies are known in the art for use in the accomplishment of paper web roll changes.
A device for gluing or otherwise securing a fresh web to an exhausting or diminishing paper web is shown in German Letters Patent No. 878 945. In this assembly, the fresh paper web is provided with a suitably prepared adhesive leading tip on the outside surface of the leading end of the paper web on the roll. The paper web roll being used, is pressed against this prepared surface of the fresh paper web roll by use of brush elements that are forced against the exhausting paper web. During the accomplishment of this web splicing, it is desirable to avoid stretching of the paper web that is being exhausted. Such a stretching of the web could result in a tearing of the web and a resultant stoppage of press operation. In this prior German Letters Patent No. 878 945 stretching of the paper web and possible paper web tearing during the pressing operation of joining the webs together is prevented by providing two movable rods or rollers. While one of these rollers presses the exhausting paper web against the surface of the new paper web roll to which it is to be spliced, the second roller moves in the opposite direction.
A limitation of this prior art device is that the two rollers have a relatively large inertia because of the mass of these rollers. This inertia cannot be overcome, during a web splice or gluing operation, in a fraction of a second. However the speed of web travel in present day high-output web-fed rotary printing presses provides only a very limited time in which the web gluing or splicing procedure must be accomplished. The relatively high inertia of this prior device is not compatible with the accomplishment of fast web changes.
In a different prior art paper web gluing or splicing device for rotary printing presses, as shown in German Democratic Republic Patent No. DD-WP 86 409, the paper web which is running out or being exhausted is brought into contact with the fresh roll by means of a guide roller. At the same time, a pressing brush that is used to press the exhausting paper web against the prepared adhesive or splice portions of the new or standby web roll, and a second roller for use in compensating for paper web length changes in the exhausting paper web are moved out. The adjusting means of the two rollers and the brush are connected to each other in such a way that the guide roller, the pressing brush, and the compensating roller are all adjusted by means of a screw drive. This screw drive is operated by a motor which can be rapidly turned on and which acts on a lever fastened on the brush shaft and to which an adjusting rod for pivoting the guide roller and the compensating roller is hinged.
A limitation of this prior art device is that it is necessary to provide a large outlay for driving and transmitting elements to accomplish the connection of the two paper webs to each other. These drive elements have a large amount of inertia due to their mass. In present high-output web-fed rotary printing presses which have paper web running speeds in the area of 15 meters/second and above, the accomplishment of a paper web splice must take place in very short periods of time. The inertia of this prior art device renders it too slow for use in present high speed devices.
It will thus be apparent that a need exists for a device for connecting paper webs which overcomes the limitations of the prior art devices. The assembly in accordance with the present invention provides such a device and is a significant advance over the prior art.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide a device for connecting paper webs.
Another object of the present invention is to provide a device for connecting two paper webs in an automatic roll changer.
A further object of the present invention is to provide a device for connecting two paper webs in an automatic roll changer of a web-fed rotary printing press.
Yet another object of the present invention is to provide a device for connecting paper webs with no increase in paper web tension.
Still a further object of the present invention is to provide a device for connecting paper webs which has a low inertia.
Even another object of the present invention is to provide a device for connecting paper webs which compensates for paper web length changes.
As will be discussed in detail in the description of the preferred embodiment which is set forth subsequently, the device for connecting paper webs in accordance with the present invention utilizes a pivotable support frame that is secured to the frame of the press. A compensation device is secured to a free end of the pivotable support frame. This compensation device utilizes two spaced double arm levers that are secured to the support frame by a rotatable shaft. These double arm levers carry guide rollers at the upper and lower ends of each of the two arms of the two armed levers. The guide rollers engage the web that is being withdrawn from the paper web roll. During a flying web change, as one guide roller is exerting increased pressure on the webs, the second guide roller is exerting reduced pressure. This is accomplished by movement of the two double arm levers in concert about their pivot or rotary shaft through the use of suitable actuating cylinders. A cutter bar is also provided to accomplish web severance after the splice has been accomplished.
The device for connecting paper webs in accordance with the present invention is low in mass and thus does not have a great deal of inertia. This allows the device to accomplish a flying paper web splice on the very fast moving webs of the present printing presses.
The paper webs are connected to each other by increasing the web pressure exerted by one of the guide rollers on the two double armed levers while at the same time reducing the web pressure exerted by the second roller. This connection of the paper webs, without any change in paper tension because of the compensation for change in the paper web length which inevitably takes place, is accomplished without the need for a great technical outlay for gears and the like, as was the case in the prior art devices. The device for connecting paper webs in accordance with the present invention prevents ripping, stretching and tearing of the paper web, even at high press speeds. The device overcomes the limitations of the prior art devices and is a substantial advance in the art.
BRIEF DESCRIPTION OF THE DRAWINGS
While the novel features of the device for connecting paper webs in accordance with the present invention are set forth with particularity in the appended claims, a full and complete understanding of the invention may be had by referring to the detailed description of the preferred embodiment which is set forth subsequently, and as illustrated in the accompanying drawings, in which:
FIG. 1 is a schematic side elevation view of the device for connecting paper webs in accordance with the present invention;
FIG. 2 is an enlarged side elevation view of the compensation device portion of the present invention, taken along line II--II of FIG. 4 and showing the device in the preparation position;
FIG. 3 is a view similar to FIG. 2 and showing the compensation device in the operating position; and
FIG. 4 is a rear elevation view of a portion of the present invention taken in the direction indicated by arrow A in FIG. 2.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring initially to FIG. 1, there is shown a preferred embodiment of a device for connecting paper webs in accordance with the present invention. A press frame of a web-fed rotary printing press is depicted generally at 1. It will be understood that the specific type of printing press with which the present invention is utilized, is not significant so long as the press is web-fed. A roll support, generally at 2, is located in the press frame 1. This roll support carries an active paper web roll 3, which is depicted as being nearly exhausted or running out, and a standby or fresh paper web roll 4 which will be spliced or connected to the paper web 24 being removed from the exhausting roll 3. A suitable adhesive tip, array of splice tape or the like is provided on the exterior surface of the leading end of the paper web on the fresh paper roll 4. The specific structure of this adhesive tip or the like is not important to the present invention and it is not specifically shown. The roll support 2 also supports a paper guide roller 6 which is supported at one end of an arm between the two paper web rolls. This paper guide roller 6 is rotatably supported at the free end of the arm or arms.
Referring again primarily to FIG. 1 and also as may be seen in FIG. 4, a pivotable support frame, generally at 7, is supported by the press frame 1. This pivotable support frame 7 utilizes a pair of parallel, spaced, lateral support elements 8 and 9 that extend generally parallel to the press frame 1. Only lateral support element 8 is visible in FIGS. 3 and 4 but it will be understood that lateral support element 9 is the same and is located at the other side of the press frame 1. The support frame 7 is movable between a rest position B, shown in dot-dash lines in FIG. 1 and an active position which is shown in FIG. 1 in full lines. A drive shaft 11 is secured between the two lateral support elements 8 and 9 and, as will be discussed in detail subsequently, is shiftable in a parallel guide, generally at 14 which is fixed on the press frame 1. First or inner ends of the two lateral support elements 8 and 9 are secured to the shaft 11. A pair of guide levers 16 and 17 are pivotably connected at first ends to the lateral support elements 8 and 9 of the support frame 7, as shown in FIG. 1. These guide levers 16 and 17 are connected at their first ends to lateral support elements 8 and 9 intermediate the ends of the support elements. These guide levers 16 and 17 are also both secured at second ends to the press frame 1. As the drive shaft 11 of the support frame 7 is actuated and moves from its rest position shown at 11.1 to its active position show at 11 in FIG. 1, the two guide levers 16 and 17 pivot so that the support frame assembly 7 moves through a pivot angle α of between about 90° to 140° and preferably through a pivot angle of about 120°.
Turning now primarily to FIGS. 2 and 3, and as seen generally in FIG. 1 a rotary shaft 12 is supported for rotation between second, free ends of the two lateral elements 8 and 9. This rotatable shaft 12 is supported by suitable bearings which are not specifically shown. A two armed lever 13 of a compensation device, generally at 15, is supported intermediate the ends of its two arms by each end of rotatable shaft 12. One such two arm lever 13 is carried by rotatable shaft 12 inboard of its associated element 8 or 9. Only one such two arm lever 13 is shown in FIGS. 1-4 but it will be understood that the compensation device 15 utilizes two such two armed levers 13. Rotatable shaft 12 forms a pivot shaft to which the two armed levers 13 are attached. As the support frame, generally at 7, moves from the rest position B, as seen in dashed lines in FIG. 1 to its active position, as seen in solid lines in FIG. 1, the compensation device 15 will move into a position generally adjacent the fresh roll 4 on the roll support 2, as also shown in FIG. 1. The compensation device, generally at 15 is now positionable either in a preparatory position, as shown in FIG. 2 or in an active or working position, as shown in FIG. 3. Once a web splice has been accomplished, the support frame 7 can be moved back to its rest position depicted at B in FIG. 1 to move the compensation device, generally at 15 out of the area of the paper web rolls.
Referring again primarily to FIGS. 2, 3 and 4, a first, lower guide roller 21 is supported for rotation between lower ends of the two double armed levers 13. This lower guide roller 21 is on the ends of the double armed levers 13 closer to the roll support 2. A second, upper guide roller 22 is supported between upper ends of the two double arm levers 13 at a location away from the roll support 2. The upper guide roller 22 is utilized as the adhesive or pressure roller during a web splice. The lower guide roller 21 supports the paper web 24 and is provided with a cutter bar 23 for severing the depleted paper web after the splice has been accomplished.
Two paper web guide rollers 26 and 27 are supported between the side frames 1 of the press after, in the direction of web travel, the compensation device 15. The paper web guide roller 26 is attached to the frame 1 at the point of frame attachment of the guide levers 16 and 17. A compensating roller 28 is placed between the two paper guide rollers 26 and 27. This compensating roller 28 can be moved in the frame 1 in the direction indicated by arrow C in FIG. 1 to compensate for changes in the length of the paper web travel path. As may be seen in FIG. 1, in the preparation of a paper web 24, the web runs from the depleting roll 3 over the fixed paper guide roll 6, over the lower and upper guide rollers 21 and 22 of the compensation device 15 of the present invention and around the guide rollers 26 and 27 and the compensation roller 28 when the pivotable support frame 7 is in its working position depicted in solid lines in FIG. 1. When the device for connecting paper webs in accordance with the present invention; i.1. support frame 7 and compensation device 15 are in the rest position B of the support frame 8, the paper web 24 is in contact with the fixed guide roller 6, the fixed guide rollers 26 and 27, and the compensating roller 28.
As may be seen most clearly in FIGS. 2 and 3, and as is also shown in FIG. 4, the compensation device 15 is positionable by movement of the pivotable support frame 7 into a position adjacent the new paper web roll 4. A standby or preparation position of the compensation device 15 is shown in FIG. 2 while a working position is shown in FIG. 3. The lower guide roller 21 is rotatably supported between the two spaced double arm levers 13 by a lower shaft 29 while the upper guide roller 22 is rotatably supported between the two double arm levers 13 by an upper shaft 31. A pair of working cylinders 32, only one of which is shown in the drawings, have first ends secured to the lateral elements 8 and 9 of the pivotable support frame 7 at pivot points 33 and have second ends secured to the upper ends of the double arm levers 13 at pivot points 34 which are generally adjacent the ends of upper shaft 31 of upper guide rollers 22. These work cylinders 32, which are preferably double acting pneumatic cylinders, are provided with operating fluid, such as compressed air under pressure through suitable connecting sockets 36. These pneumatic cylinders 32 are supplied with compressed air from a central compressed air supply installation (not shown) by way of suitable lines and control devices which are also not shown. For ease of understanding, the work cylinder 32 in FIG. 4 is depicted rotated generally 90° from its actual operating position. By actuation of the work cylinders 32, the distance "d" shown in FIG. 2 between the surface of the upper guide roller or adhesive roller 22 and the surface of the fresh paper web roll 4 can be changed. In the work position shown in FIG. 3 this distance "d" decreases to zero as the upper guide roller 22 or pressure applicator roller is used to press the depleting web 24 against the surface of fresh roll 4 to accomplish the flying web splice.
A first end of a pneumatic work cylinder 37 is attached to the lower portion of each of the two double arm levers 13 at hinge point 39. This hinge point 39 is generally adjacent hinge point 34 discussed above. A second end of each lower work cylinder 37 is connected at hinge point 41 to a first end of a coupler arm 42 that has a second end which is rotatable about the lower shaft 29 of the lower guide roller 21 on the two double arm lever 13. The cutter bar 23, used to sever the depleted web 24 after a splice has been made, is attached to the second ends of the couplers 42. This lower work cylinder 37 is also preferably a double acting pneumatic cylinder and is thus similar to the upper work cylinder 32. Suitable connecting sockets or connections 38 are used to supply compressed air to the two chambers of the lower working cylinder 37 in a controlled manner from a central compressed air supply source through suitable lines and control assemblies which are not specifically shown.
As previously mentioned, the drive shaft 11 is usable to move the pivotable support frame, generally at 7 between its rest position shown in dot-dash lines at B in FIG. 1 and its extended or active position, as shown in solid lines in FIG. 1. As may be seen most clearly in FIG. 4, the drive shaft 11 is provided on each of its ends with a toothed gear wheel 43. The shaft 11 is further provided with a suitable gear motor (not specifically shown) which is used to rotate shaft 11. Each of the toothed wheels 43 is in gear mesh engagement with a toothed rack 46 which is carried by the press frame 1. A guide roller 44 is also provided at each end of shaft 11 and these guide rollers 44 are positioned outboard from, and adjacent the toothed gear wheels 43. Each guide roller 44 for the pivotable support frame 7 is supported between upper and lower guide rails 47 and 48 which are secured to the press frame 1. Upon actuation of the drive motor for drive shaft 11, the cooperation of the toothed wheels 43 with their associated tooth racks 46 will cause the drive shaft 11 and hence the lateral support elements 8 and 9, which make up the pivotable support frame 7 to move between the two positions shown in FIG. 1. The pivotable movement of the guide levers 16 and 17 assist in constraining the movement of the pivotable support frame 7 between its rest and work positions.
The operation of the device for connecting paper webs in accordance with the present invention will now be discussed in detail. Assuming that the pivotable support frame 7 is in its rest position B, as shown in FIG. 1, the compensation device 15 carried at the free ends of lateral support elements 8 and 9 is also in a rest or retracted position. Actuation of the drive shaft 11 will now be effected, in advance of an upcoming paper web splice, to move the pivotable support frame 7 and the compensation device 15 to its preparation position which is shown in FIG. 2. Upon receipt of a control signal from the press central, or upon actuation of a suitable control by a press operator, the upper working cylinders 32 are extended and shift the upper portions of the two double arm levers 13, together with the upper guide roller or pressure roller 22 toward the surface of the fresh paper roll 4. The depleting paper web 24 from the exhausting paper web roll 3 is forced by the pressure or adhesive roller 22 against the exterior surface of the fresh paper web roll 4 which has been brought up to the appropriate rotational speed. The depleting web 24 is glued or otherwise adheres to the previously prepared adhesive tip of the fresh paper web or roll 4. At the same time that the pressure or adhesive roller 22 is being moved by the upper working cylinders 32 toward the fresh paper web roll 4, the lower guide roller 21 is being moved away from the fresh web roll 4. This is due to the rotation of the two double arm levers 13 about the central rotatable shaft 12. Thus the increase in tension of the paper web roll 24 due to the lengthening of its travel path caused by the advance of the upper roller 22 is compensated for by a corresponding decrease in its length of travel path by the retraction of the lower guide roller 21. It will be understood that the direction of advance of the upper pressure roller 22 is indicated by arrow E in FIG. 3 and that the direction of retraction of the lower guide roller 21 is indicated by arrow F, also in FIG. 3. Concurrently with the accomplishment of the flying splice, the lower coupler arms 42 and their associated cutter bar 23 give rotated by actuation of the lower work or cut-off cylinders 37. This severs the depleted paper web 24 from the depleted paper web roll 3 so that the paper web feed is now from the fresh paper web roll 4. As soon as the splice has been accomplished, the upper working cylinder 32 is retracted to move the compensation device 15 back to its standby or preparation position, as shown in FIG. 2. The drive shaft 11 for the pivotable support frame 7 is then actuated to return the support frame back to the rest position B shown in FIG. 1. The roll support 2 can now be manipulated to remove the depleted paper roll 3 and to put a new fresh paper web roll in its place. Once this has been done, the roll support 2 will be rotated through generally 180° so that the now exhausting paper web roll 4 will be placed beneath the new fresh paper web roll.
While a preferred embodiment of a device for connecting paper webs in accordance with the present invention has been set forth fully and completely hereinabove, it will be apparent to one of skill in the art that a number of changes in, for example, the roll support, the sizes of the paper web rolls, the bearings and the like could be made without departing from the true spirit and scope of the present invention which is accordingly to be limited only by the following claims. | A device for connecting paper webs in a web-fed rotary printing press utilizes a pivotable support frame to move a paper web tension compensation device into a position against the paper web prior to a flying web splice. An upper roller on the compensation device applies pressure to the depleting web to adhere it to the new web while a lower roller on the compensation device moves away from the new paper roll to maintain the effective travel path of the depleting web constant so that the web's tension remains the same and the web does not elongate. | 1 |
BACKGROUND OF THE INVENTION
The invention relates to improvements in papermaking machines, and more particularly to a method and mechanism for positive web transfer and control without rewetting in the press section of a paper machine.
In the transfer of a web between presses or from a press to a dryer, different structures and method have been employed. One arrangement is to carry the web across an open draw. However, since the sheet is unsupported, the open draw often limits the maximum machine speed due to the strength of the sheet. With types of webs made of short fibers or pulp such as bagasse, and with constructions wherein the sheet is unusually wet and heavy, breakage can occur much too easily in an open draw due to sheet flutter or normal stresses so that the use of open draws is limited to lower speeds and certain types of webs.
Another form of sheet transfer is with the sheet carried on a felt. This arrangement eliminates the problems of sheet breaks at an open draw, but there is a disadvantage in that a considerable amount of rewetting of the sheet from the felt occurs. The rewetting is counter-productive inasmuch as the function of the press is to remove as much moisture as possible to reduce the thermal energy expenditure necessary in the paper machine dryer section.
Another form of sheet transfer is on a press roll and although this eliminates the disadvantages of both the open draw and the rewetting of the sheet in felt transfer, there are geometric problems involved in having enough space around the roll to install all the associated press equipment for such transfer. The location and transfer space is determined by the location of the surface of the press roll.
It is accordingly an object of the present invention to provide an improved method and structure for the transfer of a web between presses or from a press to a dryer in a papermaking machine which eliminates the disadvantages accompanying open draw transfer, felt transfer or direct roll transfer.
A further object of the invention is to provide an improved web transfer arrangement in which the web is under complete control to avoid breakage, wherein rewetting from a felt is eliminated, and space problems are not limiting as to where the transfer is to take place.
A feature of the invention is to provide press arrangements which can either be the typical roll couple press or what has become known as extended nip press wherein prior to the transfer, the web is sandwiched between a felt and a looped endless belt which is smooth and relatively hard so that no rewetting of the sheet occurs on the offrunning side of the press nip and the sheet follows the belt after the press nip to be subsequently removed therefrom for the transfer. This arrangement utilizes the phenomena known to papermakers that the web will follow the surface having the greatest density and will follow a smooth impervious surface rather than a felt when the two are separated.
Other objects, advantages and features, as well as equivalent structures and methods which are intended to be covered herein will become more apparent with the teaching of the principles of the invention in connection with the disclosure of the preferred embodiments thereof in the specification, claims and drawings, in which:
DRAWINGS
FIG. 1 is a schematic elevational view showing a press section of a papermaking machine constructed and operating in accordance with the principles of the present invention;
FIG. 2 is another schematic elevational view showing another form of the invention;
FIG. 3 is another schematic elevational view showing still another form of the invention; and
FIG. 4 is a further schematic elevational view showing a still further form of the invention.
DESCRIPTION
As illustrated in FIG. 1, a web W is formed on a forming wire 10 which passes down over a couch roll 11 and a turning roll 12. On the downrunning transfer run of the wire, the web is picked off the wire by a pick-up felt 13 passing over a pick-up roll 14 having a suction gland therein.
The web is carried on the underside of the felt to a press nip N formed between an upper press roll 17 and the lower press roll 16. Water is transferred from the web into the felt 13 in the press nip N with the upper press roll 17 being a suction roll with a gland therein or being another form of open roll such as a grooved roll. On the offrunning side of the nip N a guide roll 19 leads the felt 13 away from the nip and away from the web.
On the underside of the web in the nip N, the web is sandwiched between the felt 13 and an endless traveling impervious belt 15. The belt has a smooth upper surface and has a smoothness and a hardness or density generally similar to a plain press roll cover, and therefore the belt acts like an expanded press roll carrying the sheet onwardly to the next press. The belt surface preferably has a hardness in the range of between 10 and 200 P&J.
Since the belt surface is impervious to water, there is no rewetting of the sheet when carried on the belt, on the offrunning side of the nip N as in the case of when a felt is used and the sheet transfer is accomplished on a felt.
The web or paper sheet follows the belt 15 following the first press nip N since the belt has a smoother or more dense surface. Also, the web is not in contact with a felt between presses, as it travels to an intermediate press nip N-I so that rewetting does not occur during the travel time between press nips.
While the presses shown as N and N-I are illustrated as conventional roll presses, extended nip presses may be employed, and the same advantages of the use of the impervious belt occurs. Extended nip presses, as will be recognized by those versed in the art, are presses utilizing elongate press nips where the pressing pressure may be obtained such as from a dynamic layer of hydraulic liquid.
The press nip N-I which may be termed an intermediate nip is formed between a first press member 21 and a second press member 22 defining a pressing zone therebetween through which the web is carried subject to a dewatering pressure. A porous felt 20 which may be termed an intermediate felt is on one surface of the web carried on the first press roll 21 which may be a grooved roll or a suction roll. The second press roll 22 is a solid roll and may be an extended press nip as indicated symbolically by the rectangle 23 or the rectangle 23 may designate a controlled crown support shoe which runs inside of a hollow roll shell 22.
Following the nip N-I, the felt 20 is separated from the nip over a guide roll 24, and the web W is pulled off of the impervious belt 15 by suitable mechanism, not shown, and the web will follow the belt on the offrunning side of the nip N-I. The web at this location in travel will have been dewatered sufficiently to gain strength to be drawn off of the belt.
In the arrangement of FIG. 2, similar to FIG. 1, a web W is carried through a first press before passing through an intermediate press, and in the intermediate press, one side of the web is supported by a nonporous smooth belt. In FIG. 2, there is a closed transfer from the press to the dryers, rather than an open draw as illustrated in FIG. 1.
Referring to FIG. 2, a web is formed on a forming wire 30 which passes down over a couch roll 31 and a turning roll 32 in a downrunning transfer run. In the transfer run, the web is transferred to a first felt 33 which passes in pick-up relation to the wire 30 over a pick-up roll 34 with a pick-up gland therein. An intermediate felt 35 is brought up under the web, guided by a roll 36, and the web is carried through a double felted first press nip N. The first press is formed between an upper press roll 37 and a lower press roll 38 which may be of various forms, and as illustrated the lower press roll 38 is an open roll such as a grooved roll or roll shell with a suction gland therein. The suction gland transfers the web to the lower felt 35, and the upper felt is guided away from the nip N by a roll 39.
The web is then carried to an intermediate press nip N-I formed between the first press member 41 and a second press member 42. 41 may be a supported controlled deflection roll or an extended press type of roll as indicated by a schematic shoe 48 within the roll shell. In each of the arrangement of FIGS. 1 and 2, the solid impervious belt 15 and 40 respectively will function as a web carrying member preventing rewetting and can also function as the belt as part of an extended nip arrangement with a sliding shoe therein indicated respectively at 23 and 48. In the sliding shoe arrangement, as is conventional with one form of extended nip, the shoe will be shaped to conform to the roll on the opposite side of the nip and will have a relieved leading edge with means for delivering a hydraulic liquid to the leading edge so that a film of dynamic hydraulic liquid builds up between the belt 40 and the shoe.
In FIG. 2 on the offrunning side of the nip N-I, the lower felt 35 is separated from the web by being led away by a roll 43. The web will follow the smooth impervious belt 40 to a last nip formed between an upper roll 44 and a lower roll 45. The last nip may be merely be a transfer nip with the web transferring onto the smooth lower roll 45 to be carried through a dryer section with successive dryer drums 47, and additional supporting felts are led onto the web in a conventional manner.
In FIG. 3, a web W is formed on a forming wire 50 led down through a pickup run over a couch roll 51 and a turning roll 52. The web is picked off the wire 50 by pick-up felt 53 running over a pick-up roll 54 with a pick-up gland therein. A lower felt 55 is brought up underneath the upper felt 53 to sandwich the web therebetween and carry it through a double felted first nip N. The first nip is formed between an upper roll 56 and a lower roll 57 which has a gland therein to transfer the web to the lower felt on the offrunning side of the nip N.
The web is picked off the lower felt by a pick-up roll 59 having a gland therein supporting a porous intermediate felt 58. A porous looped impervious belt 60 is brought up beneath the web to carry it through an intermediate nip N-1 formed between an upper press roll 61, which may be an open roll such as a grooved roll, and a lower press roll 62. The lower roll may be an extended nip press arrangement having a shoe 63 or a controlled deflection roll.
The web will follow the impervious belt on the offrunning side of the nip N-I, and the upper felt 58 is led away from the nip by a roll 68. The web is picked off the smooth impervious belt by a felt 64 traveling over a pick-up roll 65 having a pick-up gland therein, and the roll 65 is adjustable in position to bring it into pick-up touch contact with the belt. The felt 64 then carries the web through a series of dryer drums such as 67. In this arrangement, the web is under supportive control at all locations and rewetting at the final nip N-I is prevented by the one-piece impervious belt 60.
In FIG. 4, a web W is formed on a traveling forming wire 70 which is guided down over a couch roll 71 and a turning roll 72 in a pick-up run. The web is picked off of the wire by an upper felt 73 guided into pick-up relationship with the web by pick-up roll 74 having a pick-up gland therein. A lower felt 75 is brought up under the web so that it is carried in double felted arrangement through a first press nip N. The nip is formed between an upper press roll 76 and a lower press roll 77 which is a suction roll with a gland therein to transfer the web to the lower felt 75. On the offrunning side of the nip, a plain surfaced roll 78 carrying a one-piece smooth belt 86 is pressed into the felt to transfer the web W. The web will transfer to the smooth surfaced belt from the felt, and the roll 78 will be adjustable for this purpose. A lower porous felt 79 is brought up beneath the web to carry it through an intermediate nip N-1 formed between an upper press roll 80 and a lower press roll 81. The upper roll may be an extended nip roll with a shoe 82 therein, or a controlled crown roll or similar suitable support roll for the nip N-1.
The web will follow the smooth surfaced belt 86 on the offrunning side of the nip N-1, and will automatically transfer to a smooth surface roll 83 which is pressed into the belt a controlled amount by a movable belt guide roll 87. On the downrunning side of the smooth surface roll 83, the web is lifted off of the roll onto a felt 85 which carries it through a series of dryer drums 84.
In operation various arrangements are used for the initial press, but generally speaking an intermediate press nip is utilized formed between a first press member and a second press member defining a pressing zone therebetween with a porous felt on the surface of the web and an impervious nonporous smooth surface belt on the other side so that the web follows the belt on the offrunning side of the nip and is not rewet by the belt at the downside of the nip or while the web is being carried on the belt.
Thus, it will be seen that we have provided an improved mechanism for positive web transfer in a press of a papermaking machine which meets the objectives and advantages above set forth and accommodates improved handling with space conservation and enabling higher speed secure transfer of a web without rewetting. | A method and mechanism for positive web transfer in a press section of a papermaking machine including an intermediate press nip formed between first and second press members with a porous felt on one surface of the web and a nonporous looped smooth surface belt of nonextensible material impervious to water passing through the nip in direct contact with the other surface of the web so that the web follows the belt downstream of the nip with the web first being pressed between an earlier press upstream of the intermediate press, and the web being removed from the belt following the intermediate press with rewetting of the web on the offrunning side of the intermediate nip due to contact with the impervious belt being eliminated. | 3 |
The present application claims the priority benefit of U.S. provisional patent application Ser. No. 61/500,200 filed Jun. 23, 2011, the disclosure of which is incorporated herein by reference.
BACKGROUND
The present disclosure relates to a toilet. More particularly, the present disclosure relates to a toilet including a ventilation system for exhausting odorous air therefrom.
It is apparent that numerous innovations for toilets have been provided in the prior art that are adapted to be used. Furthermore, even though these innovations may be suitable for the specific individual purposes to which they address, however, they would not be suitable for the purposes of the present disclosure as heretofore described.
BRIEF SUMMARY
The present disclosure provides a method for exhausting odorous air from a toilet that avoids the disadvantages of the prior art and is simple to use.
The present disclosure provides a toilet for exhausting odorous air therefrom, comprising a bowl, a trap, a self-contained ventilation system, a water tank, and a water supply line. The bowl has a rim therearound wherein the bowl communicates with the rim. The bowl is for receiving human waste that produces the odorous air. The main trap is contained in the bowl, wherein the trap is for communicating the contents in the bowl with a drain conduit so as to provide a passageway from the bowl to a drain stack. The ventilation system includes an exhaust blower having a blower inlet and a blower outlet. The blower inlet is in communication with air space between the contents in the bowl and the rim. The blower outlet is in communication with the drain conduit downstream from the trap. The exhaust blower further including a check valve between the blower outlet and the drain conduit for preventing the odorous air from flowing upstream from the drain stack into the blower outlet. The check valve is spring biased to a closed position and when closed blocks the odorous air from the drain conduit to the blower outlet. The check valve is selectively biased to an open position when the exhaust blower is activated at a pressure at the blower outlet thereby opening the check valve to allow odorous air to flow from the blower outlet to the drain conduit; and, wherein the exhaust blower includes a cutoff switch for deactivating the exhaust blower during a flush of the toilet
The present disclosure further provides a toilet for exhausting odorous air therefrom, comprising a bowl, a trap, a self-contained ventilation system, a water tank, and a water supply line. The bowl has a rim therearound wherein the bowl communicates with the rim. The bowl is for receiving human waste that produces the odorous air. The main trap is contained in the bowl wherein the trap is for communicating the contents in the bowl with a drain conduit so as to provide a passageway from the bowl to a drain stack. The ventilation system includes an exhaust blower having a blower inlet and a blower outlet. The blower inlet is in communication with air space between the contents in the bowl and the rim. The blower outlet is in communication with the drain conduit downstream from the trap. The exhaust blower including a cut-off switch for deactivating the exhaust blower during a flush. The shut-off switch comprising a float switch operably deactivated when a float drops during a flush and operably activates when the float rises when a level of the water in the tank moves down and up, respectively. The cut-off switch interrupts power temporarily to the exhaust blower during a flush while the float drops and rises, and resumes power to the exhaust blower when the float reaches a select water level in the tank.
The novel features which are considered characteristic of the present disclosure are set forth in the appended claims. The disclosure itself, however, both as to its construction and its method of operation, together with additional objects and advantages thereof, will be best understood from the following description of the specific embodiments when read and understood in connection with the accompanying drawing.
BRIEF DESCRIPTION OF THE DRAWINGS
The figures of the drawing are briefly described as follows:
FIG. 1 is an enlarged diagrammatic cross sectional view of a toilet assembly;
FIG. 2 is an enlarged cross sectional view of a portion of a toilet bowl and rim;
FIG. 2A is an enlarged cross sectional view of a portion of the toilet bowl and rim;
FIG. 3 is a cross sectional side view of a toilet tank;
FIG. 4 is a cross sectional front view of the toilet tank; and,
FIG. 5 is an electrical circuit schematic according to the present disclosure.
DETAILED DESCRIPTION
Referring now to the figures, in which like numerals indicate like parts, and particularly to FIG. 1 , which is a diagrammatic cross sectional view of the present disclosure, the toilet assembly of the present disclosure is shown generally at 10 for exhausting odorous air (not shown) therefrom.
The configuration of the toilet assembly 10 can best be seen in FIG. 1 , which is a diagrammatic cross sectional view of the toilet 10 , and as such, will be discussed with reference thereto.
It will be understood that each of the elements described above, or two or more together, may also find a useful application in other types of constructions differing from the types described above.
While the disclosure has been illustrated and described as embodied in a toilet for exhausting odorous air therefrom, however, it is not limited to the details shown, since it will be understood that various omissions, modifications, substitutions and changes in the forms and details of the device illustrated and its operation can be made by those skilled in the art without departing in any way from the spirit of the present disclosure.
Without further analysis, the foregoing will so fully reveal the gist of the present disclosure 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 characteristics of the generic or specific aspects of this disclosure.
The present development relates to a self-contained ventilated toilet assembly 10 as illustrated in FIGS. 1 , 2 , 2 A, and 3 - 5 . The toilet 10 includes a bowl 14 defined as part of a pedestal base 18 . The pedestal base 18 defines a drain conduit 22 . The drain conduit 22 begins at a waste outlet 26 that communicates with the bowl 14 and extends to a stack outlet 30 that is adapted to communicate with a conventional drain stack of a house or other structure (not shown) in which the toilet is installed. The drain conduit 22 comprises a trap 34 that collects a volume of water to block flow of sewage gases from the drain stack into the bowl 14 by way of the drain conduit 22 . A ring or U-shaped toilet seat 38 is pivotally connected to the pedestal base 18 by a hinge 42 and generally conforms to the dimensions of a rim 46 of the bowl so as to provide a seating location for a user of the toilet 10 .
The pedestal base 18 defines a neck 50 that extends horizontally outward from the rim 46 of the bowl 14 at the rear of the rim/bowl. A tank 54 is supported on/above the neck 50 and is adapted to contain a volume of water 58 that is selectively communicated to the bowl 14 for supplying water and flushing waste from the bowl through waste outlet 26 , into the drain conduit 22 , and out of the drain conduit 22 via stack outlet 30 into the drain stack. More particularly, the rim 46 of the bowl defines an internal rim conduit 62 as shown in FIGS. 1 and 2 . A lower region of the rim conduit 62 includes a plurality of apertures 66 that communicate with the bowl. During a flush of the toilet 10 , water 58 from the tank 54 flows into a neck conduit 52 of the neck 50 which communicates with the rim conduit 62 such that the water 58 flows from the neck conduit 52 into the rim conduit 62 . Water flowing in the rim conduit 62 flows out of the apertures 66 into the bowl 14 such that the contents of the bowl 14 are flushed into the drain conduit 22 via waste outlet 26 .
As shown in FIGS. 3 and 4 , the tank 54 comprises a flush opening 70 that is in fluid communication with the neck conduit 52 (which is in fluid communication with the rim conduit 62 ). A flush valve 74 is located in the tank and normally seats over the flush opening 70 to block same. The flush valve 74 (e.g., a flapper or other type of valve) is selectively unseated by user manipulation of a flush handle 70 , which is connected to the flush valve 74 by a linkage such as a chain 82 or other member(s). When the flush valve 74 is unseated, water 58 in the tank 54 flows by gravity into the flush opening 70 , neck conduit 52 , rim conduit 62 and rim apertures 66 for flushing the bowl 14 as described above. When the user releases the handle 78 , the flapper or other flush valve 74 is normally re-seated over the flush opening 70 to block same.
As shown in FIG. 4 , the tank 54 is connected to a water supply line 86 , and a float valve 90 is located in the tank 54 and controls the flow of water 58 into the tank 54 to refill same after a flush. In particular, the float valve 90 comprises a float 94 that moves up and down with the level of water 58 in the tank 54 . When the level of water 58 in the tank drops during a flush, the float 94 drops and opens the float valve 90 to allow flow of water into the tank 54 from the supply line 86 . When the flush valve 74 closes and the level of the water 58 in the tank 54 rises to a select level, the float 94 is elevated sufficiently to close the float valve 90 to stop the flow of water into the tank via supply line 86 .
Unlike a conventional toilet, the toilet 10 comprises a self-contained ventilation system to evacuate noxious gases from the bowl 14 . In the illustrated embodiment, the self-contained ventilation system can be automatically activated when a user of the toilet 10 is seated on the toilet seat 38 , but alternative activation systems are contemplated, such as a manual on/off switch connected to the toilet 10 . The toilet 10 comprises an exhaust blower 98 housed in the pedestal base 18 (or alternatively mounted outside the pedestal base). The exhaust blower 98 is electrically connected to a low-voltage source of electrical power. In one example, the low-voltage source of electrical power comprises a rechargeable battery 102 (e.g., 12 volts) that can be also housed in the pedestal base 18 . The battery 102 can be removable for recharging and/or can be adapted to be recharged by selectively connecting the pedestal base 18 to a source of electrical power. In another example, the toilet 10 comprises a DC power supply 106 (alone or in combination with the battery) that is connected to a conventional wall outlet for input of AC electrical power and output of DC electrical power, e.g., 9 to 12 volts DC to the exhaust blower 98 . In either case, when the exhaust blower 98 is activated, it draws air and other gases into its blower inlet 110 and exhausts same through its blower outlet 114 .
According to the present development, the blower inlet 110 is in communication with the interior of the bowl 14 (i.e., generally the space in the bowl 14 between the top of the rim 46 (above) and any water or other contents of the bowl (below), and the blower outlet 114 is in communication with the drain conduit 22 downstream from the trap 34 (i.e., at a location in the drain conduit 22 preferably between the trap 34 and stack outlet 30 where gases flowing into the drain conduit 22 from the blower outlet 114 will not be able to flow back to the bowl 14 via the drain conduit 22 ). In one embodiment as shown in FIG. 2A , a nozzle 122 is connected to the rim 46 and is located in the bowl 14 between the top of the rim 46 and the contents of the bowl 14 . The nozzle 122 is in communication with the blower inlet 110 through a hose or other conduit/path 126 such that noxious fumes and odors F are drawn from the bowl 14 into the nozzle 122 and flow to the blower inlet 110 and then to the blower outlet 114 when the exhaust blower 98 is active. In another embodiment as shown in FIG. 2 , the blower inlet 110 is in communication with the rim conduit 62 (directly or via the neck conduit 52 ). In such case, the blower inlet 110 is in communication with the interior of the bowl 14 through a rim conduit hose 127 and the rim conduit apertures 66 such that noxious fumes and odors F are drawn from the bowl 14 into the apertures 66 and rim conduit 62 (and optionally also the neck conduit 52 depending upon the location where the blower inlet 110 is connected to the rim conduit 62 and/or neck conduit 52 ) and flow to the blower inlet 110 and then to the blower outlet 114 when the exhaust blower 98 is active.
During periods when the exhaust blower 98 is inactive, to prevent noxious sewer gases from flowing upstream from the drain stack and drain conduit 22 into the blower outlet 114 , through the exhaust blower 98 and into the bowl 14 by way of the blower inlet 110 , the toilet 10 further comprises a check valve 130 located between the blower outlet 114 and the drain conduit 22 . The check valve 130 is spring biased to its closed position and, when closed, blocks flow of sewer gases from the drain conduit 22 to the blower outlet 114 . When the exhaust blower 98 is activated, pressure at the blower outlet 114 opens the check valve 130 such that air and odors can flow from the blower outlet 114 into the drain conduit 22 . In one example, the check valve 130 opens in response to a predeterminable pounds per square inch (PSI) of air pressure. When the blower 98 is deactivated, the check valve 130 automatically returns to its normally closed condition.
The exhaust blower 98 can be connected to a toggle switch or other manually activated switch 138 located on the toilet or elsewhere. It is preferred, however, that the exhaust blower 98 be automatically activated when a user is seated on the toilet seat 38 . As such, the toilet comprises at least one and preferably first and second seat switches 134 , 136 (see also FIG. 5 ) that are connected to the rim 46 and that are located between the rim 46 and toilet seat 38 . If multiple switches are used, they are preferably located on opposite lateral sides of the bowl 14 or are otherwise distributed about the rim 46 . The switches 134 , 136 are adapted to be activated (closed) by pressure upon a user being seated on the toilet seat 38 . The seat switches 134 , 136 are preferably spring-loaded and are deactivated (opened) when the user is unseated from the toilet seat 38 . The exhaust blower 98 is activated when at least one of the seat switches 134 , 136 is closed, and is deactivated when both seat switches 134 , 136 are opened. Alternatively, the toilet 10 can comprise one or more contact or non-contact sensors that are activated by the presence of a user near the toilet and/or seated on the toilet seat 38 , such that the exhaust blower 98 is activated only when the sensors are activated.
The exhaust blower 98 is preferably water-compatible and/or submersible such that it is capable of drawing water into the blower inlet 110 and exhausting same via blower outlet 114 . Nonetheless, for the embodiment of FIG. 2 (where the blower inlet 110 is in communication with the neck conduit 52 and rim conduit 62 ), it has been deemed desirable to deactivate the exhaust blower 98 during a flush of the toilet 10 , to minimize noise and the possibility of drawing water from the rim conduit 62 into the blower inlet 110 . In such embodiment, the toilet 10 comprises a cut-off switch for deactivating the exhaust blower 98 during a flush. For example, as shown, the toilet 10 comprises a float switch 140 ( FIGS. 4 and 5 ) that is deactivated (opened) when the float 94 drops during a flush and that is activated (closed) when the float 94 is elevated when the level of water 58 in the tank 54 rises (which indicates that the flush valve 74 is closed and the flush has ended). When the float switch 140 is opened during a flush, electrical power to the exhaust blower 98 is interrupted and the exhaust blower 98 is temporarily deactivated, until the float switch 140 closes when the tank 54 is sufficiently re-filled.
As shown in FIG. 1 , the blower inlet 110 can be directly connected to the rim conduit and/or neck conduit 52 through a hose or other path, e.g., through a conduit defined in the porcelain or other material from which the pedestal 18 and/or bowl 14 are defined/fabricated. Alternatively, as shown in FIGS. 4 and 5 , the blower inlet 110 is connected through a hose or other conduit 144 to an open upper portion of an overflow tube 148 that is located in the tank 54 . Unlike a conventional overflow tube, the overflow tube 148 includes first and second openings 150 , 152 , one of which 150 functions as a conventional overflow tube opening (to drain excess water 58 from the tank 54 around the flush valve 74 to the neck conduit 52 ) and the other of which 152 is connected to the blower inlet 110 through the hose or other conduit 144 (shown in broken lines). Because the overflow tube 148 is in communication with the neck conduit 52 , the blower inlet 110 will also be in communication with the neck conduit 52 and rim conduit 62 and rim conduit apertures 66 .
As noted above, any hose or other conduit or path or part thereof referred to herein can be defined as an integral and/or one-piece construction with the bowl 14 and/or pedestal 18 and/or tank 54 of the toilet, i.e., the conduit or path can be defined entirely or partly by an opening defined in the toilet 10 , itself, and need not be a separate hose, pipe, etc.
FIG. 5 shows one example of a suitable electrical circuit for the toilet 10 . The battery and/or power supply 102 , 106 is connected to a relay 156 that is connected to the exhaust blower 98 and that selectively supplies electrical power to the exhaust blower 98 . In particular, the relay 156 supplies electrical power to the exhaust blower 98 only when the float switch (if present) is closed and when at least one of the seat switches 134 , 136 (or the single seat switch if only one is used) is closed. The switches 134 , 136 , 138 , 140 can be in a low voltage/amperage path (e.g., at or below a predeterminable limit (volts, amps, etc.) to maximize their life and prevent burn-out of same as could would occur without the relay. | The present disclosure further provides a toilet for exhausting odorous air therefrom, comprising a bowl, a trap, a housing, a self-contained ventilation system, a water tank, and a water supply line. The bowl has a rim therearound wherein the bowl communicates with the rim. The main trap is contained in the bowl wherein the trap is for communicating the contents in the bowl with a drain conduit so as to provide a passageway from the bowl to a drain stack. The ventilation system includes an exhaust blower having a blower inlet and a blower outlet. The blower inlet is in communication with air space between the contents in the bowl and the rim. The blower outlet is in communication with the drain conduit downstream from the trap. The exhaust blower including a cut-off switch for deactivating the exhaust blower during a flush. | 4 |
TECHNICAL FIELD
[0001] The present invention is directed to a method for forming objects from a polymer that undergoes a sol-gel transition. The invention is also directed to an apparatus for forming such objects.
BACKGROUND
[0002] Methods of producing filaments, fibres or moulded objects have been known in the art for a long time. For example, spinning techniques are used to produce fibres from polymer solutions. British patent specification GB-A-441 440 (Ziegrer) discloses one technique in which filaments are produced by passing a liquid raw, material through a porous porcelain tube. The filaments emerge from the end of the porous porcelain tube in this disclosure. An operative medium is introduced into the porous porcelain tube through the pores of the tube.
[0003] There is currently considerable interest in the development of improved processes and apparatus to enable the manufacture of polymer filaments, fibres, ribbons, sheets or moulded objects. It is theoretically possible to obtain materials with high tensile strength and toughness by engineering the orientation of the polymer molecules and the way in which they interact with one another. Strong, tough filaments, fibres or ribbons are useful in their own right for the manufacture, for example, of sutures, threads, cords, ropes, wound or woven materials. They can also be incorporated into a matrix with or without ether filler particles to produce tough and resilient composite materials. Sheets, whether formed from fibres or ribbons, can be stuck together to form tough laminated composites.
[0004] Natural silks are fine, lustrous filaments produced by the silkworm Bombyx mori and other invertebrate species. They offer advantages compared with the synthetic polymers currently used for the manufacture of materials. The tensile strength and toughness of the dragline silks of certain spiders can exceed that of Kevlar™, the toughest and strongest man-made fibre. Spider dragline silks also possess high thermal stability. Many silks are also biodegradable and do not persist in the environment. They are recyclable and are produced by a highly efficient low pressure and low temperature process using only water as a solvent.
[0005] The natural spinning process is remarkable in that an aqueous solution of protein is converted into a tough and highly insoluble material. The process in spiders and silkworms has been outlined in an article “Liquid crystalline spinning of spider silk” by Vollrath and Knight, Nature, vol 410, 29 Mar. 2002, pages 541-8. The authors not that lessons are to be learnt from the manner in which spiders and silkworms store their protein dope molecules and extrude them into strong threads. The article reviews the evidence that the natural spinning mechanism in spiders involves an addition of hydrogen ions and potassium ions and the removal of sodium ions as the spinning dope passes down the spinning duct.
[0006] It also reviews the evidence that natural spinning of proteins utilizes liquid crystalline feedstocks. The liquid crystalline state depends on a delicate balance between attractive and repulsive forces operating between molecules.
[0007] In an article by Knight and Vollrath “Biological Liquid Crystal Elastomers”, Trans. Phil. R. Soc. B. 357, 155-163 (2002), the authors note that much of the toughness of silks arise from the fact that they have a nanofibrillar composite construction; are constructed from very large amphiphilic repetitive block copolymers of the type ABAB, where A represents a hydrophobic block and B a less hydrophobic one; and are in essence liquid crystal elastomers.
[0008] The proteins spidroin and fibroin are found in two states: The first state is a safe storage state in which the extremely long protein chains are thought to be folded into fairly short and compactly folded rod-shaped molecules. The proteins in this first state are present in a highly concentrated aqueous solution and have a predominantly random coil and/or helical secondary structure. The second state is a solid state with a predominantly beta crystalline secondary structure. This second sate is a nanofibrillar composite, containing a high packing fraction of very long nanofibrils approximately 5 nm in diameter. The nanofibrils are oriented substantially parallel to the long axis of the tough thread and are thought to contain all or most of the beta crystallites. The beta crystallites have a width of about 5 nm and are arranged substantially parallel to the long axis of the nanofibrils. Small quantities of a less crystalline and more disordered material are thought to form the matrix between the nanofibrils.
[0009] The first storage state is found in the posterior and middle divisions of the gland in silkworms and in the analogous A-zone in spiders in which the protein is stored in a highly concentrated liquid crystalline state at remarkably high concentrations (20-40% w/v). In spiders, the protein is stored as ahigbly viscous liquid crystalline sol that persists through the first, second and most of third limb of the duct. In newly moulted final instar silkworms the protein is stored as a sol within the posterior and middle division of the gland, but is transformed into a gel in these divisions some while before the silkworm starts to spin. During this gel is converted back into a sol substantially close to where it enters the gland's duct. Thus in both cases, the spinning dope is present as a sol in order to flow through the duct of the gland. Knight and Vollrath have recently shown that in both silkworms and spiders, the thread is formed in a “drawn-down” process which initially commences within the lumen of the duct some distance before the point of discharge of the thread to the outside world.
[0010] In a PCT patent application No WO-A-01/38614, Knight and Vollrath have described an apparatus and method for forming materials that models the natural spinning of silk. This apparatus produces fibres and filaments by an extrusion method from dopes containing solutions of recombinant spider silk proteins or analogues or recombinant silk worn silk proteins or analogues or mixtures of such proteins or protein analogues or regenerated (redissolved) silk solution from silkworm silk. When these dopes are used in the apparatus it is necessary to store the dope prior to exclusion at a pH value above or below the isoelectric point of the protein to prevent the premature formation of insoluble material. According to this disclosure, other constituents may be added to the dope to keep the proteins or protein analogues in solution. These constituents may then be removed through the semipermeable and/or porous walls when the dope has reached the appropriate portion of the tubular passage in which it is desired to induce the transition from liquid dope to solid product, e. g. thread or fibre. The dope within the tubular passage can then be brought by dialysis against an appropriate acid or base or buffer solution to a pH value at or close to the pK value of one or more of the constituent proteins of the dope. Such a pH change will promote protein aggregation and the formation of an insoluble material. A volatile base or acid or buffer can also be diffused through the walls of the or each tubular passage from a vapour phase in the surrounding compartment or jacket to adjust the pH of the dope to the desired value. Vapour phase treatment to adjust the pH of the extruded material can also occur after the extruded material has left the outlet of the apparatus.
[0011] European patent application No. EP-A-0 072 024 (Whitney and Company) provides an example of the formation of a solid product from a liquid by gelation. In the Whitney patent application, a solid article of unsaturated polyester resin is formed in a mould by using a curing agent. The curing agent is a buffered equilibrium system of a relatively small quantity of un-ionised hydroperoxide and a salt soluble in the polyester resin, formed by the reaction of the hydroperoxide and a base. This curing agent also causes the polyester resin to gel. The teachings of the Whitney patent application are directed towards the production of moulded polyester articles and there is no suggestion that these teachings can be used in the production of moulded or extruded polypeptides or proteins.
[0012] UK Patent No. GB-A-1 539 725 (Unilever) shows an example of the production of a fibre containing a soy protein. The Unilever patent discloses the spinning of an aqueous solution of the soy protein to produce the soy fibre. Prior to or during the spinning process, the aqueous solution is heated to a temperature between 60° C. and 85° C. for a time sufficient to gel the con-glycinine fraction of the soy protein (the 7S fraction). After extrusion, the partially gelled material placed into a coagulating fluid medium in a bath which is hot enough to gel the glycinine fraction of the sol protein (11S fraction) This patent document states that the pH of the coagulating fluid medium is not a critical factor. In the two examples given in the patent document, the pH of the coagulating fluid medium is not varied.
[0013] An investigation of the gelling of some polypeptides has been published by Nowak et al “Rapidly recovering hydrogel scaffolds from self-assembling diblock copolypeptide amphiphiles”, Nature, Vol 417, 23 May 2002, pp 424-428. In this example, the gels are formed by changing the concentration of the polypeptides in water. There is no teaching of an extrusion method for the production of the solid material.
SUMMARY OF THE INVENTION
[0014] It is therefore the object of the present invention to provide an improved apparatus and method means for extruding and forming objects made of proteins.
[0015] Accordingly, the invention is first directed to a method of forming an object from a feedstock made of a protein solution. The protein in the protein solution undergoes a sol-gel transition. The method c rises the following steps: a first step of adjusting the conditions of the feedstock to cause the feedstock to flow to form the object from the solution, with the protein substantially in the sol state, and a second step of adjusting the charge distribution on the protein and thus either to gel the feedstock or to bring it close to the sol-gel transition point. The step of adjusting the charge distribution can occur either at a different time or in a different location.
[0016] The inventors have discovered that protein solutions are best formed into objects at or around the sol-gel transition point of the protein.
[0017] The object may be formed in several ways generally know to the skilled person. The first step of forming the object may e.g. comprise a step of extruding, drawing, spinning or moulding the feedstock. In the case of moulding only after the object's desired shape has been attained will the charge distribution of the feedstock be adjusted so that the feedstock protein will transition to the gel state.
[0018] The protein used for forming the object can be a natural or synthetic protein, a glycoprotein, a phospho-protein, proteoglycan, or a mixture of two or more of these. The protein may be an amphiphilic block copolymer comprised of at least four perfect or imperfect repeats of at least two different types of blocks. At least one of these blocks should carry charged side chains to enable its assembly to be controlled by pH or by the addition of salts. It is thought that the provision of charged groups on a terminal domain or terminal domains of the protein may suffice.
[0019] The protein solution may comprise substantially fibroin, spidroin and/or mixtures or homologues thereof. The term “substantially”, as used in the present context, shall indicate that, while fibroin, spidroin and/or mixtures or homologues thereof or other amphiphilic block copolymer proteins or protein analogues be the principle component of the solution, further auxiliary or residual compounds may be present in the solution, as long as they do not substantially deteriorate the process of forming the object. The proteins may be natural proteins, genetically engineered proteins or natural or synthetic polypeptides.
[0020] In a preferred embodiment of the invention, it is useful to employ amphiphilic block copolymer molecules with some of the amino acid side chains capable of being charged such that each molecule can carry at least four negative or four positive unit charges or a combination of negative or positive charges.
[0021] In contrast to conventional gel forming polymers where a gel is formed by covalent bridges or by the addition of calcium or other metal ions to form electrovalent bridges between negatively charged groups, the gel of the invention is formed by changing the ionisation of charged groups on the protein by adjusting the pH or by shielding the charged groups on the polymer or by forming metal coordination complexes by the addition of salts or polyionic compounds to provide counter ions. The reduction in net charge on the polymeric molecules or aggregates thereof produced by changing or masking the ionisation of charged groups in this way will reduce the electrostatic repulsive forces operating between protein molecules or aggregates thereof. This allows the molecules to approach one another more closely and thus leading to a strengthening of the short range attractive forces. Alternatively, changing the ionisation of an amphoteric polymer molecule may permit the formation of salt bridges or metal coordination complexes resulting from the interaction of side groups with opposite electrostatic charge on adjacent chains. Thus, in either case, it is thought that weak interactions including hydrophobic and hydrophilic effects, Van der Waals and coulombic forces are responsible for an initial reversible gelation of the protein molecules. In the case of gelation of silk proteins or their analogues produced by a change in pH these weak interactions are strengthened with time by the spontaneous formation of numerous hydrogen bonds which form beta sheets. These effectively give rise to strong multivalent links within and between the protein molecules holding them together in a way that cannot easily be reversed.
[0022] Charged lyotropic liquid crystalline polymers are particularly useful for gel formation in tat the delicate balance between attractive and repulsive forces in this state of matter can be tipped in a reversible way towards greater attraction by manipulating electrostatic charges on the molecules.
[0023] The first step of adjusting the conditions of the feedstock may preferably comprise adjusting the pH, as it was found that the pH of the solution is one of the conditions responsible for the sol-gel transition. A buffer solution may be used to adjust the pH of the feedstock. The adjustment of the pH of the solution results in the alteration of charges on the molecules of the feedstock. In the case in which the polymer in the feedstock caries charged groups, the ions added to the feedstock will alter, neutralise or shield the charges on the polymer. As explained above, this permits the molecules to interact with one another as the result of non-covalent interactions. It was found to be of particular benefit if the buffer solution is selected from the group of buffer solutions comprising a small carboxylic acid such as formic acid, or acetic acid or propionic acid. This group of acids proved particularly effective for spinning. A small carboxylic acid has a molecular weight of less than 250 Daltons. Similarly, the addition of inorganic ions also can be effective in inducing the sol-gel transition or facilitating the formation of useful material.
[0024] It has been found that the addition of glycerophosphate to the buffer solution is particularly advantageous as it promotes the spinning of the polymer.
[0025] The present invention is also directed to an apparatus. The apparatus can, but is not limited to, carry out the above-summarised method.
[0026] The apparatus comprises a protein storage compartment for storing the protein in a sol condition and a transition compartment in which the sol-gel transition is induced.
[0027] The apparatus according to the invention may further comprise a compartment for holding the protein in contact with a buffer to keep it in a substantially sol condition. This feature will prevent premature sol-gel transition.
[0028] The inventive apparatus may further comprise a gel compartment for holding the protein in contact with a buffer to induce it to be substantially gelled. The buffer solution is selected from the group of buffer solutions described above that induce the sol-gel transition in the protein.
[0029] The inventive apparatus may further comprise a storage compartment for storing the protein solution in a sol condition subsequent before it is passed to the gel compartment.
DESCRIPTION OF THE DRAWINGS
[0030] FIG. 1 is a schematic diagram of an apparatus for forming an object
[0031] FIG. 2 is a diagram showing an experimental setting for determining spinnability.
[0032] FIG. 3 is a diagram showing the effect of buffer type used.
DETAILED DESCRIPTION OF THE INVENTION
[0033] Simultaneous observation of the spinnability and the state of the polymer feedstock (discussed below) lead to the conclusion at the protein is best spinnible at or substantially close to the transition point between its sol and gel states. This provides a means for determining the spinning conditions for many proteins or polypeptides, related polymers including charged amphiphilic block copolymers produced by chemical synthesis or by genetic engineering, or a combination of the two, and other charged polymers that undergo a sol-gel transition. Thus the sol-gel transition of many biopolymers can be switched reversibly by changing pH or other ions including small anions and cations.
[0034] It is believed to be particularly useful to employ amphiphilic block copolymer molecules, which carry at least four negative or four positive unit charges or a combination of negative and positive charges.
[0035] In contrast to covalently cross-linked gels such as formaldehyde cross-linked hyaluronan, gelatine or casein, or transaminase-cross-linked lactoglobulin, the gel of the invention is formed by changing the ionisation of charged groups on the protein by adjusting the pH or by shielding the charged groups on the polymer or by forming metal coordination complexes by the addition of salts or polyionic compounds to provide counter ions. The reduction in net charge on the polymeric molecules or aggregates thereof produced by changing or masking the ionisation of charged groups in this way will reduce the electrostatic repulsive forces operating between protein molecules or aggregates thereof. This allows the molecules to approach one another more closely and thus leading to a strengthening of the short range attractive forces. Alternatively, changing the ionisation of an amphoteric polymer molecule may permit the formation of salt bridges or metal coordination complexes resulting from the interaction of side groups with opposite electrostatic charge on adjacent chains. Thus, in either case, it is thought that weak interactions including hydrophobic and hydrophilic effects, Van der Waals and coulombic forces are responsible for an initial reversible gelation of the protein molecules. In the case of gelation of silk proteins or their analogues produced by a change in pH these weak interactions are strengthened with time by the spontaneous formation of numerous hydrogen bonds which form beta sheets. These effectively give rise to strong multivalent links within and between the protein molecules holding them together in a way that cannot easily be reversed.
[0036] It will be noted that charged lyotropic liquid crystalline polymers are particularly useful for gel formation in that the delicate balance between attractive and repulsive forces in this state of matter can be tipped in a reversible way towards greater attraction by manipulating electrostatic charges on the molecules.
[0037] It has been found that buffer solutions comprising a small carboxylic acid such as formic, acetic or propionic acid can be used to induce a sol-gel transition. In the case of acid addition the gelation is initially reversible but rapidly becomes irreversible with time. In contrast the addition of calcium or magnesium ions at concentrations between 50 and 500 mM in a neutral or alkaline buffer induces a gelation which remains reversible for a period of at least four weeks. Additionally, the addition of 0.0001-0,5M glycerophosphate improves the spinnability of the thread.
[0038] FIG. 1 shows a schematic diagram of a simple extrusion apparatus 100 for forming an object 120 according to the method of the invention. The extrusion apparatus 100 has a polymer storage compartment 130 in which the polymer 150 is stored in a sol condition. The extrusion apparatus 100 has furthermore a transition compartment 140 in which the polymer 150 undergoes a sol-gel transition and in which the object 120 is formed. The object 120 emerges from the transition compartment 140 .
[0039] The sol-gel transition is induced in a number of ways. It had been noted (see above) that the spinnability of spider and silkworm protein was related to the pH of the protein The conditions in the transition compartment 140 were therefore adjusted by adjusting the pH of the polymer 150 . This can be done in a number of ways such as by the addition of buffer salts or solutions, by dialysis against buffet solutions or by exposure to vapour from volatile buffers.
[0040] As noted above, it was found to be of particular benefit if the buffet solution is selected from the group of buffer solutions comprising a small carboxylic acid, such as forms acid, or acetic acid or propionic acid or. This group of acids proved particularly effective in inducing the sol-gel transition. It is thought that the hydrogen ions react with the negatively charged carboxyl groups on the side chains of aspartic and glutamic acid to reduce the negative charge of the protein permitting initially reversible aggregation resulting from the formation of a small number of weak intermolecular interactions. This is followed by the more gradual secondary structural transition to the beta-sheet form resulting in irreversible gel formation.
[0041] It was also found to be of particular benefit to add potassium or sodium ions to the protein, preferably as a chloride.
[0042] It was also found to be of additional benefit to add small quantities of a small molecular weight polyol to the polymer solution. In the preferred embodiment glycerophosphate disodium salt is added to a final concentration of 0.0001 to 0.1 M.
[0043] In another example, it has been found that the addition of calcium ions to the protein induces the sol-gel transition. It appears that the addition of the calcium ions results in the formation of co-ordination complexes between calcium ions and the oxygen atoms of carboxyl groups' side chains of aspartic acid. These complexes can form intermolecular links between two to four peptide chains.
[0044] The polymer storage compartment 130 is connected to a first buffer compartment 160 that contains a first buffer solution. The first buffer solution could be, for example, ammonia. The first buffer solution is designed to keep the polymer 150 in a sol condition.
[0045] The transition compartment 140 is connected to a second buffer compartment 170 that contains an acidic solution to cause gelling of the polymer 150 . Suitable acidic solutions include, hut are not limited to, small carboxylic acids such as formic acid, acetic acid, or propionic acid
[0046] In an embodiment of the invention the extrusion apparatus 100 includes a further storage compartment that stores the polymer 150 in a sol condition.
[0047] It is to be noted that the use of an extrusion die as the transition compartment 140 with one or more surfaces of the inner passage of the die made semi-permeable or porous can be used to effect a sol gel transition in appropriate polymers to assist in the spinning or extrusion of the polymer. By way of example only, such an extrusion die is described in patent application WO 01/38614 (Vollrath and Knight), the teachings of which are incorporated herein by reference. It is also to be noted that the control of the sol-gel transition enables polymers to flow or be blown into the transition compartment 140 in a mould in the sol state and converted into the gel state by providing the mould with one or more semi-permeable or porous surfaces through which a gelling agent (such as an acid or calorie ions) can be introduced or by opening one or more surfaces of the mould to expose the material to the gelling agent. Alternatively, a mould with sides and bottom but no top can be used and the gelling agent applied though the open upper side.
[0048] After gelling, the protein is cross-linked using a cross-linking agent such as glutaldehyde or carbodiimide. It is advantageous to introduce additional steps after gelling and before cross-linking and after cross-linking to remove more water from the gelled protein. This can be achieved by reverse dialysis or simply by air drying.
EXAMPLE 1
Experimental Method for Determining the Conditions for Spinning Fibres
[0049] The conditions required for optimum spinning of protein dopes were determined using the apparatus 210 shown in FIG. 2 . A polycarbonate spacer 220 (about 1 mm wide and 0.5 mm thick) is first stuck to the midline in the bottom of a 53 mm plastic Petri dish 230 to form a waterproof barrier. A filter paper 240 (Whatman I and having a diameter of 42.5 mm) is cut into two halves 240 a, 240 b. One filter paper half 240 a is moistened with a suitable buffer solution, for example, 0.1 M Trizma/HCl buffer at pH 7.0 for keeping the protein dope in the sol state The moistened filter paper half 240 a is then placed on the left band side of the polycarbonate spacer 220 as shown in FIG. 1 . The other filter paper half 240 b is notched to indicate that this is the low pH side and is moistened with the test solution (a buffer solution of pH<5.5 with or without other dopants) before being placed on the right hand side of the polycarbonate spacer 220 .
[0050] A 10 mm square of dialysis membrane 250 (made by Visking and having an exclusion limit 18-20 kDa) is placed on top of the two moistened filter paper halves 240 a, 240 b with its centre over the centre of the Petri dish 230 . 5 to 20 μl of highly concentrated test protein (approximately 20% w/v) are placed in an elongated drop 245 on the top surface of the dialysis membrane 250 in such a war that a pH gradient is established across the elongated drop 245 . The protein selected was either spidroin or fibroin obtained by the dissection of glands form spiders or the larvae of Lepidopteran insects respectively. It is to be noted that gradients of pH and other diffusible ions and diffusible small molecules can be set up by diffusion through the dialysis membrane 250 into the elongated drop 245 of protein. This makes it possible to mimic the gradients between the protein dope storage and spinning regions of the silk duct in spiders, silkworms and other arthropods.
[0051] The apparatus 210 is left undisturbed for a defined period of between 5 and 30 minutes to give time for the establishment of the pH gradient Thereafter the end of the elongated drop 245 of the protein over the fight band filter paper 240 b is seized with watchmaker's forceps (DuMont Number 55 made of stainless steel) and slowly pulled from left to right in an attempt to draw out a fibre 260 . The maximum length of thread in centimeters, which can be drawn, is a measure of the spinnability of the fibre 260 . The condition of the protein dope on the fight hand side of the elongated drop 245 is also assessed by eye using a stereo microscope. If only a short cone of protein dope can be drawn out that flows back into the elongated drop 245 after rupture, the protein dope in the elongate drop 245 is preset as a sol. We further assessed the viscosity of the sol by determining how long it takes the cone to flow back into the elongated drop. If, on the other and, the protein dope is found to have a stiff rubbery consistency and little or no material can be pulled out from it, recoiling sharply when released, the protein dope is described as a solid gel. The temperature is maintained at 20° C. throughout the example.
[0052] The apparatus 210 is used to test the hypothesis that the spinnability of spider and silkworm protein removed directly from the A-zone in spiders and from he anterior and median division in silkworms was dependent on pH and potassium ion concentration. The results showed both dopes showed a marked improvement in spinnability at optimum pH values and potassium ion concentrations. It was discovered that the exposure of the protein dope to buffers of different pH revealed a remarkably sharp sol-gel transition as the pH was lowered. This transition generally occurred at a pH value between 4.0 and 6.5 that depended on the nature of the buffer used and the concentration of potassium and other ions. The addition of potassium chloride at concentrations of 50 to 500 mM produced a marked increase in the pH for the sol-gel transition point and improved spinnability. The validity of this simple method was confirmed for fibroin by spinning in a more complex biomimetic spinning device of the type described in PCT application WO-A-01/38614
[0053] In the course of these investigations it was also discovered that optimum spinnability in the simple device occurred substantially close to the sol-gel transition point It was also discovered that exposure of both protein dopes of spider and silkworm protein to acetic acid vapour from 0.01 M and glacial acetic acid at 20 to 30 degrees Centigrade produced a rapid conversion of concentrated dope sols to stiff rubbery gels in both organisms. The change could be rapidly reversed by exposure of the protein dope to ammonia vapour provided that the protein bad only been exposed to the acid for short periods of time (less than 10 minutes). Under these conditions the change appeared to be substantially reversible and could be obtained at least tour times by repeated alternate application of acetic acid and ammonia vapours. The use of the simple apparatus of FIG. 2 also enabled the discovery of the optimum conditions for spinnability and the effect of adding dopants to improve spinnability of silkworm and spider dope solutions.
[0054] These observations suggest that charged groups on the protein polymers are responsible for the pH dependent sol-gel transition in spidroins and fibroins and tat other charged repetitive amphiphilic block copolymers could be used in place of these proteins.
[0055] Five factors were shown to influence spinnability: buffer type, pH concentration of inorganic ions, and duration of exposure to buffets in the apparatus the addition of glycerophosphate and The addition of other dopants. However, further factors influencing the spinnability may be discovered and these should be understood to be comprised within the scope of the present invention.
EXAMPLE 2
Effect of Buffer Type on Spinnability
[0056] FIG. 3 shows typical results showing the effect of the type of buffer solution used to moisten the right hand filter paper 240 b of FIG. 2 on spinnability.
[0057] For fibroin and spidroin proteins, the spinnability decreased in the following order:
[0058] Ammonium acetate>ammonium formate>ammonium propionate>>>potassium phosphate>tris/HCl (tris (hydroxymethyl)aminomethane/HCL)=HEPES (4-(2-hydroxyethyl)-I-piperazine ethane-sulfonic acid)=PIPES (1,4-piperazinbis(ethanesulfonic acid>>. Thus monocarboxylic acids with a short chain length appeal to be the best buffer solutions. In this connection it is of interest to note that other proteins, such as collagens and high molecular weight glutenins, show a higher solubility in acetate buffer solutions compared with other buffer systems. These proteins resemble silk proteins in that they are repetitive amphiphilic block copolymers with a pI above 7.0. This suggests a preferential interaction of acetate ions with the proteins under acidic conditions, possibly dependent on the small size of this carboxylic ion.
EXAMPLE 3
Effect of pH an Spinnability
[0059] The pH value for obtaining the optimum spinning conditions for some of the buffer solutions was investigated.
[0060] The optimum pH value for spinning spidroin from ammonium acetate buffer solution was pH 4.7±0.1, that of ammonium formate approximately pH 4.8 whilst the optima for the other buffer solutions was about pH 6.3. The latter values are close to the estimated pH in the duct of the spider and the pH of phosphate buffer solution for maximum sensitivity to shear in dilute spidroin solutions, it is also close to the pK for the natural buffering of spidroin dope freshly removed from the spider's silk gland. Histidine groups in proteins protonate between pH 6 and 7 strongly suggesting that the observed pK, optimal sensitivity to shear and sol-gel transition (see below) for spidroin in phosphate buffer involve the protonation of histidine groups. The pH optimum for spinning silkworm fibroin in an ammonium acetate buffer solution is 4.8±0.2 and in an ammonium formate buffer solution is (5.2±0.1).
EXAMPLE 4
Duration of the Action of the Buffer Solution
[0061] The time dependency of structural changes in the test proteins together with the time taken for the diffusion of ions cross the dialysis membrane 250 means that spinnability and optimum pH value are affected by time of exposure of the protein dope to the conditions above the fight hand filter paper 40 a . Using indicators, it was shown that pH equilibration is substantially complete after 5 minutes at 20° C. This means that the results obtained with the simple apparatus shown in FIG. 2 are only a guide to the pH conditions required in spinning in a more sophisticated extrusion or spinning device involving the diffusion of buffer solutions or acid vapours into extrusion or spinning solutions. Thus pH optima will have to be varied somewhat according to conditions affecting rate of diffusion including temperature, nature of diffusion barriers, geometry of die and rate of extrusion or spinning, as will be understood by a person skilled in protein biophysics.
EXAMPLE 5
Formation of Moulded Articles Firm Proteins
[0062] One or more concentrated (10-75% w/v) solutions of fibroin or spidroin were prepared as follows:
[0063] In a first step, native fibroin was taken directly from Bombyx mori silk glands (as disclosed in international patent application No. WO-A-03/037925 (Vollrath). The native fibroin is concentrated in a dialysis bag (MWCO 5-8 KDa) by reverse dialysis for 12 hrs or overnight 8 at 4° C. against a solution condoning (in final concentrations) 20-40% w/v polyethylene glycol (MW 15-20 kDa), 0.1 M ammonium acetate buffer at pH 7.
[0064] The resulting silk solutions should have a concentration of 10-75% which can be varied by altering the concentration of the polyethylene glycol and or the length of reverse dialysis. The pH of the final solution should be between pH 7 and 8.5.
[0065] The concentrate protein solution was then placed into a mould in which the top is open at or in which at least one surface of the mould was formed by a porous or semipermeable material to enable the concentrated protein to be converted to a gel. The concentrated protein in the mould was then gelled by exposure to either acetic acid vapour (5 minutes to 3 hours at ambient temperature) or 0.1 M to 0.5M acetic acid solution (10 minutes to 1 hour).
[0066] Alternatively the protein can be gelled by exposure to a solution containing (final concentrations) 0.1 M ammonium acetate buffer pH at 7.8 and 50 to 750 calcium ions preferably as the chloride for 5 minutes to 3 hours at ambient temperature.
[0067] The gelled concentrated protein can be cross-linked in the mould by a carbodiimide solution or an aldehyde solution or vapour as will be understood by a person skilled in the art
EXAMPLE 6
[0068] In this example, native fibroin was taken directly from Wild Silk moth glands and concentrated and moulded as described in Example 5.
EXAMPLE 7
[0069] In this example, saturated aqueous solutions of regenerated fibroin solutions was prepared by dissolving degummed Bombyx mori or Wild Silkworm (Tussah silk) in said aqueous lithium bromide solutions and dialysing this solution for 12 hours at 4° C. against distilled water (at least three changes) followed by concentration by reverse dialysis for 12 hours at 4° C. against excess of a solution containing polyethylene glycol and ammonium acetate as described in Example 5 but containing in addition a final concentration of 0.5 M lithium bromide.
[0070] Moulded samples were prepared as in Example 5. | The invention utilizes the sol-gel transition behavior of certain proteins for forming objects. The invention is directed to a method and apparatus for forming an object from a feedstock made of a protein solution, the protein undergoing a sol-gel transition and comprising the following steps: a first step of adjusting the conditions to cause the feedstock to flow to form the object from with the protein substantially in the sol state, a second step of adjusting the conditions of the feedstock either to gel the feedstock or bring it close to the sol-gel transition point. Particularly preferred proteins are spidroin and fibroin, while one of the conditions of the feedstock will be adjusting the pH of the solution e.g., with a carboxylic acid. | 3 |
FIELD OF THE INVENTION
This invention relates to rooftop air conditioners installed on mobile homes, vans, boats and the like.
DESCRIPTION OF THE PRIOR ART
In air conditioners for installation on roofs of vans, mobile homes and the like, a single-member base may provide a housing foundation for locating air conditioning components. A common alignment for these components is a forward evaporator compartment, followed by an evaporator blower compartment, a motor compartment, and a condenser blower compartment adjacent to the rear of the base.
In such units it is customary to use a number of individual sheet metal pieces fastened onto the base and each other, to space the components from each other and to provide compartment walls and blower scrolls. Separate additional pieces provide for ducting condenser exhaust air to outlet vents and preventing its re-entry into condenser inlet chamber areas. Streamlined outer shrouds serve merely to protect the assembled air conditioning components from outside weather factors. Upon removing the shroud, there is no easy access to those components which may need servicing; such servicing ordinarily requires removal and replacement of numerous parts and can require several hours of a serviceman's time.
A major part of time conventionally required for servicing may be devoted to caulking. This would include not only providing new caulking in those previously caulked joints which are broken when the shroud is removed to service the unit, but also re-caulking joints which have hardened and cracked in service, such as those at junctions of vertical metal walls with a metal base. Such cracked joints may seriously impair the cooling efficiency of the unit. Caulking is also conventionally applied to seal the wiring raceway entrance, into the base of the rooftop unit.
Vans and mobile homes are ordinarily provided with standard-sized rectangular roof vents. On removing the vent covers, the rooftop air conditioners may be installed over these vents, to accommodate both return air and the delivery of conditioned air. Generally, it is necessary to have some securement means to react sideward and fore-and-aft forces, such as bumping, bouncing, cross-winds, etc. This is of particular importance for installations on the roofs of railroad cars.
SUMMARY OF THE INVENTION
The complex assembly and servicing requirements for prior art rooftop air conditioners are minimized by the molded plastic three-piece housing of the present invention. The three members are a base member to which the air conditioning components are mounted in the typical conventional alignment above mentioned, an intermediate member, and a shroud. The base member and intermediate member meet at a substantially central mating plane; together they provide at least lower and upper molded halves for the evaporator and the condenser area compartment walls and scrolls, and in the preferred embodiment, the wiring raceway and its hood. The shroud abuts sealedly along a ridge on the roof of the intermediate member to prevent recirculation within the shroud of outlet air from the condenser blower. The intermediate member is so tailored as to leave the outlet plenum side open when the shroud is removed. This openness, together with a simple access door from the plenum outlet side into the motor compartment, affords easy access for servicing all the components aft of the evaporator compartment.
The undersurface of the base housing member includes a single self-locating rectangular area. This area includes an opening through which the room air is returned upward from the room space; and through this same rectangular area the conditioned air is discharged downward. This area also contains the lower opening of an integrally molded wiring raceway. Molded locator projections, extending downward inwardly of the margin of this rectangular area, facilitate the positioning of the unit onto a roof and provide resistance to sideward displacement during movement of the vehicle.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an exploded perspective view of a threemember housing for a rooftop air ccnditioner embodying the present invention.
FIG. 2 is an assembled plan view, partly broken away, of the base and intermediate members of the embodiment of FIG. 1.
FIG. 3 is a plan view from below corresponding to FIG. 2.
FIG. 4 is a cross section taken along line 4--4 of FIG. 2. The outer shroud is shown installed in phantom lines.
FIG. 5 is a partial cross section taken along line 5--5 of FIG. 2.
FIG. 6 is a partial cross section taken along line 6--6 of FIG. 2.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The molded plastic rooftop air conditioner housing of the present invention, generally designated 10 and shown assembled in FIG. 1, includes three members, a base member generally designated 14, an intermediate member generally designated 120, and an outer shroud member generally designated 190, all hereafter described.
The base member 14 is molded from an engineering grade of structural foam plastic, selected by conventional engineering procedures to be sufficiently strong to support the chosen components of an air conditioning unit. Proceeding from the left in FIGS. 1 and 4, its area includes the lower halves of a forward evaporator compartment 16, an evaporator blower compartment 18, and a condenser area generally designated 80.
The undersurface of the base member 20, shown in FIG. 3, is provided, near its forward end, with a molded rectangular margin 22 having inwardly thereof a plurality of downwardly molded projections 24. The projections 24 are used to locate the base 14 about an opening, of substantially the same size as the margin 22, in the roof of the vehicle upon which the base member 14 is to be mounted. The margin 22 is lined with a sealing gasket 26.
Within the rectangular margin 22 is a forward rectangular opening 28 through which return air, entering from the room space below the roof, flows upward. Aft of the return air opening 28 is an outlet 30, surrounded by a sealing strip 31, for the downward discharge of conditioned air into the room space. Adjacent to the outlet 30, is a wiring raceway opening 32, seen in FIG. 5, through which the air conditioner wiring 34 extends downward into the room space. Such wiring 34 is retained against the base member 14 by a metal closing clip 36. A rigid foam insulating liner 38 fits against a rounded undersurface portion of an evaporator blower scroll bottom wall 64, later described.
Aft of the rectangular margin 22, the base undersurface 20 may be provided with resilient support pads 40, preferably of the same material as the margin gasket 26. In the embodiment shown in FIG. 3, such pads 40 are located at the rear of the base member 14 and also along one side below where a compressor is to be mounted as hereinafter described.
Further referring to FIG. 2, the base member 14 is provided along its outer margin 42 with air intake and outlet ventilating slots 44, 46 which supplement similar slots of the shroud member 190, as later described.
The top surface of the base member 14 is provided with a series of portions molded upwardly from the bottom wall 48, which for the most part, have upper edges 50 terminating in a common, substantially horizontal plane. These provide lower half compartment walls and lower scrolls for the air conditioner components. As best shown in FIG. 1, these portions include the forward and side lower half-walls 52, 54 of the evaporator compartment 16 which are outwardly adjacent to the return air opening 28. A portion of the bottom wall 48 immediately aft of the return air opening 28 and extending from one side wall 54 to the other provides a transverse bridge 56 for supporting an evaporator coil, not shown.
Aft of the evaporator coil bridge 56 and centered between angled flanking portions 58 is a venturi inlet half-wall 60 leading to the evaporator blower compartment 18. This compartment is further defined by a side and bottom scroll wall 62, which is rounded about a fore-and-aft scroll axis a-a and which contains the conditioned air downward outlet 30, as well as by an aft half-wall 66. The outer side surfaces 68 of the side and aft walls 62, 66 are vertical. Parallel to and spaced outwardly from them are surrounding left and right side wall portions 70 and a rear wall portion 74, which joins the angled flanking portions 58 as shown in FIG. 1.
A molded one-piece foam insulating liner 76, best seen exploded in FIG. 1, lines the inner surfaces of the forward and side walls 52, 54 and the bridge portion 56 of the evaporator compartment 16, as well as the spaces between the vertical outer side surfaces 68 and the parallel surrounding wall portions 70, 74. The insulating liner 76 has a bottom opening 78, corresponding to the return air opening 28; it has no bottom between its vertical walls, which fit in the insulation space about the vertical sides and rear surfaces 68 of the evaporator compartment 32. It is shown installed in FIG. 4.
Aft of the evaporator blower compartment is the condenser area 60. As shown in FIG. 1, it is divided into a narrower outlet plenum side 84 and a wider inlet chamber side 82 by a series of aft-extending walls, including a first separator half-wall 86 and a second separator half-wall 88; it terminates in a lower closure 90 extending to the base margin 42.
The first separator half-wall 86, seen in FIG. 1, defines, on the inlet chamber side 82, a motor compartment 92. Metal motor mounts 94, shown in phantom lines in FIG. 4, are provided for mounting a motor within this compartment; to stabilize the forward mount, the aft surrounding wall 74 of the evaporator blower compartment 18 is thickened locally at its center, as by the thickened wall 96 shown in FIG. 4. Four lands 98 for mounting a compressor are provided on the outlet plenum side 84 of the separator half-wall 86.
The second separator half-wall 88, likewise seen in FIG. 1, defines the length of a condenser blower compartment 100. On the inlet chamber side 82 of the wall, the compartment 100 has two opposite inlets. The first inlet half-wall 102 extends perpendicular to the second separator half-wall 88, at its juncture with the first separator half-wall 86. Opposite it is a second inlet half-wall 104. Between these two inlet half-walls 102, 104 is the lower half scroll 106 of the condenser blower compartment 100, rounded about the fore-and-aft axis a-a and seen in FIGS. 1 and 6. Opposite to the second separator half-wall 88 is a vertical outer half-wall 108 for the condenser scroll, seen in the cross-sectional view of FIG. 6.
The inlet lower half-walls of the evaporator and condenser blower compartments 60, 102 and 104 have rounded venturi openings. Each of these walls may be thicker than other walls of the base member 14 so as to provide the curved shape needed. To achieve this thickness, without affecting the curing time, these walls may be cored upward.
Also provided on the outlet plenum side 84 of the condenser area 80 and immediately adjacent to the evaporator blower compartment 18 is a vertical wiring raceway 110, molded upwardly from the wiring raceway opening 32. A narrow L-shaped bottom wall 112 space for a condenser coil is provided just inwardly of the right and rear margins of the base member, that is, outward of the juncture of the second condenser inlet 104 with the outer half-wall 108, which supports the scroll wall 106.
Upper half compartment walls and upper scrolls for the chosen air conditioning components are provided by portions molded downwardly from roof portions of the intermediate member 120. For the most part, these downwardly molded portions have lower edges 122 terminating in a substantially horizontal mating plane.
As shown in FIG. 1, the upper half of the evaporator compartment 116 has at its juncture with the evaporator blower compartment 18, a relatively narrow transverse roof portion 124 from which extends downwardly-molded side half-walls 126 and a downwardly sloping forward half-wall 128. The lower edges 122 of these forward and side upper half-walls 128, 126 may be slightly flanged outwardly and downwardly so as to provide a secure, water-resistant fit over the upper edges 50 of the corresponding forward and side half-walls 52, 54 of the base member 14.
Along the rear of the evaporator compartment roof 124, and extending on each side downward to the mating plane, is a transverse ridge 130 covered with a resilient sealing strip 132. Two parallel sealing strips 134 of the same material extend perpendicularly from the transverse ridge 130 to the edge of the forward wall 128. A liner 136 of rigid foam insulation is formed to fit closely against the inner surfaces of the roof 124 and the side and forward walls 126, 128.
Aft of the evaporator compartment roof ridge 130 is the inlet upper half-wall 138 to the evaporator blower compartment 18, formed to mate with the lower inlet half-wall 60 of the base member 14, as shown in the broken away portion of FIG. 1. The compartment 18 is further defined by a side-and-top scroll wall 140 rounded about the same fore-and-aft axis a-a as the side-and-bottom scroll wall 62 of the base member 14, as well as by an upper aft half-wall 142. As seen in FIG. 5, at the juncture of the lower aft half-wall 66 of the base member 14 with this upper aft half-wall 142 is a centrally located rounded opening 146 provided with a seal, not shown, for accommodating the motor shaft.
Mating with the lower evaporator blower compartment outer or surrounding side wall portions 70 of the base member 14, are two vertical outer upper walls 148 extending aft from the upper inlet wall 138 to the upper aft half-wall 142; these are spaced outwardly from the side-and-top scroll wall 140, as seen in FIG. 5. A semi-cylindrical rigid foam insulating liner 150, shown exploded in FIG. 1 and in place in FIGS. 2 and 5, is molded to fit over the outer surface of the upper scroll wall 140, in the space provided between these outer walls 148 and the side-and-top scroll wall 140. The liner 150 is provided with a narrow fore-and-aft sealing strip 152 of resilient material, extending aft from the transverse sealing strip 132, to a top central roof ridge 164 hereafter referred to.
The first upper portion 154 is an aft-extending vertical wall which mates with the first separator half-wall 86 of the base member 14. It has a rectangular opening normally closed by a removable access door 160 to the motor compartment 92. This opening and its access door 160 extends upward from the first upper wall portion 154, then angularly sideward toward the roof ridge 164 to join that portion of the roof 162 over the motor compartment 92. The roof 162 continues across it to the eave 166 which covers the condenser coil space 112 as hereinafter described. The side of the motor compartment 92 adjacent to this coil space is open.
The lower edge 122 of the first upper portion 154 is provided with a wiring passage hood 168 on its outlet plenum side 84 which fits closely over the upper edge 50 of the first separator wall 86. As seen in FIGS. 1 and 2, the hood 168 accommodates and protects wiring 34 to the motor compartment 92, clamping it in a downward-bent loop so that any rain water may drip off harmlessly (see phantom lines in lower illustration of FIG. 1); also making a conventional strain relief fitting unnecessary. A second wiring passage hood 170, best seen in FIGS. 2 and 5, provided on the outlet plenum side 84 adjacent to the evaporator blower compartment 18, similarly protects and restrains the wiring emerging from the vertical wiring raceway 110 of the base member 14.
As seen in FIGS. 1 and 6, the second upper portion 156 is in effect a window from the condenser blower compartment 100, extending from the upper edge 50 of the base member second separator half-wall 88 to the roof 162. There is provided on the inlet chamber side 82 of the condenser area 80 and molded downward from the roof 162, first and second upper inlet half-walls 172, 174 to mate with the corresponding inlet half-walls 102, 104 of the base member 14.
Between these inlets 172, 174 and opposite the condenser blower compartment window 156 is the upper half scroll portion 176, cored for molding downward from the roof 162 and rounded about the fore-and-aft axis a-a, shown in FIG. 6. A vertical outer wall 178 is molded downwardly from the roof 162 to mate with the lower outer half-wall 108 of the base member 14.
As referred to hereinabove, the roof 162 of the intermediate member 120, best seen in FIGS. 1 and 2, has a topmost ridge 164 running centrally aft from its juncture with the evaporator blower compartment 18 to the second upper inlet 174 and then transversely along the upper closure 158 and down to the mating plane. The ridge 164 is provided with a resilient sealing strip 180 along its full length.
The roof 162 is further provided with an outwardly extending eave 166, seen in FIGS. 1, 2 and 4, on the inlet chamber side 82. Commencing at the evaporator blower compartment aft wall 142, it extends aft and then inward, over the L-shaped condenser coil space 112, to the upper closure 158. It directs and confines the inflow of air through the condenser coil space 112.
The intermediate member 120 is secured to the base member 14 by a plurality of screws into the foam plastic material of that member. Such screws, not shown, extend through lugs molded onto the upper half compartment walls, which lugs terminate at the horizontal mating plane. The screws engage lands, extending upward from the base member 14 along its upward extending walls, to meet the lugs at the mating plane. Typical are the forward and central lugs 182, 184 shown in the center illustration of FIG. 1, and the forward and central lands 186, 188 shown in its bottom illustration.
The third member of the air conditioner housing 10 is a low-profile shroud 190 of a high-impact, injection molded or thermal formed plastic, shown exploded in FIG. 1 and in place in phantom lines in FIG. 4. It is a thin streamlined shell-like enclosure whose lower edge 192 conforms to the margin 42 of the base member 14. The base member has, inwardly of its margin 42, a plurality of shroud-stabilizing projections 43 extending upward along the inner mold line of the shroud 190, starting with and continuing at intervals aft of the transverse ridge 130. Attachment of the shroud 190 to the base member 14 is by readily removable screws, not shown.
The shroud's forward wall 194 slopes upwardly from its lower edge 192 to fit closely against the forward upper wall of the evaporator compartment 128. Commencing at the edge 192, its right and left side 196, 198 and aft 200 walls begin substantially vertically, and slope to merge into the top wall 206. The right side and aft walls 196, 200 contain a plurality of ventilating slots 202 through which air is drawn in into the condenser coil space 112. The left side wall 196 has ventilating slots 204, symmetrical with those of the right side wall 198, through which air flows that has been discharged through the condenser blower compartment window 156. These slots 202, 204 cooperate with the corresponding slots 44, 46 of the base member 14 to provide maximum air flow. The top wall 206 of the shroud 190 has a crest running aft and then transversely to the side juncture of the top wall 206 with the aft and left side walls 200, 196, shown by the phantom line 208, which is in registration with the separator ridge 164 of the intermediate member 120.
As seen in FIG. 4, when the shroud 190 is placed over the intermediate member 120 and attached to the base member 14 with its undersurface drawn tightly against the sealing strips described, its forward wall 194 fits sealedly against the two parallel sealing strips 134 of the intermediate member forward evaporator compartment wall 128. The transverse ridge 130 with its sealing strip 132 at the aft end of the evaporator compartment 16 fits sealedly against the undersurface of the shroud side and top walls 196, 198, 206 to seal off the evaporator compartment 16 from the condenser area compartments. Hence, behind the transverse ridge 130, the shroud 190 is divided by the fore-and-aft sealing strips 152, 180 into sealed inlet chamber and outlet plenum sides 82, 84, and circulation of air between the two sides is prevented.
The construction of the present invention greatly simplifies the installation of the air conditioner components. The housing 10 replaces the conventional use of a number of individual pieces fastened onto a base and to each other to provide compartment walls and scrolls; the base and intermediate members 14, 120 alone serve these functions. The installation of the assembled rooftop air conditioner is speeded by the locating projections 24 on the undersurface 20 of the base member 14; these not only locate and position the base over the vehicle's vent opening, they also serve as skid members which protect the gasket 26 as the unit is slid into position. Further they prevent sideward displacement of the base 14 during movement of the vehicle.
An outstanding advantage of the present invention is that the time required for opening the unit for servicing, and closing it after servicing, is reduced to a small fraction of that heretofore required. There are no caulked joints to be opened and replaced. Upon removal of the shroud 190 and the access door 160 to the motor compartment 90, all of the air conditioner components aft of the evaporator blower compartment 18 are easily accessed for servicing, including the motor, the controls and their wiring, the compressor, and the condenser coil.
The present substitution of integrally molded and filleted walls and scrolls for separate pieces having caulked joints, also greatly extends the effective useful life of the entire air conditioner. With age, caulked joints become brittle; shock and vibration accompanying use on a moving recreational vehicle will crack such joints. If not recaulked by a skilled serviceman, an otherwise useful unit may readily lose efficiency, say approximately 15%, within a relatively short time. In contrast the integral fillets of the base and intermediate members 14, 120 provide for stream flow of air without any caulking. The foam material itself is an excellent insulator, improving the efficiency of air conditioning.
As modifications may be made in the constructions herein described and illustrated without departing from the scope of the invention, it is intended that all matter contained in the foregoing description or shown in the accompanying drawings shall be interpreted as illustrative rather than limiting. | A three-member molded plastic housing for rooftop air conditioners, including base and intermediate members having molded portions which together provide component lower and upper compartment walls and blower scrolls. The third member, an outer shroud, abuts sealedly along a roof ridge of the intermediate member to prevent recirculation within the shroud of condenser blower outlet air. The base member has downwardly molded projections for facilitating positioning the unit over a roof opening and resisting sideward forces. | 1 |
BACKGROUND OF THE INVENTION
The present invention relates to a fuel supply unit consisting of a pump and an electromotor, in which the pump rotor and motor armature are mounted on a common fixed axis and possess a rotation-locking connection. In existing fuel supply units of this type, the pump rotor is either rigidly connected with the motor armature or they are connected together via a tube section which provides common bearing for the pump rotor and motor armature. However, as the stresses which are exerted on the pump rotor bearing in a radial direction are substantially greater than are those forces which are exerted on the motor armature, the end of the shaft which supports the common pump rotor and motor armature bearing is worn far more rapidly than the bearing on the opposite end of the motor armature. This wear is especially marked during dry operation of the pump which occurs occasionally, for example, when the fuel tank is empty and also when using certain newer types of fuel which have relatively poor lubricating properties. Unilateral wear of the bearings has the following disadvantages:
(1) THE MOTOR ARMATURE NO LONGER OPERATES CONCENTRICALLY WITH RESPECT TO THE FIXED AXIS WHICH HAS A DETRIMENTAL AFFECT ON MAGNETIC FORCES;
(2) THE PUMP ROTOR IS ALSO INCLINED AS A RESULT OF THE INCLINATION OF THE MOTOR ARMATURE WHICH RESULTS IN INCREASED UNILATERAL AXIAL FORCES BETWEEN THE PUMP ROTOR AND LIMITING WALL OF THE PUMP;
(3) THE INCLINATION OF THE MOTOR ARMATURE CAUSES EXCESSIVE STRESS TO BE EXERTED ON THE COUPLING BETWEEN THE PUMP ROTOR AND THE MOTOR ARMATURE, THEREBY CAUSING EXCESSIVE WEAR OF THESE ELEMENTS.
Accordingly, these disadvantages result in excessive current assumption by the electromotor and a reduction in the quantity of fuel supplied as well as reduction in the pressure in the pump thus leading very possibly to failure of the fuel supply system.
OBJECTS AND SUMMARY OF THE INVENTION
The primary advantage of the fuel supply unit according to the present invention resides in the fact that completely different bearings can be used for the pump rotor and the motor armature, with these bearings being made of materials which are adapted to the particular load and type of use.
A further advantage of the invention consists in ensuring that forces are not transmitted from one of the two rotating parts to the other parts thereof.
It is also still another advantage of the invention that the bearings which are arranged to cooperate one with another are rigidly connected to the rotating parts associated therewith.
Yet another object of the invention is to provide a novel rotation-locking connection between the armature and the pump rotor.
The invention will be better understood as well as further objects and advantages thereof become more apparent from the ensuing detailed description of a preferred embodiment taken in conjunction with the drawing.
BRIEF DESCRIPTION OF THE DRAWING
Four embodiments of the invention will be described in greater detail hereinafter with reference to the accompanying drawings, in which:
FIG. 1 is a longitudinal sectional view of the first embodiment of the entire fuel supply unit;
FIGS. 2-5 are longitudinal sectional views of a portion of the other embodiments of the unit.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Turning now to the drawings, the fuel supply unit comprises a fuel pump 1 and an electromotor 2 which are housed in a cup-shaped housing 3 which comprises a vacuum connection 4 for a fuel hose connected to one end of the housing, the other end of which is closed by a perforated cap 5, on which a pressure connection socket 6 and a non-return valve 7 constituting a pressure valve, are disposed. A seal-like packing member 8 is disposed between the housing 3 and the cap 5. The cap is secured to the housing by bending terminal bar members 9 on the open end of the housing 3. In the housing 3 as viewed in FIG. 1 the fuel enters the housing and passes through a base plate 11 by aperture means, not shown, and is then transported by the pump unit over the electromotor to cool the same and then exits through a check valve positioned in the exit end of the cap 5.
The base plate 11 is provided with a central bore in which a shaft 12 is pressed. An intermediate plate 13 and a supporting plate 14 are disposed axially adjacent to the base plate 11. The base plate, intermediate plate and support plate are clamped together by means of screws 16 and receive between them the pump rotor 17 which is mounted on the shaft 12 via a bearing 18. The pump communicates with the chamber 19 via openings on its suction side which are not shown. The chamber 19 is confined between the curved wall of the housing 3 and the base plate 11. The pressure side of the pump communicates with a chamber 20 which houses the electromotor 2 and leads to the pressure valve 6. A pressure control valve 21 is provided in an aperture in the base plate 11 between chambers 19 and 20, respectively. The connections from the pump to the chambers 19 and 20 are only controlled by the pump rotor but are preferably open channels.
The electromotor 2 consists of an armature formed of a winding 23, armature plates 29, a radial collector 24 and a magnetic part 25.
The motor armature is mounted via journal bearings 27 on the shaft 12. The journal bearings are disposed in the opposite ends of a rigid tube 28 on which the armature plates 29, the armature winding bundle 30 and the commutator bush 31 are attached. The aforementioned elements are attached partly by pressure and partly by means of plastic filler parts which, after the individual elements have been sprayed, ensure a good rotation-locking axial connection. A bush 32 is disposed on the end of the rigid tube 28 which extends toward the pump which includes at least one tang 33 in the manner of a revolving coupling in a complemental recess 34 in the pump rotor 17.
The commutator brushes 35, which are disposed in cages 36, slide on the commutator bush 31. The cages 36 are connected with connection clamps (not represented) disposed outside of the housing 3.
The magnetic part 25 of the electromotor 2 includes a permanent magnet 38 which is disposed in a tubular sheet 39 comprising a magnetically conductive material.
Any radial loads which are exerted on the journal bearings 27 of the motor armature 23 are relatively low. The layer structure of these bearings in the direction of the axis of the shaft 12 is as follows:
a steel backing;
a copper layer;
and a porous tin-bronze layer, the pores of which are filled with PTFE and lead.
A circlip 41 is disposed in a groove 40 provided in the shaft 12 and thus serves to restrain the axial forces of the motor armature 23 as well as to prevent these forces from acting on the pump rotor 17 and urging it against its axial limiting wall. A support disk or annulus 42 which can be made of a suitable slippery material is disposed between the circlip 41 and the end of the journal bearing 27 and its rigid tube 28. The other end of the shaft 12 is also provided with a groove 40, a circlip 41 and a support disk 42, all of which form an additional locking device to prevent axial movement of the motor armature 23 in the opposite direction.
The bearing 18 of the pump rotor 17 is preferably constructed of materials which are capable of absorbing relatively powerful radial forces, such as a polyamide or artificial carbon or a roller bearing having satisfactory dry operating properties.
FIGS. 2 and 3 show a further embodiment of this invention in which, as contrasted with the first embodiment shown in FIG. 1, the bearings are not used for a rotation-locking connection between the pump rotor and the motor armature. In this embodiment an intermediate ring 44 is used as the coupling part. The intermediate ring 44 is slipped onto the end of the rigid tube 28 and its integral tang 45 engages in the corresponding recesses 34 of the rotor 17. The ring 44 is provided with at least two recesses 47, as shown. The extensions 48 on the end of the element 32 which is rigidly connected with the motor armature 23, engage in the recesses 47. The relative axial position provided between the pump rotor 17 and the motor armature 23 is ensured by the circlips 41 that are mounted on each end of the shaft supporting the motor armature 23. Accordingly, a rotation-locking connection is permanently ensured by the ring 44. The advantage of this embodiment of the invention is that, apart from the low cost of this type of coupling, no transverse stressing is produced between the rotor and the armature, even when the bearing 18 of the pump rotor 17 is considerably worn. Transverse stresses of this nature would cause additional stressing of the other bearing.
In the third embodiment of the invention shown in FIG. 4 the bearing 50 of the pump rotor projects from the bore 51 of the pump rotor which receives the bearing. The bearing 50 is arranged in the form of a bush which is pressed into the bore 51. A reliable rotation-locking connection between the bush 50 and the rotor 17 is provided by a shoulder portion 52 being used on the journal bearing which extends into a corresponding recess 53 that is available in the pump rotor 17. The recesses 54 in which the tenons 55 on the plastic element 32 engage extend in an axial direction on the journal bearing 50 toward the motor armature 23. Only one of these recesses 54 is shown. The motor armature 23 is supported by the rigid tube 28 or the journal bearing 27 in the axial direction directly on the journal bearing 50. This eliminates axial locking of the motor armature 23 but the pump rotor 17, however, is axially loaded by the motor armature 23. The advantage resides in the very simple type of rotation-locking coupling and in the versatility of the bearing 50 which is capable of more readily absorbing the radial forces than a narrow bearing on account of its elongated shape and is better able also to absorb the axial forces of the motor armature 23.
Polyamide or electrographitized artificial carbon are preferably used for the bearings 18 and 50 of the pump rotor described in the preceding examples. The frictionless properties and resistance of the journal bearings can be improved by the addition of fillers such as graphite. Owing to elevated creep resistance the risk of form variation is relatively low. Thermal expansion is also essentially linear as compared to steel. Polyamide can be availed of in a form of sintering operation to form a suitably prepared rotor. It is also easy to work polyamide by removing burrs or slivers therefrom. In the embodiment of the invention shown in FIGS. 1 and 2 the bearing can expand into the recesses 34 without causing wedging in the direction of the axis of shaft 12. The artificial carbon bearing has excellent temperature resistance and universal chemical resistance. The strength and wear resistance properties of polyamide can be improved by impregnation with coal tar pitch, synthetic resins or metals. Artificial carbon can also be readily worked by removing slivers therefrom.
In the fourth embodiment of this invention, shown in FIG. 5, a roller bearing 57 in the form of a needle bearing acts as a bearing for the pump rotor. A roller bearing is suitable for absorbing both powerful radial forces and for dry operation. As in the first two embodiments, tenons can be used as rotation-locking couplings with these tenons being arranged to engage in corresponding recesses. A mass-produced roller bearing could be used for this purpose.
According to one feature of the invention, outwardly projecting tangs 59 are disposed on the outer race 58 of the bearing 57. These tangs 59 are keyed to engage in corresponding recesses 60 provided in the plastic carrier element 32. The roller bearing 57 can also be connected in a rotation-locking manner with respect to the pump rotor 17 by means of an inwardly extending tang. To reduce wear, the cage of the needle bearing can be coated with a solid lubricant such as molybdenum disulfide therm, wolfram sulfide therm or frictionless varnish. The advantage of this bearing in addition to the minimal friction it affords is the high load capacity and the simple form of rotation-locking entrainment. | This invention relates to a pump and motor unit which is particularly adapted for supplying fuel and which comprises a pump rotor and motor armature, the bearings of which are disposed independently of each other on a fixed axis. | 5 |
CROSS REFERENCE TO RELATED APPLICATION
The present application is a U.S. National Stage Application of PCT application Serial No. PCT/AU2010/000540, filed on 11 May 2010, which claims priority from Australian Patent Application Serial No. AU 2009902368, filed on 25 May 2009, and AU 2009905392, filed on 5 Nov. 2009, all of which are incorporated by reference in their entireties.
FIELD OF THE INVENTION
The present invention relates to embellishing processes including embossing and debossing. In particular, the invention relates to aligning dies used in such processes.
BACKGROUND ART
Debossing creates a depression in stock (such as sheets or paper) and the equivalent process in embossing creates an upstanding portion which is therefore in relief. Debossing is therefore a mirror image of embossing. With an embossing die, which is a female die, there is an equivalent male die termed a counter. The planar stock is passed between the two dies which are then subjected to pressure and thereby creates the raised image.
One type of female die used in these processes is a photopolymer die. Typically the photopolymers used have a high Shore hardness. The photopolymers are processed by means of photoresist. The non image area is washed away with water by soft nylon brushes. The photopolymer is adhered to a thin metal backing plate which is preferably steel. The photopolymer die is secured to a platen base by means of adhesive tape and recently by means of magnetic attraction between the backing plate and magnets positioned in the platen or cylinder bed.
Counters can be made in accordance with at least three known prior art methods. The first is that the counters are cut by hand from paper using the PRAGOPLAST (Registered Trade Mark) system which involves feathered paper with an adhesive backing. The second is the use of moulded counters which are fabricated from fiberglass, putty, and various other plastics which are moulded under both heat and/or pressure to form the male counter. The third type of counter is fabricated from photopolymer and has a film backing which is also of polymeric or other plastic material. The film backing normally is transparent or translucent and thus aids in the alignment of the two dies since the operator can visualize the intended mating.
It is necessary to align or position the counter on the platen of the stamping machine, or cylinder in the case of a rotary machine. For the first type of counters, the counter is hand cut in position after being secured to the platen or cylinder. For both moulded counters and film backed photopolymer counters, the counter is positioned by means of a “reverse” fit. That is to say, the male counter is positioned by hand over the female die until the male protrusions of the counter appear to mate with the recesses of the female die. Once a snug fit has been achieved, double sided adhesive tape is placed on the back of the counter (that is the surface of the counter away from the female die). Then the platen or cylinder is brought into contact with the adhesive tape in order to fasten the counter (or male die) to the platen or cylinder.
However, there is a danger that the counter can move out of its correct position or alignment in the process of fastening the counter to the platen or cylinder. There is also a risk that the male counter can be damaged in the securing process.
Die cutting involves the use of a die to cut and/or crease stock (such as paper sheets or thin sheets of plastic) so as to fabricate a blank for an article such as an envelope, a folder, or the like. The die normally has a base of inexpensive material such as timber, five ply, particle board, or the like. Mounted on the base, edge upper most, are thin strips of steel. In the case of a desired cut, the upper edge is sharp and constitutes a knife. In the case of a desired crease, the upper edge of the strip is rounded. Extending along either side of at least the knife strips is a strip of resilient material which in its uncompressed state has a surface higher than the upper edge of the knife. The two strips of resilient material function as an ejector mechanism to prevent the cut stock becoming jammed on the knife.
In general cutting stock to shape using die cutting is a separate function to that of embossing or debossing of the stock. Thus if a job calls for cutting, and embossing or debossing 1000 items, in general this requires 2×1000 or 2000 operations as the item must be separately embossed or debossed, and then die cut.
However, in recent times it has been known to combine both cutting and either embossing or debossing. This has been possible using an expensive magnesium (or other metal) die to carry out the embossing/debossing. Such metal dies require environmentally burdensome acids to etch away the die material or must be hand engraved or CNC machined. The embossing/debossing die is generally held on the cutting die by means of double sided adhesive tape or screwed or bolted into the cutting tool and must be painstakingly aligned with the cutting die and with any counter required.
GENESIS OF THE INVENTION
The genesis of the present invention is a desire to provide an alternative arrangement in which the above-mentioned disadvantages are at least ameliorated to some extent.
SUMMARY OF THE INVENTION
In accordance with a first aspect of the present invention there is disclosed a set of dies for use in embossing or debossing and comprising a male die and a mating female die, wherein each of said dies has a magnetic or magnetically permeable backing.
In accordance with a second aspect of the present invention there is disclosed a method of mutually aligning a male and a female die which are complementary, said method comprising the steps of:
(i) fabricating each die with at least a magnetic or magnetically permeable backing, and
(ii) in either order or substantially simultaneously, approximately aligning said dies and applying an attractive magnetic force between said dies;
whereby said magnetic force mates the male and female portions of said approximately aligned dies to accurately align same.
According to another aspect of the present invention there is provided a planar substrate of paper, cardboard or like printing stock embossed or debossed with dies aligned in accordance with the above-mentioned method or embossed or debossed with the above-mentioned set of dies.
The female die can take the form of a steel backed metal block (the metal being non-ferrous such as brass, copper, magnesium, zinc or aluminum) or a steel backed photopolymer block or any substrate that can laminated with a steel backing, all of which can enjoy the benefits of the abovementioned magnetic mounting and alignment.
Similarly the male die can be a steel block or a steel backed block fabricated from a material such as fiberglass, plastic, epoxy resin, photopolymer, non-ferrous metals or any substrate that can laminated with a steel backing and thus enjoy the benefits of the magnetic mounting and alignment
BRIEF DESCRIPTION OF THE DRAWINGS
A preferred embodiment of the invention will now be described, by way of example only, with reference to the accompanying drawings in which:
FIG. 1 is an exploded perspective view of a set of embossing dies of a first embodiment,
FIG. 2 is a perspective view of a cutting and creasing die adapted to receive an embossing die, and
FIG. 3 is a perspective view of the male embossing die to be received by the die of FIG. 2 .
DETAILED DESCRIPTION
As seen in FIG. 1 , a printing machine such as a foil stamping machine or a die cutting machine is provided with bed (conventional and not illustrated in FIG. 1 ) and to the upper surface of which a base plate 1 is secured. The machine also has a conventional platen or cylinder drum 2 . Positioned above the base plate 1 is a female photopolymer die 4 having a backing plate 5 . Positioned above the female die 4 is a complementary male die 7 also fabricated from photopolymer and having a complementary male shape. In this connection it will be apparent that the female die 4 has two recesses 14 and 24 which are respectively triangular and quadrilateral in shape. The male die 7 has two protrusions or bosses 17 and 27 which are also respectively triangular and quadrilateral in shape. The male die 7 and the female die 4 are complementary in the sense that the bosses 17 and 27 mate with the recesses 14 and 24 .
In use the paper substrate, for example, is passed between the two dies 4 and 7 . The mating of the bosses 17 , 27 with the recesses 14 , 24 results in the substrate being embossed or debossed with the shape of the recesses 14 , 24 .
As seen in FIG. 1 , the male die 7 is provided with a photopolymer body 37 and a thin sheet steel backing plate 47 . The bosses 17 , 27 project downwardly from the lower surface of the photopolymer body 37 . The upper surface of the backing plate 47 is provided with an array of adhesive strips 9 (the adhesive strips can be placed on the platen or cylinder 2 , or the backing plate 47 as illustrated, or both) which are provided with adhesive on both sides and thus are used to interconnect the male die 7 and the platen 2 .
However, before this interconnection takes place, the male die 7 must be correctly aligned with the female die 4 .
In accordance with the invention disclosed in International Patent Application No. WO2007/045037 (PCT/AU2007/001553), the contents of which are hereby incorporated herein for all purposes, the base plate 1 is provided with an embedded array of magnets (not illustrated in FIG. 1 ). These magnets magnetically clamp the base plate 1 to the bed of the machine. The same magnets also secure the backing plate 5 of the female die 4 to the base plate 1 with a strong magnetic attraction. This strong magnetic attraction is sufficient to easily withstand vibration forces and other forces applied to the female die 4 during the processing.
However, fabricating the male die 7 so as to have a magnetically permeable backing plate 47 means that there is also a relatively weak magnetic attraction between the backing plate 47 and the magnets of the baseplate 1 . This force is weak relative to the strong magnetic forces between the bed and baseplate 1 and between the baseplate 1 and backing plate 5 , because the backing plate 47 is always spaced from the baseplate 1 by a substantial distance and because most of the magnetic flux generated by the baseplate magnets passes through the backing plate 5 . This weak magnetic force is approximately of the same strength as the magnetic force between a fridge magnet and the metal of a fridge door.
A consequence of the weak magnetic attraction between the male die 7 and the base plate 1 is that the male die 7 can be approximately correctly aligned with the female die 4 by hand and the weak magnetic attraction will guide the bosses 17 , 27 into the recesses 14 , 24 because this draws the backing plate 47 closer to the magnets in the base plate 1 . Consequently, the two dies 4 , 7 when correctly aligned with the bosses 17 , 27 mated with the recesses 14 , 24 represent a lower energy state and thus are magnetically urged into that state. Thus the correct alignment is to some extent automatic.
In addition, some machines utilize an inverting bed which swings out and inverts the base upon which the dies reside. Thus normally in such a machine the male counter is located beneath the female die when the bed is swung outwardly. For such machines, the above described arrangement assists the operator in holding the dies securely before final fastening.
Once the correct alignment has been achieved, the adhesive strips 9 can be placed on the backing plate 47 and the platen 2 brought into contact with the adhesive strips 9 . Since the adhesion between the adhesive strips 9 and the platen or cylinder 2 is greater than the weak magnetic attraction between the backing plate 47 and the magnets in the base plate 1 , this means that the platen 2 with the adhered male die 7 can be raised out of contact with the female die 4 but the correct alignment between the two dies 4 , 7 is maintained.
Turning now to FIG. 2 , a substantially conventional cutting and creasing die 50 is illustrated having a base plate 51 fabricated from timber, 5 ply, particle board or some other such inexpensive material. Located on the base plate 51 are knives 53 and crease formers 54 . As seen in the right hand enlargement of FIG. 2 , the crease former 53 takes the form of a thin strip of metal embedded edgewise into a groove cut into the base plate 51 and having an upper edge 56 which is rounded.
As seen in the left hand enlargement in FIG. 2 , each knife 53 take the form of a very thin strip of metal again embedded edgewise into a groove cut into the base plate 51 . The upper edge of the knife 53 is sufficiently sharp to cut the stock, typically paper or cardboard. Extending along each side of the knife 53 is a corresponding ejector strip 58 which is slightly taller than the knife 53 and is fabricated from resilient material such as foamed plastics.
The cutting and creasing die 50 is conventionally used to cut and crease planar printing stock so as to create a blank, for example of an envelope. In the die 50 in FIG. 2 the envelope outline has a front surface 60 , a rear surface 61 and two edge flaps 62 and 63 . In conventional fashion, when the stock is compressed between the base plate 51 and an overhead platen or cylinder (not illustrated), the knives 53 cut out the outline of the envelope blank. The resilient ejector strips push the cut stock away from the knives 53 and so prevent the cut or slit stock becoming jammed on the knife 53 . The stock is also bent over each crease former 54 and so creased to thereby form the location for corresponding folds in the cut stock.
The above description of the cutting and creasing die 50 is thus far conventional. The die 50 is modified in accordance with the second embodiment of the present invention by the cutting away, or routing, of the base plate 51 to form a cavity 59 which is preferably of a standard dimensional size eg. A6, A7, A8, etc. Located within the cavity 59 is a male embossing die 67 , a magnetic base plate 68 and a thin steel plate 72 as illustrated (to an enlarged vertical scale) in FIG. 3 . The male embossing die 67 could be fabricated by etching a metal block such as a magnesium, brass, copper, zinc or steel block but this requires environmentally difficult acids. Where a metal other than steel is used the die 67 preferably includes a thin steel backing plate. Alternatively, the die 67 could be hand engraved or CNC machined. Instead the embossing die 67 is preferably formed from a photopolymer layer 74 and a steel backing plate 75 . Preferably the upper surface of the photopolymer layer 74 is shaped using photo resist techniques (which are water based and thus environmentally benign) so as to form a logo 70 or image such as the four interlinked rings of the AUDI Registered Trade Mark.
A magnetic base plate 68 (with its array of magnets 69 ) is located on the thin steel plate 72 within the cavity 59 . The thin steel plate 72 is preferably held in place by means of double sided adhesive tape (not illustrated in FIGS. 2 and 3 but illustrated as 9 in FIG. 1 ) or other such suitable strong adhesive. Thus, in this embodiment, the thin steel plate 72 always remains with the cutting tool die 50 .
There is a counter 80 (illustrated in phantom in FIGS. 2 and 3 ) which has a reverse (ie female) image of the logo 70 and which can be magnetically guided into registration with the die 67 as described above in relation to FIG. 1 . Once the counter 80 is in register with the die 67 , the counter 80 can be adhered by means of double sided adhesive tape to the platen (or cylinder) which is to compress the stock against the cutting and creasing die 50 .
As a result of the above describe arrangement, the stock is simultaneously compressed against the die 50 thus forming the shape of the desired blank, and also compressed between the counter 80 and the embossing die 67 thereby simultaneously embossing the logo 70 onto the front surface 60 of the envelope. Thus cutting the envelope and embossing same are achieved simultaneously by means of a single pass through the machine.
The magnetic base plate 68 can be removed from the cutting die 50 and used on other jobs. The magnetic base plate 68 , either with the embossing die 67 or a different embossing die, can be held on the thin steel plate 72 on another occasion when embossing or debossing is required. It is convenient for the thin steel plate 72 to remain with the die 50 and for the magnetic plate 68 to be transferred from job to job.
The foregoing describes only two embodiments of the present invention and modifications, obvious to those skilled in the printing arts, can be made thereto without departing from the scope of the present invention.
For example, the backing plate 47 can be fabricated from material which is magnetic, or magnetized, so as to create the desired weak magnetic attraction between the male die 7 and the platen 2 . Other magnetic and magnetically permeable arrangements, which contain ferric material, for example, will be apparent to those skilled in the magnetic arts.
Similarly, the die 67 can have a male representation of the logo 70 , and the counter 80 can have the female representation of the logo 70 , in which case the logo 70 is debossed onto the front 60 of the envelope rather than embossed.
Furthermore, some cutting tool dies have provision for multiple tools so that, say, eight envelopes are cut simultaneously. Under these circumstances such a die would have eight recesses 67 each with a thin steel plate 72 so that each of the eight envelopes can be simultaneously cut and embossed at the one time.
The term “comprising” (and its grammatical variations) as used herein is used in the inclusive sense of “including” or “having” and not in the exclusive sense of “consisting only of”. | A set of dies for embossing or debossing is disclosed. The set has a female die ( 4, 80 ) and a male die ( 7, 67 ) each which has a steel backing plate ( 5, 47, 75 ). One of the dies is strongly magnetically attracted to a base plate ( 1, 68 ) which results in a weak magnetic attraction between the two dies ( 4, 7 or 67, 80 ). The weak magnetic attraction enables the set of dies to be substantially automatically self-aligning. Furthermore, such a set of dies can be used with a cutting and creasing die ( 50 ) to permit embossing or debossing simultaneously with cutting and/or folding during the same run. | 1 |
TECHNICAL FIELD
[0001] The present invention relates to a liquid material filling device and method for filling a liquid material into a liquid material discharge device. More particularly, the present invention relates to a liquid material filling device and method capable of, at the start of use of the liquid material discharge device, filling the liquid material in a manner of preventing air bubbles from remaining in a flow passage where the liquid material is not yet filled.
BACKGROUND ART
[0002] As an example of devices for discharging liquid materials, there is known a device that a shaft member being rotatable or movable forward and backward is disposed in a flow passage extending from a supply port to which the liquid material is supplied, to a discharge port from which the liquid material is discharged, and that the liquid material is discharged from the discharge port with the operation of the shaft member (see, e.g., Patent Document 1).
[0003] In the device disclosed in FIG. 1 of Patent Document 1, a liquid material stored in a syringe is introduced to a flow passage, which is formed in a housing of a distributor, through a hole, and the liquid material is discharged from a nozzle with forward movement of a shaft. Here, the shaft is inserted in a flow bore, and the flow passage is formed by a gap between the flow bore and the shaft inserted in the flow bore. Moreover, a seal ring is fitted over the shaft to avoid the liquid material from leaking toward a control mechanism that is a drive source for the shaft.
[0004] Accordingly, the liquid material stored in the syringe is in such a state that the flow passage being present inside the distributor and leading to the discharge port of the nozzle is fully filled with the liquid material.
[0005] In relation to the discharge device constituted as described above, it is known that, if air bubbles exist within the flow passage, an amount of the liquid material discharged from the device may vary. Furthermore, if air bubbles are mixed into the liquid material at the start of use, the mixed air bubbles are difficult to expel out, and accurate discharge is impeded. More specifically, discharge failures may occur; namely, the air bubbles are discharged during the discharge and the liquid material is not discharged, or a droplet is not formed even when the liquid material is discharged. For that reason, it has been usual so far to perform a centrifugal debubbling process or a vacuum debubbling process on the reservoir (syringe) filled with the liquid material, and then to mount the reservoir to a body of the discharge device.
[0006] In a discharge device of ink jet type, there also arises a problem with mixing of air bubbles. More specifically, if air bubbles are mixed into ink, pressure of an expanding bubble generated due to heating and providing ink discharge energy, or pressure of a driver for pushing the ink is not appropriately transmitted to the nozzle. Hence a failure in ink discharge from a head nozzle tends to occur. To cope with the above problem, Patent Document 2 proposes a liquid filling method of placing a work inside a chamber of an airtight structure, reducing pressure in the chamber to a level close to a vacuum, and filling a fixed amount of liquid into the work by differential pressure between the vacuum pressure in the chamber and the atmospheric pressure in a supply tank where the liquid is stored.
CITATION LIST
Patent Documents
[0007] Patent Document 1: Japanese Patent Laid-Open Publication No. 2004-322099
[0008] Patent Document 2: Japanese Patent Laid-Open Publication No. 2006-248083
SUMMARY OF INVENTION
Technical Problem
[0009] With the prior art, even though the air bubbles can be removed from the liquid material in the reservoir (syringe), the following problem still remains unsolved. When the liquid material is introduced from the reservoir to the flow passage inside the body of the discharge device, gas existing in the flow passage remains in a bent portion or a stepped portion of the flow passage, thus causing new air bubbles to be generated.
[0010] The filling method disclosed in Patent Document 2 is able to remove air bubbles in the ink reservoir, but it still has a possibility that new air bubbles may mix into ink in a flow passage communicating the ink reservoir and a cap with each other. More specifically, there is a possibility that, because a three-way valve and a flow control valve, which are disposed between the ink reservoir and the cap, include bent portions and stepped portions, air bubbles may remain in those portions. Furthermore, there is a possibility that air bubbles are generated when the ink is sucked into an air bypass upon switching-over of the three-way valve (see paragraph [0039] in Patent Document 2), and hence that the ink including the air bubbles remains in the flow passage even after the ink has been discharged out to an ink pan.
[0011] In view of the above-mentioned state of the art, an object of the present invention is to provide a liquid material filling device and method, which can prevent air bubbles from remaining along an entire length of a flow passage extending from a liquid material reservoir to a discharge port.
Solution to Problem
[0012] The present invention provides a liquid material filling device for filling a liquid material into an inner flow passage of a discharge device, the liquid material filling device comprising a chamber of an airtight structure, a pressure regulator for regulating pressure in the chamber, and a control device, wherein the discharge device includes a liquid reservoir that has an outlet in communication with a discharge port, and that has a connector, the pressure regulator includes a negative pressure supply source, a chamber communication pipe in communication with the chamber, a discharge device communication pipe in communication with the connector of the liquid reservoir, an on-off valve A for establishing or cutting off communication between the chamber communication pipe and a gas supply port, an on-off valve B for establishing or cutting off communication between the chamber communication pipe and the discharge device communication pipe, an on-off valve C for establishing or cutting off communication between the discharge device communication pipe and a gas supply port, and a pressure gauge, and the control device includes pressure reducing means for communicating the negative pressure supply source with the chamber communication pipe and with the discharge device communication pipe, and reducing the pressure in the chamber and pressure in an upper space of the reservoir to a vacuum or a low pressure level close to a vacuum, degassing means for maintaining the inside of the chamber and the upper space of the reservoir in a low-pressure state for a certain time, and expelling out air bubbles in the liquid material, filling means for communicating the upper space of the reservoir with the gas supply port, introducing gas to flow into the relevant space, and increasing the pressure in the relevant space to become higher than the pressure in the chamber such that the liquid material within the reservoir is filled into the discharge device, filling stop means for communicating the upper space of the reservoir with the inside of the chamber, and establishing a pressure equilibrium state, and pressure release means for communicating the inside of the chamber and the upper space of the reservoir with the gas supply port.
[0013] The liquid material filling device described above, preferably, further comprises a changeover valve for changing over a first position at which the chamber communication pipe and the negative pressure supply source are communicated with each other, and a second position at which the chamber communication pipe and the gas supply port are communicated with each other, and the control device operates the changeover valve to the first position in the pressure reducing means, and operates the changeover valve to the second position in the pressure releasing means. More preferably, the liquid material filling device described above further comprises a first flow control valve disposed in a flow passage through which the chamber communication pipe and the gas supply port are communicated with each other, and a second flow control valve disposed in a flow passage through which the discharge device communication pipe and the gas supply port are communicated with each other. Even more preferably, a maximum flow rate through the first flow control valve is set to be not less than three times a maximum flow rate through the second flow control valve.
[0014] In the liquid material filling device described above, the control device may further include a sensor for sending a liquid detection signal.
[0015] The present invention provides a liquid material filling method for filling a liquid material into an inner flow passage of a discharge device that is placed inside a chamber, the discharge device including a liquid reservoir that has an outlet in communication with a discharge port, and that has a connector connected to a pipe through which negative pressure is supplied, wherein the liquid material filling method comprises a pressure reducing step of reducing pressure in the chamber and pressure in an upper space of the reservoir to a vacuum or a low pressure level close to a vacuum, a degassing step of maintaining the inside of the chamber and the upper space of the reservoir in a low-pressure state for a certain time, and expelling out air bubbles in the liquid material, a filling step of communicating the upper space of the reservoir with a gas supply port, introducing gas to flow into the relevant space, and increasing the pressure in the relevant space to become higher than the pressure in the chamber such that the liquid material within the reservoir is filled into the discharge device, a filling stop step of, after detecting that a droplet has flowed out from the discharge port, promptly communicating the upper space of the reservoir with the inside of the chamber, thus establishing a pressure equilibrium state and stopping the filling of the liquid material, and a pressure release step of communicating the inside of the chamber and the upper space of the reservoir with a gas supply port, and introducing gas to flow into the chamber and the relevant space.
[0016] In the liquid material filling method described above, in the pressure reducing step, a flow control valve may be adjusted with time to moderately expel out air in the chamber and the reservoir.
[0017] In the liquid material filling method described above, in the filling step, the gas may be moderately introduced to flow into the upper space of the reservoir while a flow control valve is adjusted with time, and in the pressure release step, the gas may be moderately introduced to flow into the upper space of the reservoir while a flow control valve is adjusted with time. Preferably, in the pressure release step, a maximum flow rate through the flow control valve is set to be not less than three times a maximum flow rate through the flow control valve in the filling step.
[0018] In the liquid material filling method described above, the discharge device may be a discharge device including a rod that is operated in a liquid chamber in communication with the discharge port.
Advantageous Effect of Invention
[0019] According to the present invention, a liquid material filling device and method are provided which can prevent air bubbles from remaining along an entire length of a flow passage extending from a liquid material reservoir to a discharge port.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] FIG. 1 is a schematic view illustrating the constitution of a liquid material filling device according to the present invention.
[0021] FIG. 2 is a perspective view illustrating a state where a discharge device is installed inside the liquid material filling device according to the present invention.
[0022] FIG. 3 is a block diagram illustrating the configuration of a control device.
[0023] FIG. 4 is a partly-sectioned side view illustrating the constitution of the discharge device.
DESCRIPTION OF EMBODIMENTS
[0024] One exemplary embodiment for carrying out the present invention will be described below with reference to the drawings.
<Constitution>
[0025] As illustrated in FIG. 1 , a liquid material filling device 1 according to the present invention includes, as main components, a chamber 10 , a pressure regulator 70 , and a control device 100 . A discharge device 50 is installed in the chamber 10 of an airtight structure, and a filling step is performed in such a state. The pressure regulator 70 is to regulate respective pressures in the chamber 10 and a reservoir 51 of the discharge device 50 , and the operation of the pressure regulator 70 is controlled by the control device 100 .
[0026] As illustrated in FIG. 2 , the chamber 10 includes a door 11 fixed in place by hinges, a grip 12 , locking members 13 and 14 , and an airtight sealing member 15 .
[0027] The door 11 is opened and closed by a user grasping the grip 12 . The inside of the chamber can be kept airtight by fixedly holding the door 11 with engagement of the locking member A 13 and the locking member B 14 in a state that the door 11 is closed and is pressed against the airtight sealing member 15 disposed in the form of a frame. The control device 100 and the pressure regulator 70 are installed in a rectangular parallelepiped housing above the chamber 10 . A negative pressure gauge A 87 and a negative pressure gauge B 88 are disposed at the front of the housing such that the user can visually recognize those negative pressure gauges from the front side.
[0028] The pressure regulator 70 includes a negative pressure supply source 71 , flow control valve 80 to 82 , on-off valves 83 to 85 , a changeover valve 86 , and the negative pressure gauges 87 and 88 .
[0029] The negative pressure supply source 71 is to supply predetermined negative pressure, and it can be constituted, for example, as a combination of a vacuum pump and a pressure reducing valve.
[0030] The changeover valve 86 changes over a first position at which the negative pressure supply source 71 and the on-off valve A 83 are communicated with each other, and a second position at which the on-off valve A 83 and a gas supply port 92 are communicated with each other through the flow control valve C 82 .
[0031] One end of a pipe A 90 inserted into the chamber 10 is opened to a chamber space. One end of a pipe B 91 inserted into the chamber 10 is communicated with a lower end outlet of the reservoir 51 . The pipe A 90 and the pipe B 91 are communicated, as illustrated in FIG. 1 , with the gas supply ports 92 and 93 and with negative pressure supply source 71 through the flow control valves 80 to 82 , the on-off valves 83 to 85 , and the changeover valve 86 . While, in this embodiment, the gas supply ports are communicated with the atmosphere to supply atmospheric gas, the gas supply ports may be communicated with an inert gas supply source to supply inert gas.
[0032] As illustrated in FIG. 3 , the control device 100 is electrically connected to a droplet detection sensor 61 and individual components of the pressure regulator 70 . The control device 100 includes an arithmetic device and a storage device. In a filling step described later, the control device 100 automatically controls the operations of the changeover valve 86 and the on-off valves 83 to 85 in accordance with signals from the droplet detection sensor 61 and the negative pressure gauges 87 and 88 . When the operations of the components of the pressure regulator 70 are controlled on the basis of a time schedule, the control device 100 may include a timer that is implemented with hardware or software.
[0033] The droplet detection sensor 61 detects a droplet (or a liquid in the form of a string) discharged from a discharge port 53 of the discharge device 50 , and sends a detection signal to the control device 100 . A weighing device for measuring the weight of the droplet may be provided in a receiving pan 62 , and the discharge of the droplet may be detected depending on a weight change of the receiving pan 62 .
[0034] FIG. 4 is a partly-sectioned side view illustrating the constitution of the discharge device 50 .
[0035] The reservoir 51 and a discharge device body 52 are coupled to each other through a liquid feed member 56 including a flow passage formed therein. An electromagnetic valve 57 is fixed to one lateral surface of the discharge device body 52 .
[0036] A tip of a rod 55 extending in a vertical direction is arranged in a liquid chamber 54 in communication with the discharge port 53 . The rod 55 is reciprocally moved within the liquid chamber 54 by a rod driving source that is constituted by, e.g., a piezoelectric element.
[0037] The reservoir 51 has an outlet at its lower end and an opening at its upper end. An air tube is connected to a cover member (connector) that covers the opening of the reservoir 51 , and is communicated with an air supply port of an air pressure supply unit 58 . A controller 59 controls the operations of the electromagnetic valve 57 and the air pressure supply unit 58 .
[0038] When the discharge device 50 is installed inside the chamber 10 , the discharge device 50 is disconnected from the air pressure supply unit 58 and the controller 59 . On that occasion, the rod 55 is fixedly held at an elevated position such that the rod 55 does not close the flow passage communicating the liquid chamber 54 and the discharge port 53 . In other words, the discharge device 50 is installed inside the chamber 10 in a state where the discharge port 53 and the outlet of the liquid reservoir 51 are communicated with each other.
[0039] In use, the discharge device 50 is mounted to an application apparatus including a work table on which an application object is placed, an XYZ-direction moving device for relatively moving the discharge device, which discharges a fixed amount of the liquid, and the work table, and a control unit for controlling the operation of the XYZ-direction moving device.
[0040] The discharge device 50 illustrated in FIG. 4 is merely one example, and the present invention is applicable to any type of discharge device in which a rod is operated in a liquid chamber communicating with a discharge port. The present invention can be applied to, e.g., a discharge device of jet type in which a valve member is impinged against a valve seat disposed at an end of a flow passage in communication with a nozzle, or it is stopped immediately before impinging against the valve seat, thereby causing a liquid material to be discharged in a flying way, a discharge device of plunger type in which the liquid material is discharged by moving a plunger through a predetermined distance, the plunger sliding in close contact with an inner surface of a reservoir that includes a nozzle at its tip, and a discharge device of screw type in which the liquid material is discharged with rotation of a screw.
<Filling Step>
(Preparation Step: Mounting of Discharge Device, etc.)
[0041] An operator performs the following operations as a preparation step.
(1) Mount the discharge device 50 to a holder 60 disposed inside the chamber 10 . (2) Connect the pipe B 91 to the cover member covering the opening of the reservoir 51 that stores the liquid material, thereby forming a closed space in the reservoir 51 on the upper side. (3) Install the receiving pan 62 under the discharge port 53 of the discharge device 50 . (4) Adjust a detection range of the droplet detection sensor 61 to be overlapped with a vertical line extending from the discharge port 53 of the discharge device 50 downwards.
(First Step: Reducing Pressures in Chamber and Reservoir)
[0046] The control device 100 operates the changeover valve 86 to the first position at which the negative pressure supply source 71 and the on-off valve A 83 are communicated with each other, opens both the on-off valve A 83 and the on-off valve B 84 , and closes the on-off valve C 85 . In this state, the negative pressure supply source 71 is communicated with the chamber 10 through the pipe A 90 and with the reservoir 51 through the pipe B 91 . Therefore, pressure in the chamber 10 and pressure of gas present in the upper space of the reservoir 51 are reduced due to the negative pressure supplied from the negative pressure supply source 71 .
[0047] Because the discharge port 53 of the discharge device 50 is opened to the chamber space, pressure in an inner flow passage of the discharge device body 52 communicating with the discharge port 53 is also reduced with reduction of the pressure in the chamber 10 . On that occasion, the control device 100 preferably performs control to adjust the flow control valve A 80 with time such that air in both the chamber 10 and the reservoir 51 is not abruptly evacuated. The reason is that, if an abrupt pressure change is generated in the flow passage inside the discharge device 50 and the reservoir 51 , a possibility of mixing of air bubbles occurs, and that, particularly if the liquid material in the reservoir 51 is disturbed, the possibility of mixing of air bubbles increases significantly.
(Second Step: Removal of Air Bubbles)
[0048] When detection values of the negative pressure gauge A 87 and the negative pressure gauge B 88 each reach desired pressure (i.e., a vacuum or low pressure close to a vacuum), the control device 100 closes the on-off valve A 83 . With the closing of the on-off valve A 83 , the supply of the negative pressure from the negative pressure supply source 71 to both the chamber 10 and the reservoir 51 is stopped, thus resulting in a state where the pressure in the chamber 10 , the pressure in the reservoir 51 , and the pressure in the inner flow passage of the discharge device body 52 are equal to one another. In such a state, the inner flow passage of the discharge device body 52 is substantially brought into a vacuum state, and air bubbles are removed from all the liquid material present inside the chamber 10 . This step of removing the air bubbles is continued for a certain time set in advance.
(Third Step: Start of Filling of Liquid Material)
[0049] After the lapse of the certain time, the control device 100 closes the on-off valve B 84 to cut off the communication between the pipe A 90 and the pipe B 91 . As a result, the communication between the chamber 10 and the upper space of the reservoir 51 is also cut off. Thereafter, the control device 100 closes the flow control valve B 81 and then opens the on-off valve C 85 . At that time, because the flow control valve B 81 is closed, a reading of the negative pressure gauge B 88 is not changed.
[0050] The control device 100 then gradually opens the flow control valve B 81 . With the opening of the flow control valve B 81 , atmospheric gas flows into the upper space of the reservoir 51 from the gas supply port 93 through the on-off valve C 85 . On that occasion, the control device 100 preferably adjusts an opening degree of the flow control valve B 81 such that the liquid material in the reservoir 50 does not abruptly flow into the inner flow passage of the discharge device body 52 .
[0051] As an amount of the atmospheric gas flowing into the reservoir 51 increases, the pressure in the reservoir 51 rises and the reading of the negative pressure gauge B 88 also increases. The inflow of the atmospheric gas into the reservoir 51 (i.e., a pressure rise therein) is continued until the negative pressure gauge B 88 indicates a desired pressure value. Because the communication between the flow passage (pipe) B 91 and the flow passage (pipe) A 90 is kept cut off with the presence of the liquid material inside the reservoir 51 , a reading of the negative pressure gauge A 87 does not increase. A difference between the reading of the negative pressure gauge A 87 and the reading of the negative pressure gauge B 88 indicates a differential pressure between the reservoir 51 and the inner flow passage of the discharge device body 52 . The differential pressure serves as propulsion pressure for feeding the liquid material inside the reservoir 51 to the inner flow passage of the discharge device. The negative pressure in the chamber 10 is, e.g., −60 to −100 kPa, and the differential pressure between the negative pressure gauge A and the negative pressure gauge B is, e.g., several ten kPa to several hundred kPa.
[0052] While the above description is made in connection with the method of opening the on-off valve C 85 and then opening the flow control valve B 81 by the control device 100 , the on-off valve C 85 may be opened after setting the opening degree of the flow control valve B 81 in advance by the control device 100 .
(Fourth Step: Stop of Filling of Liquid Material)
[0053] Upon the reading of the negative pressure gauge B 88 reaching the desired value, the control device 100 closes the on-off valve C 85 . Instead of utilizing the reading of the negative pressure gauge B 88 , the on-off valve C 85 may be closed after the lapse of a certain time. On that occasion, the differential pressure between the negative pressure gauge A 87 and the negative pressure gauge B 88 is maintained with the on-off valve B 84 being kept closed. Accordingly, the liquid material continues to moderately flow into the inner flow passage of the discharge device body 52 from the reservoir 51 . When it is ascertained from the detection signal from the droplet detection sensor 61 that the liquid material having flowed from the reservoir 51 has reached the discharge port 53 , the control device 100 opens the on-off valve B 84 to communicate the pipe A 90 and the pipe B 91 with each other. As a result, the difference between the pressure in the reservoir 51 and the pressure in the chamber 10 is eliminated, and the inflow of the liquid material into the inner flow passage of the discharge device body 52 from the reservoir 51 is stopped. At that time, the readings of the negative pressure gauge A 87 and the negative pressure gauge B 88 are equal to each other (pressure equilibrium state).
(Fifth Step: Release of Negative Pressure in Chamber)
[0054] The control device 100 sets the changeover valve 86 to the second position, thereby communicating the on-off valve A 83 and the flow control valve C 82 with each other. At that time, the on-off valve A 83 and the flow control valve C 82 are in the closed state, and the on-off valve B 84 is in the opened state. Then, the control device 100 opens the on-off valve A 83 and gradually opens the flow control valve C 82 . As a result, the atmospheric gas flows, from the gas supply port 92 , into the chamber 10 through the pipe A 90 , and into the upper space of the reservoir 51 through the pipe B 91 . Accordingly, the pressures in the chamber 10 and the reservoir 51 rise and become equal to the atmosphere pressure.
[0055] While the above description is made in connection with the method of opening the on-off valve A 83 and then opening the flow control valve C 82 by the control device 100 , the on-off valve A 83 may be opened after setting the opening degree of the flow control valve C 82 in advance by the control device 100 .
[0056] Alternatively, in this step, the atmospheric gas may be introduced, from the gas supply port 93 , to flow into the chamber 10 and the upper space of the reservoir 51 . In other words, the control device 100 may, from the state where the on-off valve A 83 , the on-off valve C 85 and the flow control valve B 81 are closed and the on-off valve B 84 is opened, open the on-off valve C 85 and gradually open the flow control valve B 81 . Also on that occasion, the on-off valve C 85 may be opened after setting the opening degree of the flow control valve B 81 in advance by the control device 100 . When the negative pressure in the chamber is released through the gas supply port 93 , the changeover valve 86 is not required, and the flow control valve A 80 and the on-off valve A 83 can be directly coupled to each other.
[0057] However, the inflow ports for the atmospheric gas are preferably provided as separate ports in some cases for the reason that, comparing the inflow of the atmospheric gas into the reservoir 51 in the third step and the inflow of the atmospheric gas into the chamber in the fifth step, the inflow amount of the atmospheric gas is much larger in the fifth step. Stated in another way, the case of providing the changeover valve 86 as well is advantageous in that it is possible to introduce the atmospheric gas to flow in from the gas supply port 92 through one valve adapted for a large flow rate, and to introduce the atmospheric gas to flow in from the gas supply port 93 through another valve adapted for a small flow rate. As a result, the negative pressure in the chamber can be quickly released in the fifth step. For example, a maximum flow rate through the flow control valve C 82 can be set to be not less than three times (preferably not less than five times and more preferably not less than ten times) that through the flow control valve B 81 .
(Posterior Step: Taking-Out of Discharge Device)
[0058] The operator visually checks that the readings of the negative pressure gauges A 87 and B 88 have returned to the atmospheric pressure, and then takes out the discharge device 50 (i.e., the reservoir 51 and the discharge device body 52 ) from the chamber 10 .
[0059] While the above-described first to fifth steps are automatically executed in principle, it is a matter of course that a part or the whole of those steps may be manually performed.
[0060] According to the liquid material filling device 1 described above, since the liquid material is filled in the vacuum state or in the substantially vacuum state where the atmosphere does not remain, the liquid material with no air bubbles remained therein can be caused to fill throughout the flow passage extending from the reservoir to the discharge port. Furthermore, since the discharge device is itself placed in the chamber and is held in the vacuum state, there is no possibility that gas flows into the inner flow passage of the discharge device from the discharge port.
[0061] Thus, according to the present invention, since no air bubbles remain in the flow passage extending from the reservoir to the discharge port, advantageous effects are obtained in that an amount of the discharged liquid material is stabilized, and that discharge failures are not caused. Furthermore, since liquid dripping or posterior dripping from the discharge port attributable to the remaining air bubbles does not occur, the liquid material can be discharged in a clean condition. Moreover, in a discharge device of the type discharging the liquid material from the discharge port in a state of droplets, accuracy of droplet-landed positions is increased. The present invention is so much effective especially in a mechanical discharge device in which a tip of an operating shaft (rod) is arranged in a liquid chamber communicating with a discharge port.
LIST OF REFERENCE SIGNS
[0000]
1 : liquid material filling device
10 : chamber
11 : door
12 : grip
13 : locking member A
14 : locking member B
15 : sealing member
50 : discharge device
51 : reservoir (syringe)
52 : discharge device body
53 : discharge port
54 : liquid chamber
55 : rod
56 : liquid feed member
57 : electromagnetic valve
58 : air pressure supply unit
59 : controller
60 : holder
61 : droplet detection sensor
62 : receiving pan
70 : pressure regulator
71 : negative pressure supply source
80 : flow control valve A
81 : flow control valve B
82 : flow control valve C
83 : on-off valve A
84 : on-off valve B
85 : on-off valve C
86 : changeover valve
87 : negative pressure gauge A (pressure gauge A)
88 : negative pressure gauge B (pressure gauge B)
90 : pipe A (chamber communication pipe)
91 : pipe B (discharge device communication pipe)
92 : gas supply port
93 : gas supply port
100 : control device | A liquid material filling device and method are provided which are intended to prevent air bubbles from remaining along an entire length of a flow passage extending from a liquid material reservoir ( 51 ) to a discharge port ( 53 ). The liquid material filling device includes a chamber ( 10 ) of an airtight structure, a pressure regulator ( 70 ) for regulating pressure in the chamber ( 10 ), and a control device ( 100 ). The liquid material is filled as follows. A negative pressure supply source ( 71 ) is communicated with a chamber communication pipe ( 90 ) and with a discharge device communication pipe ( 91 ) to reduce the pressure in the chamber ( 10 ) and pressure in an upper space of the reservoir ( 51 ) to a vacuum or a low pressure level close to a vacuum, and a resulted low-pressure state is maintained for a certain time to expel out air bubbles in the liquid material. | 1 |
BRIEF SUMMARY OF THE INVENTION
This application is a division of appliction 839,273, filed on the 4th Oct. 1977 now U.S. Pat. No. 4,176,519, which, in turn, was a division of application 638,052, filed on the 5th Dec. 1975 now U.S. Pat. No. 4,064,690, which is a C.I.P. of application 471,176, filed on the 17th of May 1974 now U.S. Pat. No. 3,443,703.
U.S. Pat. No. 2,950,082, and inventor's U.S. Pat. No. 3,943,703 show ceramic turbine rotors having an integral stub shaft to be fitted to a metal shaft structure. Those designs, however, do not include efficient means for preventing relative rotation between rotor and shaft structure, while retaining the desirable resilient properties necessary with respect to the different coefficents of expansion and the brittleness of the ceramic material.
Gas turbine power plants, especially small sized ones, where it is difficult to provide a cooling of the turbine, suffer from certain disadvantages, mainly high specific fuel consumption, high costs and specific space requirements. One of the most efficient remedies is to raise the gas temperature, but the strength of conventional, uncooled metallic, heat resistant materials will set a limit to that. Ceramic materials, on the other hand, have a far better capacity to withstand high temperatures, but their strength is generally much less than that of metallic materials. For commercially available ceramic materials, suitable for mass production, the practically useful strength is roughly about one half only, of the finest heat resistant metallic materials, taking brittleness and production statistics into account.
Many proposals for making turbine rotors wholly or partly of ceramic materials have been put forward, but have, so far, been no practical success due to these limitations, and to lack of full understanding of the behaviour of ceramic material and statistics from production (Weibulls's number, etcetera).
In order to secure simplicity of design the turbine driving the compressor is mounted upon the same shaft as the latter. It is here presupposed that the gas turbine plant is of sufficient advanced design to have at least one further turbine delivering external power, and that the components are of conventional turbo type, i.e. centrifugal or axial compressor and axial or radial turbine.
The ceramic rotor has to be fitted to a metal shaft, which requires much care to be taken due to the different coefficients of expansion, and the inherent strengths of the two materials. Different means have been proposed for resiliently retaining the rotor at the shaft, but the transfer of torque from the turbine for driving the compressor causes a tendency for relative rotation between rotor and shaft.
The aim of the present invention is to propose means for counteracting such relative rotation, and includes a resilient clamping member and a tightening rod for engagement with said stub shaft, and mating, interengaging parts for preventing relative rotation during torque transfer.
The stub shaft is formed with a polygonal cross section, said clamping member and the void in said hollow shaft being formed with mating, but successively bigger cross sections, which ensures a safe grip between the components.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING
FIG. 1 is a longitudinal section through a turbine having rotor means according to the invention,
FIG. 2 shows, on a larger scale, the mounting of the stub shaft at the hollow shaft, and
FIG. 3 is a cross section through the shaft end.
DETAILED DESCRIPTION
FIG. 1 illustrates a simple gas turbine power plant suitable for automotive installation and having a compressor 30 driven by a first turbine rotor 32 of undersized diameter, being incapable of supplying the necessary power for driving the compressor. This rotor will thus be working with considerably reduced centrifugal and other stresses.
The compressor 30 is mounted upon a hollow shaft 31, which carries a rotor 32 with integral vanes, made of ceramic material. This rotor is releasably and flexibly mounted upon shaft 31 by means of an internal, threaded rod 33 and nut means, not shown. Second and third rotors 34 and 35, respectively, of which at the last mentioned one is manufactured of metallic material, are arranged downstream of first rotor 32, and are both connected to a planetary gear 36.
An output shaft 37 from the ring wheel of this gear drives the wheels of the vehicle denoted by 38, while a second shaft 39 connected to its sun wheel supplies additional power for driving the compressor by way of a variable transmission 40. The arrangement permits rotor 34 to deliver power to the compressor and the auxiliaries also during temporary stops of the vehicle.
Due to the very low inertia of the "undersized" turbine rotor and the variable transmission and the power turbine inertia effect, it is possible to obtain a fast acceleration of the gas producer part without the overtemperatures occuring in a conventional plant. the "undersized" compressor turbine will thus operate at low peripheral speed, and not be subjected to the same temperature gradients as in conventional turbines, which reduces the mechanical, as well as the thermal strains upon the rotor, especially in its vanes and rim. This makes it possible to use available ceramic material, and also to manufacture rotor and vanes as an integral component, e.g. by sintering or hotpressing. It is thus possible to raise the temperature of the gases from the combustion chamber, while still using a simple turbine design.
Air from compressor 30 passes up to a plenum chamber 41 enclosing a combustion chamber 42. Part of the air passes downwards, and enters openings 43 in hollow shaft 31, from which it is conveyed to rotor 32 for cooling the same, as well as the shaft and a flexible clamping member locating the rotor.
The combustion chamber is provided with burner means 44. Fuel pumping and governing means (not shown) are provided to ensure a supply of fuel, resulting in gas temperatures considerably in excess of those used in conventional turbines, with a first rotor of metallic material.
FIG. 2 illustrates one way of resiliently mounting a rotor of ceramic material upon a metal shaft, so due consideration will be taken to the different coefficients of thermal expansion for those two materials.
Rotor 32 of the gas turbine in FIG. 1 is made of ceramic material with integral vanes and a centrally located stub shaft 46, which fits into a void at one end of hollow shaft 31. The rod 33 extending through this shaft is at its end remote from the rotor provided with nut means for tightening the attachment.
The end of rod 33, adjacent to the rotor, is formed as an open-ended sleeve ending in a number of axially directed bent fingers, engaging an annular bead 48 at the root of stub shaft 46.
The connection between the open-ended sleeve clamping member and rod 33 proper is formed as an axial spring element 33a. This is desirable as the shaft end, in order to obtain a secure positioning of the rotor disc, extends so it obtains contact with the latter.
As mentioned in connection with FIG. 1 air from the compressor is supplied to the interior of shaft 31. The sleeve end of rod 33 is provided with openings 49a at its inward end and slots 49b between the fingers at its outward end, so air can pass axially through the fitting for cooling the same, as well as the rotor shaft, which is provided with axial slots, 31a, for the cooling air.
This fitting will maintain a safe grip, irrespective of thermal changes in the axial or the radial direction.
In order to prevent a rotation between the stub shaft and the enclosing hollow shaft, the stub shaft 46b has a polygonal cross section. The polygon shape is here of the 3-lobe type, but may have four or more lobes. The clamping member 47b, and the void at the end of hollow shaft 31b will be formed with correspondingly shaped, but bigger cross sections.
A characterizing feature of a polygon shaped cross section is that the "diameters", i.e. transverse measures through the centre are constant. The respective measures for the internal surface of the hollow shaft and the external surface of the stub shaft, are denoted dy an di, respectively.
These surfaces may be simply ground, and the polygon shape will ensure a safe torque transfer.
The clamping member is provided with axial, or substantially axial corrugations 47, and the axial spring member 33a, shown in FIG. 2, will ensure a satisfactory resiliency in the axial direction.
Alternatively the clamping member may be provided with transverse corrugations, provided with slots for permitting axial air flow. The transverse corrugations will ensure resiliency in the axial direction, but also compensate temperature movements in the radial direction. | A ceramic turbine rotor fitted to a metal shaft has an integral stub shaft extending into the hollow end of the metal shaft, and is resiliently retained therein by a clamping and tightening member. In order to prevent relative rotation between the rotor and the shaft during torque transfer, the stub shaft within the metal shaft has a polygonal cross section, and the clamping member and the void on the hollow shaft have mating, but successively bigger cross sections. | 5 |
[0001] This patent application is a continuation-in-part of U.S. patent application Ser. No. 13/832,989 filed on Mar. 15, 2013 and entitled “Color-Changing Wood Filling Composition”, the disclosure of which is hereby incorporated by reference herein in its entirety and made part of the present U.S. utility patent application for all purposes.
BACKGROUND OF THE INVENTION
[0002] The described invention relates in general to compositions for repairing wood and similar surfaces, and more specifically to a wood-filling composition that includes a color-based indicator of dryness.
[0003] Current wood fillers are often tinted to match a particular color of a wood surface that requires repair or so the consumer may stain the repaired area to a desired color. However, current commercially available wood fillers do not provide the consumer with an accurate indicator of dryness so that sanding for eventual staining can be performed. Thus, in most cases, the consumer must wait for a predetermined period of time before sanding and staining or simply guess the appropriate time for such activity. Current wood fillers that utilize waterborne formulations technology are affected by relative humidity; thus, when evaluating the condition of such wood fillers, the end user is often left with the inability to know when to continue with the next repair step. Because an incorrect guess can result in an incomplete repair or unacceptable repair quality, there is an ongoing need for a wood-filling composition that includes an accurate visual indicator of dryness.
SUMMARY OF THE INVENTION
[0004] The following provides a summary of certain exemplary embodiments of the present invention. This summary is not an extensive overview and is not intended to identify key or critical aspects or elements of the present invention or to delineate its scope.
[0005] In accordance with one aspect of the present invention, a first wood-filling composition is provided. This composition includes a modified styrene butadiene latex or similar composition; at least one pH indicator, wherein the pH indicator is operative to provide a visual indication that the wood filling composition is dry, and wherein the visual indication is based on a color change of the composition that occurs as the composition dries; and microspheres, wherein the microspheres further include glass, and wherein the microspheres are operative to provide durability and stainability to the wood-filling composition.
[0006] In accordance with another aspect of the present invention, a second wood-filling composition is provided. This composition includes at least one modified styrene butadiene latex or the like; at least one pH indicator, wherein the pH indicator is operative to provide a visual indication that the wood filling composition is dry, and wherein the visual indication is based on a color change of the composition that occurs as the composition dries; and microspheres, wherein the microspheres further include glass, and wherein the microspheres are operative to provide durability and stainability to the wood-filling composition.
[0007] In yet another aspect of this invention, a third wood-filling composition is provided. This composition includes at least one modified styrene butadiene latex or the like; at least one pH indicator, wherein the pH indicator is operative to provide a visual indication that the wood filling composition is dry, and wherein the visual indication is based on a color change of the composition that occurs as the composition dries; and microspheres, wherein the microspheres further include glass, and wherein the microspheres are operative to provide durability and stainability to the wood-filling composition; and at least one pigment.
[0008] Additional features and aspects of the present invention will become apparent to those of ordinary skill in the art upon reading and understanding the following detailed description of the exemplary embodiments. As will be appreciated by the skilled artisan, further embodiments of the invention are possible without departing from the scope and spirit of the invention. Accordingly, the associated descriptions are to be regarded as illustrative and not restrictive in nature.
DETAILED DESCRIPTION OF THE INVENTION
[0009] Exemplary embodiments of the present invention are described below. Although the following detailed description contains many specifics for the purposes of illustration, a person of ordinary skill in the art will appreciate that many variations and alterations to the following details are within the scope of the invention. Accordingly, the following embodiments of the invention are set forth without any loss of generality to, and without imposing limitations upon, the claimed invention.
[0010] The present invention relates to a liquid or semi-solid wood-filling composition that includes a visual indicator of dryness following the application of the composition to a surface. This composition further includes one or more styrene butadiene rubber (SBR) polymers and glass or ceramic microspheres that provide superior product performance, primarily with regard to durability and stainability. The visual indicator is based on pH and when the wood filler of the present invention changes color (e.g., purple to white, magenta to beige, etc.) the repaired area is dry enough to be sanded and then painted, stained or otherwise processed without damage to or significant disruption of the wood filling composition.
[0011] A first exemplary formulation includes the following ingredients: water; a first pH controller that includes an amino alcohol such as AMP-95® manufactured by Angus Chemical Company (2-amino-2-methyl-1-propanol containing 5% water); a non-ionic surfactant such as Burco® APR-4007 manufactured by Burlington Chemical Co., LLC; a dispersant or anionic detergent polymer such as Burcosperse® AP Liquid manufactured by Burlington Chemical Co., LLC); a freeze-thaw stabilizer such as propylene glycol; a second pH controller such as potassium hydroxide (45% soln.); a SBR polymer such as the modified styrene butadiene latex Encor® DL 215 manufactured by Arkema, Inc.); a bactericide that includes aqueous blends of chlorinated and non-chlorinated isothiazolinones and 2-bromo-2-nitro-1,3-propanediol such as Acticide® LA manufactured by Thor, Inc.; a defoamer that includes insoluble oils, polydimethylsiloxanes and other silicones, alcohols, stearates and glycols or combinations thereof, such as Defoamer XZ manufactured by Nanjing Sixin Scientific and Technological Application Research Institute Co., Ltd; a thickener that includes hydroxypropyl methylcellulose such as Methocel™ F4M manufactured by The Dow Chemical Company; a first calcium carbonate filler that includes dry ground marble such as Calwhite® manufactured by Imerys; a second calcium carbonate that includes dry ground calcium carbonate such as #10 White™ manufactured by Imerys; a first film-forming composition that includes a slow-evaporating glycol ether such as Dowanol DPnP manufactured by The Dow Chemical Company (dipropylene glycol n-propyl ether), a second film-forming composition that includes slow-evaporating, hydrophobic glycol ether such as Dowanol DPnB manufactured by The Dow Chemical Company (dipropylene glycol n-butyl ether); a pH indicator such as o-Cresolphthalein; and glass microspheres such as 3M™ Glass Bubbles K20 (density: 0.20 g/cc) manufactured by 3M Company. Example 1 (see below), includes these ingredients in specific percentages by weight. The formulation provided in Example 1 is referred to as Formula ZA55867 and changes from purple to white to indicate the appropriate time for sanding and staining or painting.
Example 1
[0012]
[0000]
Raw Material
% (by wt.)
Description
Water
11.20
—
AMP-95 ®
0.30
pH controller
Burco APR-4007
0.75
surfactant/wetting agent
Burcosperse AP Liquid
0.75
dispersant
Propylene Glycol
2.50
freeze-thaw stabilizer
Potassium Hydroxide (45% soln.)
0.25
pH controller
Encor DL215
15.50
SBR polymer
Acticide LA
0.10
bactericide
Defoamer XZ
0.10
defoamer
Methocel F4M
0.45
thickener
Calwhite
41.15
calcium carbonate filler
#10 White
22.00
calcium carbonate filler
Dowanol DPnP
0.55
film former
Dowanol DPnB
0.30
film former
o-Cresolphthalein
0.10
pH indicator
3M Glass Bubbles K20
4.00
glass microspheres
100.00
[0013] A second exemplary formulation includes the following ingredients: water; a first pH controller that includes an amino alcohol such as AMP-95® manufactured by Angus Chemical Company (2-amino-2-methyl-1-propanol containing 5% water); a wetting agent such as Burco® APR-4007 manufactured by Burlington Chemical Co., LLC; a dispersant or anionic detergent polymer such as Burcosperse® AP Liquid manufactured by Burlington Chemical Co., LLC); a freeze-thaw stabilizer such as propylene glycol; a first colored pigment such as Joratint Umber 2TC; a second colored pigment such as Joratint Yellow TC; a second pH controller such as potassium hydroxide (45% soln.); a SBR polymer such as the modified styrene butadiene latex Encor® DL 215 latex manufactured by Arkema, Inc.); a bactericide that includes aqueous blends of chlorinated and non-chlorinated isothiazolinones and 2-bromo-2-nitro-1,3-propanediol such as Acticide® LA manufactured by Thor, Inc.; a defoamer that includes insoluble oils, polydimethylsiloxanes and other silicones, alcohols, stearates and glycols or combinations thereof, such as Defoamer XZ manufactured by Nanjing Sixin Scientific and Technological Application Research Institute Co., Ltd; a thickener that includes hydroxypropyl methylcellulose such as Methocel™ E4M manufactured by The Dow Chemical Company; include a first calcium carbonate filler that includes dry ground marble such as Calwhite® manufactured by Imerys; a second calcium carbonate that includes dry ground calcium carbonate such as #10 White™ manufactured by Imerys; a first film-forming composition that includes a slow-evaporating glycol ether such as Dowanol DPnP manufactured by The Dow Chemical Company (dipropylene glycol n-propyl ether), a second film-forming composition that includes slow-evaporating, hydrophobic glycol ether such as Dowanol DPnB manufactured by The Dow Chemical Company (dipropylene glycol n-butyl ether); a pH indicator such as o-Cresolphthalein; and glass microspheres such as 3M™ Glass Bubbles K20 (density: 0.20 g/cc) manufactured by 3M Company. Example 2 (see below), includes these ingredients in specific percentages by weight. The formulation provided in Example 2 is referred to as Formula ZA55868 and changes from magenta to beige to indicate the appropriate time for sanding and staining or painting.
Example 2
[0014]
[0000]
Raw Material
% (by wt.)
Description
Water
11.20
—
AMP-95 ®
0.30
pH controller
Burco APR-4007
0.75
surfactant/wetting agent
Burcosperse AP Liquid
0.75
dispersant
Propylene Glycol
2.50
freeze-thaw stabilizer
Joratint Umber 2TC
0.10
color pigment
Joratint Yellow TC
0.35
color pigment
Potassium Hydroxide (45% soln.)
0.25
pH controller
Encor DL215
15.50
SBR polymer
Acticide LA
0.10
bactericide
Defoamer XZ
0.10
defoamer
Methocel E4M
0.45
thickener
Calwhite
40.68
calcium carbonate filler
#10 White
22.00
calcium carbonate filler
Dowanol DPnP
0.55
film former
Dowanol DPnB
0.30
film former
o-Cresolphthalein
0.12
pH indicator
3M Glass Bubbles K20
4.00
glass microspheres
100.00
[0015] While the present invention has been illustrated by the description of exemplary embodiments thereof, and while the embodiments have been described in certain detail, it is not the intention of the Applicant 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. Therefore, the invention in its broader aspects is not limited to any of the specific details, representative devices and methods, and/or illustrative examples shown and described. Accordingly, departures may be made from such details without departing from the spirit or scope of the applicant's general inventive concept. | A composition for use as a wood-filler that includes a modified styrene butadiene latex; at least one pH indicator, wherein pH indicator causes the composition to change color as the composition dries; and one or more types of microspheres, wherein the microspheres provide durability and stainability to the wood-filling composition. | 2 |
FIELD OF THE INVENTION
[0001] The field of the invention is cell phone cases
BACKGROUND
[0002] It is known in the art to use mobile devices to conveniently access and manipulate data, view multimedia files and presentations, make phone calls, and access wireless networks. As used herein, a “mobile device” includes, among other things, laptops, portable media players (i.e. mp3 players and projectors), and cellular phones. The more portable a computer, however, the more susceptible the computer is to receiving damage from being dropped or being otherwise mishandled.
[0003] Protective cases have long been used for mobile devices. U.S. Pat. No. 4,294,496 to Murez discloses a mobile device having a hard outer metallic shell that protects the delicate computer screen and keyboard from damage by folding the screen and keyboard against one another. However, surrounding each computer's user interface within a hard metallic shell increases the time it takes for a user to access the user interface and reduces response time when a user needs to access the computer. Murez and all other extrinsic materials discussed herein are incorporated by reference in their entirety. Where a definition or use of a term in an incorporated reference is inconsistent or contrary to the definition of that term provided herein, the definition of that term provided herein applies and the definition of that term in the reference does not apply.
[0004] Unless the context dictates the contrary, all ranges set forth herein should be interpreted as being inclusive of their endpoints, and open-ended ranges should be interpreted to include commercially practical values. Similarly, all lists of values should be considered as inclusive of intermediate values unless the context indicates the contrary.
[0005] US20090302799 to Marquet teaches a rigid case for a mobile telephone that substantially surrounds the entire body of the mobile phone, but leaves the keyboard and screen of the phone exposed so that a user could easily access buttons on the phone. However, if a user drops Marquet's case in a way where the front of the phone hits the ground, the screen could crack or become otherwise damaged easily.
[0006] US20100302716 to Ganhdi teaches a rigid case for a mobile telephone that extends slightly from a surface of the screen to prevent the screen from being damaged if the phone falls face-down on a flat surface. When the phone hits a flat surface, the extending portions of the case will hit the ground first, protecting the phone from suffering damage through a direct impact with the ground. However, since Ganhdi's case is rigid, the mobile phone could still suffer damage through an indirect impact of impact forces traveling through the surface of the rigid case into the phone itself.
[0007] U.S. Pat. No. 7,933,122 to Richardson teaches a protective case for a mobile telephone having three layers of protection: (1) an inner flexible membrane layer that holds the computer, (2) a hard shell cover layer over the flexible membrane, and (3) an outer flexible cushion layer that wraps around the hard shell cover. This allows the protective case to protect further against damage to the mobile telephone by allowing the outer flexible cushion layer and the inner flexible membrane layer to distribute an impact force while the hard shell cover layer prevents the case from substantially deforming during such an impact. Richardson's case, however, is difficult to put together and is extremely cumbersome to enclose over the mobile phone.
[0008] Thus, there is still a need for improved mobile device cases that are easier to manufacture and are easier to use.
SUMMARY OF THE INVENTION
[0009] It has yet to be appreciated that a mobile device case could be constructed by injection-molding a soft overmold layer around a hard shell layer through injection mold ports disposed about surfaces of the hard shell layer, interdigitating the soft and hard shells into a single case having the distributive properties of a soft case as well as the deform-resistant properties of a hard case.
[0010] The present invention provides apparatus and methods in which a case for a mobile device protects the mobile device by providing a hard shell layer having injection mold ports disposed about at least one surface and a soft overmold layer mechanically coupled to the hard shell layer via injection-molded protrusions of the overmold layer extending through at least one of the injection molded ports. As used herein, a “hard shell layer” means a material different from the soft overmold layer which has a Young's modulus higher than the soft overmold layer. In other words, the hard shell layer is more rigid than the soft overmold layer.
[0011] The hard shell layer preferably comprises a rigid thermoplastic polymer, such as a polycarbonate material, having a Young's modulus of at least 10, 20, 30, 40, or 50. Generally, the hard shell layer also has one, two, three, or more sets injection mold ports disposed along several surfaces, such as opposing surfaces of two walls that wrap around opposing sides of the mobile device, or orthogonal walls that cradle a corner of the mobile device. In an exemplary embodiment, each wall of the hard shell layer has at least one set of injection mold ports to maximize the mechanical coupling between the hard shell layer and the soft overmold layer. The hard shell layer preferably comprises at least three walls orthogonal to one another to cover a corner of the mobile device. As used herein, a “set” of injection mold ports comprises a bank of similarly-shaped ports along a line drawn across a surface of the hard shell layer. Such injection mold ports could be sized or shaped in any suitable manner to allow for the soft overmold layer to thread through the port before solidifying, such as rectangular ports, square ports, cylindrical ports, pentagonal ports, ovoid ports, tear-shaped ports, star-shaped ports, and other regular or irregular shapes.
[0012] The soft overmold layer preferably covers both an interior surface and an exterior surface of the hard shell layer. As used herein, an “interior surface” faces the mobile device when the mobile device is housed within the case, and an “exterior surface” faces away from the mobile device when the mobile device is housed within the case. If the soft overmold layer was only on an exterior portion of the case, then the rigid hard shell layer could scratch or otherwise damage a surface of the mobile device when the case suffers from an impact collision. If the soft overmold layer was only on an interior portion of the case, then the soft overmold layer would not be able to distribute as much impact force. By providing a soft overmold layer which covers portions of both the interior and the exterior surface, the elastic properties of the soft overmold layer will exteriorly distribute force received from an exterior impact, and will also interiorly distribute force delivered to the mobile device.
[0013] The soft overmold layer preferably comprises an elastomeric material such as rubber or a thermoplastic elastomer. In a preferred embodiment, the soft overmold layer is a Versaflex™ alloy provided by PolyOne™ GLS. The elastomeric material preferably has a Durometer rating of no greater than 50, 40, 30, or 20, and preferably has a Durometer rating of no greater than 25.
[0014] The soft overmold layer is generally mechanically coupled with the hard shell layer via injection-molded protrusions that thread through different sets of injection mold ports in the hard shell layer. Although, the process could conceivably be reversed, where the hard shell layer is threaded through sets of injection ports within the soft overmold layer. In one embodiment, the soft overmold layer forms mushroom-shaped protrusions which can not be pulled back through the injection mold ports without tearing or otherwise permanently deforming the soft overmold layer. In another embodiment, the soft overmold layer wraps completely around a wall of the hard shell layer and threads through the injection mold port to meet with itself In either case, the soft overmold layer preferably covers common high-impact sights around the exterior wall of the hard shell layer, such as the corners, and preferably comprises at least one raised wall or rib that projects from a surface of the hard shell layer. In a preferred embodiment, the soft overmold layer is distributed along each exterior surface of the hard shell layer such that when the case is placed on a surface in any orientation or direction, no part of the hard shell layer touches the surface upon which the case is placed.
[0015] A ferromagnetic material could be coupled to the hard shell layer, the soft overmold layer, or to both layers to allow for the case to be magnetically coupled to a separate ferromagnetic surface. As used herein, a “ferromagnetic material” is one that is attracted to magnets, and could be magnetized, but is not necessarily a magnet in and of itself Preferably, the ferromagnetic material coupled to the case is not a magnet itself, so as to protect the mobile device case from magnetic waves. Furthermore, the ferromagnetic material is preferably shaped as a plate so as to shunt a magnetic field emanating from magnets attached to the ferromagnetic surface. As used herein, a material shaped as a “plate” is one having a width more than 5 times thinner than its length and/or height. Preferably, the ferromagnetic plate is rectangular-shaped, although other plate shapes are contemplated without departing from the scope of the invention.
[0016] Since ferromagnetic materials tend not to absorb impact very well, the ferromagnetic material is preferably mounted within a recess of the case in order to prevent the ferromagnetic material from being exposed to an impact if the case is dropped upon a hard surface. The ferromagnetic material is preferably made out of a reflective steel so as to provide a surface that doubles as a mirror for the user.
[0017] Using such a mounting, the case could then be mounted to any magnet via the ferromagnetic material. As used herein, a “magnet” is any material that produces a magnetic field, whether a naturally induced magnetic field, such as those produced by neodymium, or an electrically induced magnetic field. Such magnets could be conveniently coupled to a variety of convenient non-ferromagnetic surfaces as temporary mounts for the mobile device case, such as the dashboard of a car, a tabletop, a briefcase, a wall, or a portion of a user's clothing. In an exemplary embodiment, the magnet is coupled to a surface using a permanent adhesive, such as double-sided tape or glue. In another embodiment, the magnet is coupled to a surface using a temporary coupling mechanism, such as a suction cup, a mating indent/detent, or a pair of magnets that wrap around the surface. In a preferred embodiment, where the ferromagnetic plate is located within a recess of the rear surface of the hard shell layer, a portion of the magnet is sized and dimensioned to mate with that recess.
[0018] In a preferred embodiment, the magnet comprises a rear magnetic plate and a front magnetic plate which could couple to a thin non-ferromagnetic material, such as a portion of a user's clothing, by placing the front magnetic plate on a front surface of the thin material, and the rear magnetic plate on a rear surface of the thin material. As used herein, a “thin material” is material that is thinner than the thickness of the case, and is more preferably thinner than half or a quarter of the thickness of the case. The gripping surface of the front and the rear magnetic plate could be lined with a plurality of blunt or sharpened projections or matching recesses/detents to help the front and rear magnetic plates grip to the thin material, especially where the thin material is flexible. Once the magnet is coupled to the thin material, the mobile device case could then be mounted to the thin non-ferromagnetic material by coupling the ferromagnetic plate to the front magnetic plate. In a preferred embodiment, where the ferromagnetic plate is located within a recess of the rear surface of the hard shell layer, the front magnetic plate is sized and dimensioned to mate with that recess.
[0019] The front magnetic plate and the rear magnetic plate could both comprise magnets of substantially similar strength, but could be made of magnets of differing strengths without departing from the scope of the current invention. Preferably, the front magnetic plate, rear magnetic plate, and ferromagnetic plate are all configured such that the magnetic force between the front magnetic plate and rear magnetic plate exceeds the magnetic force between the front magnetic plate and the rear magnetic plate—even when the front magnetic plate and rear magnetic plate are separated by the thin non-ferromagnetic material.
[0020] In some embodiments, a kickstand is coupled with a surface of the case in order to allow for the case to be propped up for viewing on a flat surface. Preferably, the kickstand is sized and disposed so as to prop up the case such that a screen of the mobile device is viewed at from an angle with respect to the flat surface upon which the case is propped up upon. The kickstand may be made from any suitable material, but is preferably made from a rigid material, such as polypropylene, or from the same material as the hard shell layer. The kickstand could further be sized and disposed so as to rest within a recess of the hard shell layer to allow the case to lay flat when the kickstand is not disposed. The kickstand could be removably coupled to hard shell layer using matching indents/detents or some other quick-snap mechanism, but could also be coupled to the hard shell layer using a living hinge.
[0021] Various objects, features, aspects and advantages of the inventive subject matter will become more apparent from the following detailed description of preferred embodiments, along with the accompanying drawing figures in which like numerals represent like components.
BRIEF DESCRIPTION OF THE DRAWING
[0022] FIG. 1 is a front perspective view of an exemplary hard shell layer.
[0023] FIG. 2 is a rear perspective view of the hard shell layer of FIG. 1 .
[0024] FIG. 3 is a front exploded view of an exemplary case, showing a soft overmold layer, the hard shell layer of FIG. 1 , and a ferromagnetic plate.
[0025] FIG. 4 is a rear exploded view of the exemplary case of FIG. 3 .
[0026] FIG. 5 is a front perspective view of the case of FIG. 3 , having a transparent soft overmold layer.
[0027] FIG. 6 is a rear perspective view of the case of FIG. 5 .
[0028] FIG. 7 is an exploded view of the exemplary case separated from the mobile device.
[0029] FIG. 8 is a front perspective view of an exemplary case coupled with a mobile device.
[0030] FIG. 9 is a rear perspective view of the exemplary case of FIG. 8 coupled with a magnet mount.
[0031] FIG. 10 is an exploded view of the exemplary case of FIG. 10 separated from the magnet mount.
[0032] FIG. 11 is a rear perspective view of the exemplary magnet mount of FIG. 10 .
[0033] FIG. 12 is an exploded view of the exemplary magnet mount of FIG. 12 , having a front magnet plate and a rear magnet plate.
[0034] FIG. 13 is an exploded view of the front magnet plate of FIG. 13 .
[0035] FIG. 14 is an exploded view of the rear magnet plate of FIG. 13 .
[0036] FIG. 15 is an exploded view of the kickstand of the exemplary case of FIG. 10 .
[0037] FIG. 16 is a rear perspective view of the exemplary case of FIG. 10 having the kickstand engaged in an upright position.
[0038] FIG. 17 is a front perspective view of the exemplary case of FIG. 10 having the kickstand engaged in a side position.
DETAILED DESCRIPTION
[0039] As used herein, and unless the context dictates otherwise, the term “coupled to” is intended to include both direct coupling (in which two elements that are coupled to each other contact each other) and indirect coupling (in which at least one additional element is located between the two elements). Therefore, the terms “coupled to” and “coupled with” are used synonymously.
[0040] One should appreciate that the disclosed techniques provide many advantageous technical effects including integrally molding a soft overmold layer to a hard shell layer, providing soft protrusions from the soft overmold layer to prevent scratching or otherwise damaging the mobile device or the hard shell layer, providing an easy way to temporarily yet securely mount the mobile device to any surface using a magnetic mount, and providing methods to prop up a mobile device.
[0041] The following discussion provides many example embodiments of the inventive subject matter. Although each embodiment represents a single combination of inventive elements, the inventive subject matter is considered to include all possible combinations of the disclosed elements. Thus if one embodiment comprises elements A, B, and C, and a second embodiment comprises elements B and D, then the inventive subject matter is also considered to include other remaining combinations of A, B, C, or D, even if not explicitly disclosed.
[0042] FIG. 1 shows a hard shell layer 100 having left wall 110 , right wall 120 , rear wall 130 , upper wall 140 , and lower wall 150 . Rear wall 130 has been overmolded to ferromagnetic plate 160 using tabs 137 such that ferromagnetic plate 160 is locked in place along three dimensional axis with respect to hard shell layer 100 . Ferromagnetic plate 160 also has injection ports 164 and 162 which are left open to accept overmolding from a soft overmold layer (not shown).
[0043] Right wall 120 has a set of injection ports 122 along an axis of the wall which are sized and disposed to accept overmolding from a soft overmold layer (not shown). Left wall 110 , conversely, has an upper section 112 and a lower section 114 . While lower section 114 is substantially similar to right wall 120 by having a set of injection ports 115 , upper section 112 has custom ports 113 which are customized to give access to a user interface of a particular mobile device through left wall 110 . Upper wall 140 and lower wall 150 have a shorter height than left wall 110 and right wall 120 , and each has a set of injection ports 142 and 152 , respectively.
[0044] Rear wall 130 has two sets of injection ports 131 and 132 which are placed along each side of rear window 136 . The rear side of each set of injection port has a ledged recess which is sized and disposed to accept a mushroom-shaped overmolding (not shown) from a soft overmold layer to help hold the layer in place against rear wall 130 . Rear wall 130 also has a custom port 133 that is custom-made to give access to a user interface of the mobile device (not shown). While each of the left wall 110 , right wall 120 , rear wall 130 , upper wall 140 , and lower wall 150 have a set of injection ports 115 , 122 , 131 , 142 , and 152 , respectively, more or less sets could be disposed on each wall without departing from the scope of the invention.
[0045] Rear wall 130 also has windows 136 and 138 which form recesses when overmolded upon ferromagnetic plate 160 . The recesses are sized and disposed to accept a magnet (not shown) and a kickstand (not shown) so that each of the magnet and kickstand could rest within the recess and not significantly project outwards from the rear surface of rear wall 130 . Rear wall 130 also has upper lanyard holes 134 and lower lanyard holes 135 which allow a user to thread a small lanyard thread through either the upper holes or the lower holes to attach hard shell layer 100 to a lanyard (not shown). By placing a plurality of lanyard holes within hard shell layer 100 , the case is configured to be attached to a lanyard in multiple directions.
[0046] In FIGS. 3 and 4 , an exploded view of the soft overmold layer 300 , the hard shell layer 100 , and the ferromagnetic plate 160 are shown, separated from one another. As explained above, hard shell layer 100 is generally overmolded over ferromagnetic plate 160 and is held in place within hard shell layer 100 via tabs 137 which line the left and right sides of a window in rear wall 130 . Soft overmold layer 300 is then overmolded over both hard shell layer 100 and ferromagnetic plate 160 and interlocks with hard shell layer 100 in several areas.
[0047] The left wall 310 of soft overmold layer 300 interlocks with each of the injection ports 115 by threading through each of the injection ports. Thus, between each hole 316 in wall 310 , under each set of gripping detents 317 , lies one of injection ports 115 which provides an interlocking segment. Soft volume control buttons 313 also project through one of custom ports 113 to provide access to a volume control user interface buttons on the mobile device itself (not shown). The right wall 320 also interlocks with the set of injection ports 122 by threading through each injection port in the areas between each of the ports 322 under sets of gripping detents (not shown) similar to gripping detents 317 . Upper wall 240 has upper projections 342 which thread through injection ports 142 while lower wall 250 has lower projections 252 that thread through injection ports 152 . Rear wall 330 of soft overmold layer has two sets of mushroom-shaped projections 331 and 332 which thread through each set of injection ports 131 and 132 , respectively, to hold soft overmold layer 300 against rear wall 130 . It should be noted that soft overmold layer 300 also has a projection 362 which threads through injection port 162 in ferromagnetic plate 160 .
[0048] The threading between hard shell layer 100 and soft overmold layer 300 is better illustrated through FIGS. 5 and 6 , which show views of the hard shell layer 100 integrated with a transparent soft overmold layer 300 .
[0049] Use of an exemplary case with a mobile device is illustrated in FIGS. 7 and 8 , where case 700 is shown mating with mobile device 800 . Mobile device 800 is shown here euphemistically as a cellular phone device, however other mobile devices are contemplated, such as laptops, tablets, audio players, and PDA devices. Case 700 has soft projections 710 , 720 , and 730 extending from all corners and flat surfaces of the case to prevent either the hard shell layer 750 of the case or the mobile device 800 from being scratched if case 700 were to fall upon a flat surface. Mobile device 800 has a user interface 802 representing a volume control which is accessible through case 700 through soft buttons 702 , which allow a tactile input through the soft overmold layer to be transmitted to user interface 802 . Mobile device 800 also has a user interface 804 represented as a button which is accessible through a window formed in hard shell layer 750 , and mobile device 800 has a user interface 806 represented as a touch screen which is freely accessible via a user by not being covered by a case at all. Although user interface 806 is not covered by case 700 , user interface 806 is still protected via projections 730 should the case ever fall upon a flat surface on that side of the case.
[0050] Case 700 could also be configured to mate with magnet 900 as shown in FIGS. 9 and 10 by providing an exposed ferromagnetic plate 760 . Magnet 900 also has lanyard holes 910 and 920 which allow case 700 to be removably coupled to a lanyard for convenience. Magnet 900 also has removable backing 930 which could be removed to expose an adhesive surface which could be used to couple magnet 900 in a permanent manner to any of a variety of surfaces, such as a table top, a wall, or a car dashboard. While magnet 900 is currently shown as projecting slightly from the rear surface of case 700 when in its mated position, magnet 900 could be configured with a thinner thickness so as to be substantially flush with the rear surface of case 700 without departing from the scope of the invention. As used herein, “Substantially flush” means a surface which does not recess or project from another surface by more than 2 mm, and more preferably by no more than 1 mm.
[0051] In an exemplary embodiment, magnet 900 could be composed of two parts, rear magnetic plate 1100 and front magnetic plate 1200 , as shown in FIGS. 11 and 12 , which both work cooperatively to allow magnet 900 to couple to a non-ferromagnetic object (not shown) that is placed in between rear magnet 1100 and front magnet 1200 . Contemplated non-ferromagnetic objects include clothing and wall partitions.
[0052] FIG. 13 shows rear magnetic plate 1100 having recesses 1110 and 1120 which couple to magnets 1130 and 1140 , respectively. Mushroom-shaped 1112 and 1122 could be overmolded to magnets 1130 and 1140 , although other coupling mechanisms could be used, such as adhesives or a recess comprising a ferromagnetic wall. Rear magnetic plate 1100 could also have gripping projections 1150 which could be used to provide additional grip to an intervening non-ferromagnetic surface disposed between rear magnetic plate 1100 and front magnetic plate 1200 . Similar to rear magnetic plate 1100 , FIG. 14 shows front magnetic plate 1200 having recesses 1210 and 1220 , which both couple to magnets 1230 and 1240 , respectively, using mushroom-shaped projections 1212 and 1222 , respectively. Magnets 1130 , 1140 , 1230 , and 1240 are preferably strong earth metal-type magnets, such as neodymium, but could be made from other magnetic material without departing from the scope of the invention. In an alternative embodiment, magnets 1130 and 1140 could be substituted with a ferromagnetic metal.
[0053] FIG. 15 shows an exploded view of an exemplary kickstand 1500 having a main body 1520 and a lock 1510 . When lock 1510 is disengaged from main body 1520 , the proximal end of main body 1520 could be squeezed, allowing projections 1524 to fit within recess 1610 in case 1600 . Then, when kickstand 1500 is properly placed within recess 1610 , projection 1512 could then be snapped into recess 1522 to lock projections 1524 in place, which then act as a hinge for kickstand 1500 . In this manner, kickstand 1500 could be easily replaced should it get damaged or worn down in the future. By kickstand 1500 within 1, 2, or 3 cm from the edge of case 1600 , kickstand 1500 could be used to prop case 1600 upright as shown in FIG. 16 , or on its side as shown in FIG. 17 .
[0054] It should be apparent to those skilled in the art that many more modifications besides those already described are possible without departing from the inventive concepts herein. The inventive subject matter, therefore, is not to be restricted except in the scope of the appended claims. Moreover, in interpreting both the specification and the claims, all terms should be interpreted in the broadest possible manner consistent with the context. In particular, the terms “comprises” and “comprising” should be interpreted as referring to elements, components, or steps in a non-exclusive manner, indicating that the referenced elements, components, or steps may be present, or utilized, or combined with other elements, components, or steps that are not expressly referenced. Where the specification claims refers to at least one of something selected from the group consisting of A, B, C . . . and N, the text should be interpreted as requiring only one element from the group, not A plus N, or B plus N, etc. | A modular case for a mobile device is formed by providing a hard shell layer within a soft overmold layer. The soft overmold layer preferably lines both an inner and an outer surface of the hard shell layer so as to both protect the mobile device from scratches and to distribute any impact forces to the case across the surface of the soft overmold layer. The hard shell layer generally has multiple sets of injection mold ports so that when the soft overmold layer is formed over the hard shell layer, the soft overmold layer threads through the injection ports, providing an interlocking union of the two layers. | 0 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of Korean Patent Application No. 10-2008-0122426 filed on Dec. 4, 2008, in the Korean Intellectual Property Office, the disclosure of which is incorporated herein by reference.
BACKGROUND
[0002] 1. Field
[0003] The present invention relates to a refrigerator and a method of controlling the same. More particularly, the present invention relates to a refrigerator equipped with a door opening device enabling a user to easily open a door of the refrigerator and a method of controlling the refrigerator.
[0004] 2. Description of the Related Art
[0005] Generally, a refrigerator cools articles stored therein through a cooling cycle of a compressor, a condenser, and an evaporator. The refrigerator is provided therein with a storage compartment to allow a user to store and take out the articles in the refrigerator. The refrigerator includes at least one storage compartment according to the capacity of the refrigerator. For example, the storage compartment may be divided into two compartments, such as a cooling compartment and a refrigerating compartment, or may be divided into four compartments, such as a cooling compartment, a refrigerating compartment, an auxiliary cooling compartment, and an auxiliary refrigerating compartment.
[0006] Meanwhile, the refrigerator having at least one storage compartment includes a door, which opens/closes the storage compartment. The door is divided into a hinge coupling type door that is rotatably open/closed relative to the storage compartment and a drawer type door that is open/closed relative to the storage compartment like a drawer.
[0007] Meanwhile, typically, a user must pull a door of a refrigerator when the user wants to manually open the door. In addition, when the user wants to close the door, the user must push the door using a hand or a foot such that the door can be closed by the weight thereof.
SUMMARY
[0008] Accordingly, it is an aspect of the present invention to provide a refrigerator and a method of controlling the same, capable of automatically opening/closing a door using a motor.
[0009] In addition, it is another aspect of the present invention to provide a refrigerator and a method of controlling the same, capable of reducing noise in the process of changing a direction of a motor when a door is open/closed.
[0010] Further, it is still another aspect of the present invention to provide a refrigerator and a method of controlling the same, capable of setting a door in an initial position when the refrigerator is powered on.
[0011] Additional aspects and/or advantages of the invention will be set forth in part in the description which follows and, in part, will be apparent from the description, or may be learned by practice of the invention.
[0012] The foregoing and/or other aspects of the present invention are achieved by providing a refrigerator including first and second doors which open/close first and second storage compartments defined in a body, respectively, and a door opening device. The door opening device includes a plurality of sliding bars which selectively open the first and second doors, and a motor which opens/closes the first door or the second door by moving back and forth the sliding bars in directions opposite to each other.
[0013] The door opening device may further include a switch unit inputting a door opening signal used to open the first door or the second door.
[0014] The door opening device may further include a controller controlling the first door or the second door to be open according to the door opening signal input to the switch unit.
[0015] The door opening device may further include a plurality of position detectors detecting at least one protrusion provided at one side of the sliding bars.
[0016] The door opening device may further include a display unit displaying failure of the door opening device.
[0017] According to another aspect of the present invention, there is provided a method of controlling a refrigerator including a door opening device, which includes first and second doors opening/closing first and second storage compartments defined in a body, a plurality of sliding bars selectively opening the first and second doors, a motor opening the first door or the second door by moving back and forth the sliding bars in directions opposite to each other, a plurality of position detectors detecting at least one protrusion provided in one side of the sliding bars, a switch unit inputting door opening signals, and a controller controlling operation of the first and second doors according to the door opening signals, and the method includes opening/closing the first and second doors by controlling the door opening device if the door opening signals are input in order to open the first door or the second door.
[0018] The sliding bar may be moved by driving the motor for a first set time sufficient for enabling the at least one protrusion to deviate from a detection region of the position detector if the door opening signals are input.
[0019] A time point, at which the at least one protrusion enters the detection region of the position detector, is recognized if the first set time elapses.
[0020] The sliding bar may be moved by driving the motor for a second set time sufficient for enabling the at least one protrusion to enter a reliable detection region of the position detector if the at least one protrusion has entered the detection region of the position detector.
[0021] The motor may be stopped if the second set time elapses, so that the first door or the second door maintains an open state for a third set time.
[0022] The sliding bar may be moved by driving the motor for a fourth set time sufficient for enabling the at least one protrusion to deviate from the detection region of the position detector if the third set time elapses.
[0023] The time point, at which the at least one protrusion enters the detection region of the position detector, is recognized if the fourth set time elapses.
[0024] The sliding bar may be moved by driving the motor for a fifth set time sufficient for enabling the at least one protrusion to enter the reliable detection region of the position detector if the at least one protrusion has entered the detection region of the position detector.
[0025] If the door opening signals of the first and second doors are simultaneously input, the controller may determine an input sequence of the door opening signals to recognize only the door opening signal that is primarily input such that one of the first and second doors corresponding to the primary door opening signal is open.
[0026] If the door opening signals of the first and second doors are simultaneously input, the controller may not recognize all the door opening signal, or recognizes only the door opening signal of a preset door.
[0027] If the door opening signal for one of the first and second doors is input when a remaining one door is open/closed, the door opening signal may not be recognized.
[0028] According to still another aspect of the present invention, there is provided a method of controlling a refrigerator equipped with first and second doors opening/closing first and second storage compartments partitioned in a body. The refrigerator includes a door opening device including a plurality of sliding bars selectively opening the first and second doors, a motor opening the first door or the second door by moving back and forth the sliding bars in directions opposite to each other, a plurality of position detectors detecting at least one protrusion provided at one side of the sliding bar, a switch unit inputting door opening signals, and a controller controlling operation of the first door and the second door according to the door opening signals. The method of controlling the refrigerator includes detecting a position of the at least one protrusion if the refrigerator is powered on, and controlling the first and second doors to be closed according to a position of the at least one protrusion.
[0029] The method may further include rotating the motor in one preset direction if the position of the at least one protrusion is not detected.
[0030] The method may further include controlling the first and second doors such that the first and second doors are closed according to the position of the at least one protrusion if the position of the at least one protrusion is detected due to the rotating of the motor.
[0031] The method may further include recognizing that the at least one protrusion is placed at a preset position if the at least one position of the protrusion is not detected.
[0032] The method may further include controlling the first and second doors such that the first and second doors are closed according to the at least one position of the protrusion.
[0033] If the position of the at least one protrusion is not detected for a predetermined time when the first and second doors are controlled to be closed, the door opening device may be regarded as failed.
[0034] The door opening device may further include a display unit, and the display unit displays failure of the door opening device if the door opening device is regarded as failed.
[0035] As described above, according to one aspect, a plurality of doors can be open by moving two sliding bars using one motor, so that the manufacturing cost can be reduced.
[0036] According to another aspect, when a door is open due to the rotation of the motor, or the door position is changed from the maximum open state to a closed state, the operation of the door is performed after a predetermined time has elapsed, so that noise can be reduced when the door is open/closed.
[0037] According to still another aspect, when power is turned off and then turn on due to cut-off of electric current, a state of the door can be exactly determined by the position detectors, so that the door can return to a waiting state without an unnecessary operation.
BRIEF DESCRIPTION OF THE DRAWINGS
[0038] 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:
[0039] FIG. 1 is a view showing a refrigerator employing a door opening device according to one embodiment;
[0040] FIG. 2 is a control block diagram showing the door opening device according to one embodiment;
[0041] FIGS. 3A to 3C are schematic views showing a door opening device according to a first embodiment;
[0042] FIG. 4 is a view showing a table representing the detection state of position detectors based on the open state of doors according to the first embodiment;
[0043] FIGS. 5A and 5B are flowcharts showing the control procedure of the door opening device according to the first embodiment;
[0044] FIG. 6 is a flowchart showing an initialization operation when the door opening device is powered on according to the first embodiment;
[0045] FIGS. 7A to 7E are sectional views schematically showing a door opening device according to a second embodiment;
[0046] FIG. 8 is a table showing the detection state of position detectors when a door is open according to the second embodiment; and
[0047] FIG. 9 is a flowchart showing an initialization operation of the door opening device upon a power-on state according to the second embodiment.
DETAILED DESCRIPTION OF EMBODIMENTS
[0048] Reference will now be made in detail to the embodiments, examples of which are illustrated in the accompanying drawings, wherein like reference numerals refer to the like elements. The embodiments are described below by referring to the figures.
[0049] FIG. 1 is a view showing a refrigerator employing a door opening device 20 according to one embodiment.
[0050] As shown in FIG. 1 , the refrigerator according to one embodiment includes a body 10 divided into a first storage compartment (not shown) and a second compartment (not shown). First and second doors 11 and 12 are installed at both sides of a front surface of the body 10 to open/close the first and second storage compartments. Generally, in such a refrigerator, the first storage compartment serves as a cooling compartment, and the second storage compartment serves as a refrigerating compartment. Upper and lower portions of the first and second doors 11 and 12 are pivotally coupled to the body 10 by a hinge assembly 13 . In addition, first and second handles 14 and 15 are provided on front surfaces of the first and second doors 11 and 12 .
[0051] The door opening device 20 may be mounted on a top surface of the body 10 to push the upper portions of the first and second doors 11 and 12 forward and open the first and second doors 11 and 12 , so that a user can easily open the first and second doors 11 and 12 .
[0052] FIG. 2 is a control block diagram showing the door opening device 20 according to one embodiment.
[0053] As shown in FIG. 2 , the door opening device 20 includes first and second switch units 16 and 17 allowing a user to input a door opening signal, first, second, and third position detectors 31 , 32 , and 33 detecting positions of first and second sliding bars 40 and 41 , a memory 34 storing a program to control the operation of a motor 38 , a timer 35 measuring a driving time of the motor 38 , a controller 30 controlling the driving of the motor 38 using information from the first to third position detectors 31 to 33 and the timer 35 , a motor driver 36 driving the motor 38 under the control of the controller 30 , and a display unit 37 displaying the failure of the door opening device 20 .
[0054] The first and second switch units 16 and 17 are provided at the first and second handles 14 and 15 of the first and second doors 11 and 12 to allow a user to control the operation of the motor 38 . The first and second switch units 16 and 17 may be detectors that detect touch of the user on the first and second handles 14 and 15 , or power switches that directly turn on/off power applied to the motor 38 .
[0055] The first to third position detectors 31 to 33 may detect a rotation position of the motor 38 , that is, a position of the first and second sliding bars 40 and 41 . The first to third position detectors 31 , 32 , and 33 may detect the rotation position of the motor 38 by detecting first, second, and third protrusions 42 , 43 , and 44 . In addition, the first to third position detectors 31 to 33 may be a typical optical sensor. According to the present embodiment, the first to third position detectors 31 to 33 are turned on if a signal phase is changed due to the first and second protrusions 42 and 43 , and turned off if the signal phase is not changed.
[0056] The memory 34 stores a program to control the operation of the motor 38 , and the timer 35 can measure the driving time of the motor 38 .
[0057] The controller 30 can transmit an operational control signal for the motor 38 to the motor driver 36 according to the program previously stored in the memory 34 by using door opening signals of the first and second switches 16 and 17 , information delivered from the first to third position detectors 31 to 33 , and the timer 35 .
[0058] The display unit 37 may be a display (not shown) positioned on the front surface of the body 10 of the refrigerator, and can display the failure of the door opening device 20 .
[0059] FIGS. 3A to 3C are schematic views showing the door opening device 20 according to a first embodiment of the present invention.
[0060] As shown in FIG. 3A , the door opening device 20 according to the first embodiment includes the first and second sliding bars 40 and 41 capable of selectively opening the two first and second doors 11 and 12 , the motor 38 moving the sliding first and second bars 40 and 41 , the first and second position detectors 31 and 32 capable of detecting the positions of the first and second sliding bars 40 and 41 , and the first and second protrusions 42 and 43 protruding from one side of the first sliding bar 40 to be detected by the first and second position detectors 31 and 32 .
[0061] The first and second sliding bars 40 and 41 are geared with both sides of the motor 38 (e.g., a rack and a pinion assembly) to selectively push the two first and second doors 11 and 12 . The two first and second protrusions 42 and 43 are provided on the first sliding bar 40 to detect the position of the first sliding bar 40 by the first and second position detectors 31 and 32 . Meanwhile, as shown in FIG. 3A , although the two first and second protrusions 42 and 43 are provided at one side of the first sliding bar 40 , the two first and second protrusions 42 and 43 may be provided at one side of the second sliding bar 41 .
[0062] The motor 38 is geared with the first and second sliding bars 40 and 41 (e.g., a rack and a pinion assembly) to rotate. When the motor 38 rotates in a first direction (clockwise), the first door 11 can be open by the first sliding bar 40 . When the motor 38 rotates in a second direction (counterclockwise), the second door 12 can be open by the second sliding bar 41 .
[0063] The first and second position detectors 31 and 32 may be installed in order to detect the rotation position of the motor 38 , that is, the position of the first sliding bar 40 . The first and second position detectors 31 and 32 detect the two first and second protrusions 42 and 43 of the first sliding bar 40 through an optical sensor (not shown) to detect the rotation position of the motor 38 . In addition, the first and second position detectors 31 and 32 include typical optical sensors. According to one embodiment, the first and second position detectors 31 and 32 are turned on if the signal phase is changed by the two first and second protrusions 42 and 43 , and turned off if the signal phase is not changed.
[0064] Meanwhile, the present invention is not limited to the first and second position detectors 31 and 32 , but can employ a lead switch to detect the positions of the first and second protrusions 42 and 43 and a limit switch to detect the positions of the first and second protrusions 42 and 43 in the contact with the first and second protrusions 42 and 43 .
[0065] Hereinafter, the operation of the door opening device 20 will be described with reference to FIGS. 3B and 3C .
[0066] If a user grasps or pulls the second handle 15 of the first door 11 in order to open the first door 11 , the motor 38 operates with the manipulation of the second switch unit 17 . In this case, as shown in FIG. 3B , the motor 38 rotates in the first direction (clockwise) to push the first sliding bar 40 geared with the motor 38 (e.g., a rack and a pinion assembly) forward so that the first door 11 can be opened. If the first position detector 31 detects the second protrusion 43 of the first sliding bar 40 , and the second position detector 32 does not detect any protrusion, it is determined that the first door 11 is at the maximum open state, and the motor 38 is stopped. Meanwhile, according to one embodiment, when open commands of the first and second doors 11 and 12 are issued, the first and second doors 11 and 12 are open through the driving of the motor 38 , and then, when a predetermined time elapses, the first and second doors 11 and 12 are closed. Details thereof will be described later.
[0067] In addition, if the user grasps or pulls the first handle 14 of the second door 12 in order to open the second door 12 , the motor 38 rotates in the second direction (counterclockwise) with the manipulation of the first switch unit 16 to push the second sliding bar 41 forward, so that the second door 12 is open. In addition, if the second position detector 32 detects the first protrusion 42 , and the first position detector 31 does not detect any protrusion, it is determined that the door 12 has the maximum open state, and the motor 38 is stopped.
[0068] FIG. 4 is a view showing a table representing the detection state of the first and second position detectors 31 and 32 based on the open state of the first and second doors 11 and 12 according to the first embodiment.
[0069] As shown in FIG. 4 , when the first and second position detectors 31 and 32 detect all of the first and second protrusions 42 and 43 , the first and second doors 11 and 12 of the refrigerator are in a waiting state, that is, a closed state.
[0070] In addition, if the first position detector 31 detects a protrusion, and the second position detector 32 does not detect a protrusion, the controller 30 determines that the first door 11 is open. In contrast, if the first position detector 31 does not any protrusion, and the second position detector 32 detects a protrusion, the controller 30 determines that the second door 12 is open.
[0071] If both of the first and second position detectors 31 and 32 do not detect the first and second protrusions 42 and 43 , the controller 30 may determine that the first door 11 or the second door 12 is open or is being opened.
[0072] FIGS. 5A and 5B are flowcharts showing the control procedure of the door opening device 20 according to the first embodiment.
[0073] As shown in FIG. 5A , if an open command of the first door 11 or the second door 12 of the refrigerator according to one embodiment is input, the motor 38 is driven. In other words, if a user grasps or pulls the first or second switch unit 16 or 17 provided on the first or second handle 14 or 15 of the first or second door 11 or 12 to control the operation of the motor 38 , the motor 38 is driven with the operation of the first or second switch unit 16 or 17 . In detail, if the user manipulates the second switch 17 provided on the second handle 15 of the first door 11 , the motor 38 rotates in the first direction (clockwise). If the user manipulates the first switch 16 provided on the first handle 14 , the motor 38 rotates in the second direction (counterclockwise) (operation S 10 and S 20 ).
[0074] Subsequently, if the motor 38 is driven due to the user manipulation of the first switch unit 16 or the second switch unit 17 , the controller 30 measures a time, in which the motor 38 is driven, to determine if a first preset time elapses. The first preset time is previously stored in the memory 34 , and is obtained by experimentally calculating a time spent until the first and second protrusions 42 and 43 of the first sliding bar 40 deviate from detection regions of the first and second position detectors 31 and 32 after the motor 38 in the waiting state is driven (operation S 30 ).
[0075] Next, if the controller 30 determines that the first preset time has elapsed in operation S 30 , the controller 30 determines if a first state comes. In this case, the first state means an initial time point at which the first protrusion 42 enters the detection region of the second position detector 32 or the second protrusion 43 enters the detection region of the first position detector 31 due to continuous rotation of the motor 38 after the first and second protrusions 42 and 43 of the first sliding bar 40 have deviated from the detection regions of the first and second position detectors 31 and 32 (operation S 40 ).
[0076] Thereafter, the controller 30 determines if a second preset time elapses after the first state is determined in operation S 40 . The second preset time is previously stored in the memory 34 , and means a time spent until the first protrusion 42 of the first sliding bar 40 or the second protrusion 43 moves into a reliable detection region of the second position sensor 32 or the first position sensor 31 from the initial time point at which the first protrusion 42 enters the detection region of the second position detector 32 or the second protrusion 43 enters the detection region of the first position detector 31 (operation S 50 ).
[0077] Next, if the controller 30 determines that the second preset time has elapsed in operation S 50 , the controller 30 stops the motor 38 and determines if a third preset time elapses. In this case, the third preset time is previously stored in the memory 34 , and means a time, in which the motor 38 is stopped, in order to reduce noise created when the direction of the motor 38 is changed (operations S 60 and S 70 ).
[0078] As shown in FIG. 5B , if the third preset time has elapsed in operation S 70 , the controller 30 drives the motor 38 . In other words, the controller 30 rotates the motor 38 in directions opposite to a direction, in which the motor 38 has rotated in operations S 20 to S 50 , to commence to close the first door 11 or the second door 12 again (operation S 80 ).
[0079] Then, if the motor 38 is driven, the controller 30 measures the driving time of the motor 38 to determine if a fourth preset time has elapsed. The fourth preset time is previously stored in the memory 34 . In addition, the fourth preset time is obtained by experimentally calculating a time spent until the motor 38 is driven in a door open state so that the first protrusion 42 or the second protrusion 43 of the sliding bar 40 deviates from the detection region of the second position detector 32 or the first position detector 31 (operation S 90 ).
[0080] Thereafter, if the fourth preset time has elapsed in operation S 90 , the controller 30 determines if a second state comes. The second state means an initial time point at which the first and second protrusions 42 and 43 of the first sliding bar 30 enter the detection regions of the first and second position detectors 31 and 32 due to the continuous rotation of the motor 38 after the first protrusion 42 or the second protrusion has deviated from the detection region of the second position detector 32 or the first position detector 31 (operation S 100 ).
[0081] Then, the controller 30 determines if a fifth preset time has elapsed after the second state has come in operation S 100 . The fifth preset time is previously stored in the memory 34 , and means a time spent until the first protrusion 42 or the second protrusion 43 of the first sliding bar 40 moves into the reliable region of the second position detector 32 or the first position detector 31 from the initial time point at which the first protrusion 42 or the second protrusion 43 enters the detection region of the second position detector 32 or the first position detector 31 (operation S 110 ).
[0082] Thereafter, if the fifth preset time has elapsed in operation S 110 , the controller 30 stops the motor 38 to terminate a door opening/closing operation (operation S 120 ).
[0083] Meanwhile, the above operational procedure prevents the motor 38 from erroneously operating due to chattering. The chattering refers to a phenomenon in which an electrical contact is abnormally turned on/off for a very short time due to mechanical vibration. According to the present embodiment, the above operation procedure is performed in order to drive the motor 38 for several times previously stored in the memory 34 and open/close the first door 11 or the second door 12 , so that the motor 38 moves the sliding bar 40 or 41 into a reliable detection region of the position detectors 31 and 32 .
[0084] FIG. 6 is a flowchart showing an initialization operation when the door opening device 20 is powered on according to the first embodiment.
[0085] As shown in FIG. 6 , if power is applied to the refrigerator, the controller 30 turns on the timer 35 to set time (T) to ‘0’ (operations S 200 and S 210 ).
[0086] Then, the controller 30 determines if the time (T) of the timer 35 exceeds a preset time T. If the time (T) does not exceed the preset time T, the controller 30 determines if the first door 11 or the second door 12 of the refrigerator stays in a waiting state. In other words, the controller 30 determines if the first and second protrusions 42 and 43 are simultaneously detected by the second and first position detectors 32 and 31 , respectively, to determine if both of the first and second doors 11 and 12 are closed (operations S 220 and S 230 ).
[0087] Thereafter, if the first door 11 or the second door 12 of the refrigerator is in the waiting state in operation S 230 when power is applied to the first door 11 or the second door 12 of the refrigerator, the controller 30 determines the operational state of the motor 38 . If the motor 38 is driven, the controller 30 stops the operation of the motor 38 to terminate the initialization operation. However, if the first door 11 or the second door 12 is in the waiting state when power is applied to the refrigerator, since the motor 38 is in a stop state, the initialization operation is instantly terminated (operations S 260 and S 270 ).
[0088] Meanwhile, if the first door 11 or the second door 12 is not in the waiting state in operation S 230 , the controller 30 determines if the first door 11 is open. In other words, the controller 30 determines if the second protrusion 43 of the sliding bar 40 is detected by the first position detector 31 . However, the first and second position detectors 31 and 32 do not detect the type of the first and second protrusions 42 and 43 . Accordingly, if the first position detector 31 detects a protrusion, and the second position detector 32 does not detect a protrusion, the controller 30 determines that the first door 11 is open through the program previously stored in the memory 34 (operation S 240 ).
[0089] Thereafter, if the controller 30 determines that the first door 11 is open in operation S 240 , the controller 30 rotates the motor 38 in the second direction (counterclockwise) to move the first sliding bar 40 such that the first door 11 is closed (operation S 280 ).
[0090] Then, if the controller 30 determines that the first door 11 is not open in operation S 240 , the controller 30 determines if the second door 12 is open. In other words, the controller 30 determines that the first protrusion 42 of the first sliding bar 40 is detected by the second position detector 32 . However, the first and second position detectors 31 and 32 do not detect the type of the protrusions 42 and 43 . Accordingly, if the second position detector 32 detects the protrusion, and the first position detector 31 does not detect the protrusion, the controller 30 determines that the second door 12 is open through the program previously stored in the memory 34 (operation S 250 ).
[0091] Thereafter, if the controller 30 determines that the second door 12 is open in operation S 250 , the controller 30 rotates the motor 38 in the first direction (clockwise) to move the first sliding bar 40 such that the second door 12 is closed (operation S 290 ).
[0092] Meanwhile, if the controller 30 determines that the first door 11 or the second door 12 is not in any one of the waiting state, a first door open state, and a second door open state in operations S 230 to S 250 , the controller 30 rotates the motor 38 in a reference direction stored in the memory 34 . In other words, in the case of an open state of a certain door as shown in the table of FIG. 4 , that is, in the case in which the first and second position detectors 31 and 32 do not detect any protrusion, the controller 30 rotates the motor 38 in a preset direction and returns to operation S 220 to determine the state of the first door 11 or the second door 12 (operation S 300 ).
[0093] Thereafter, if the motor 38 is rotated in operations S 280 to S 300 , the controller 30 returns to operation S 220 to determine if the time T of the timer 45 exceeds the preset time T 1 . If the time T of the timer 45 does not the preset time T 1 , the controller 30 determines if the doors 11 and 12 are adjusted to the waiting state due to the rotation of the motor 38 . In this case, if the doors 11 and 12 do not become the waiting state until the time T of the timer 45 exceeds the preset time T 1 , the controller 30 stops the operation of the motor 38 , determines that the door opening device 20 is failed, and displays the failure of the door opening device 20 on the display unit 37 (operations S 310 to S 330 ).
[0094] If the door 11 or 12 becomes the waiting state within the preset time T 1 through the above procedure, the controller 30 determines the operational state of the motor 38 and then stops the motor 38 to terminate the initialization operation (operations S 260 and S 270 ).
[0095] FIGS. 7A to 7E are sectional views schematically showing the door opening device 20 according to a second embodiment, and FIG. 8 is a table showing detection states of position detectors as a door is open according to the second embodiment of the present invention. Meanwhile, the same reference numerals will be assigned to elements identical to those of FIG. 3A .
[0096] As shown in FIG. 7A , a door opening device 20 according to the second embodiment includes first and second sliding bars 40 and 41 capable of selectively opening two first and second doors 11 and 12 , a motor 38 moving the first and second sliding bars 40 and 41 , first, second, and third position detectors 31 , 32 , and 33 capable of detecting positions of the first and second sliding bars 40 and 41 , and first, second, and third protrusions 42 , 43 , and 44 protruding from one sides of the first and second sliding bars 40 and 41 to be detected by the first to third position detectors 31 to 33 .
[0097] The sliding bars 40 and 41 are geared with both sides of the motor 38 (e.g., a rack and a pinion assembly) such that the two first and second doors 11 and 12 can be selectively pushed, and the two first and second protrusions 42 and 43 are provided on the first sliding bar 40 to be detected by the first and second position detectors 31 and 32 . One protrusion 44 is provided on the second sliding bar 41 , so that the position of the second sliding bar 41 can be detected by the third position detector 33 .
[0098] The motor 38 is geared with the first and second sliding bars 40 and 41 (e.g., a rack and a pinion assembly) to rotate. When the motor 30 rotates in a first direction (clockwise), the first door 11 is open by the first sliding bar 40 . When the motor 38 rotates in a second direction (counterclockwise), the second door 12 can be open by the second sliding bar 41 .
[0099] The first to third position detectors 31 to 33 detect the rotation position of the motor 38 , that is, positions of the first and second sliding bars 40 and 41 . In detail, the first to third position detectors 31 to 33 can detect magnets (not shown) provided in the three protrusions 42 , 43 , and 44 to detect the rotation position of the motor 38 .
[0100] Meanwhile, when both of the two first and second doors 11 and 12 are closed, that is, when both of the two first and second doors 11 and 12 are in a waiting state, the first and second position detectors 31 and 32 detect the second and third protrusions 42 and 43 , and the third position detector 33 does not detect the third protrusion 44 .
[0101] Hereinafter, the operation of the door opening device 20 will be described with reference to FIGS. 7B to 7E .
[0102] As shown in FIGS. 7B , 7 C, and FIG. 8 , if a user grasps or pulls a handle 15 of the first door 11 in order to open the first door 11 , the motor 38 is driven with the manipulation of a second switch unit 17 . In this case, as shown in FIG. 7B , since the motor 38 rotates in the first direction (clockwise) to push the sliding bar 40 forward, the door 11 is open. Further, when the first to third position detectors 31 to 33 do not detect the first to third protrusions 42 to 44 of the first and second sliding bars 40 and 41 , the controller 30 recognizes an open state A of the first door 11 .
[0103] As shown in FIG. 7C , when the motor 38 rotates in the first direction (clockwise) so that the first position detector 31 detects the second protrusion 43 , and the second and third position detectors 32 and 33 do not detect any protrusions of the first and second sliding bars 40 and 41 , the controller 30 recognizes a maximum open state A of the first door 11 .
[0104] In addition, as shown in FIGS. 7D , 7 E, and FIG. 8 , if the user grasps or pulse a first handle 14 of the second door 12 in order to open the second door 12 , the motor 38 is driven with the manipulation of a first switch unit 16 . In this case, as shown in FIG. 7D , since the motor 38 rotates in the second direction (counterclockwise) to push the second sliding bar 41 forward, the second door 12 is open. Further, if the first and second position detectors 31 and 32 do not detect the first and second protrusions 42 and 43 , and the third position detector 33 detects the third protrusion 44 , the controller 30 recognizes the open state B of the second door 12 .
[0105] In addition, as shown in FIG. 7E , the motor 38 rotates in the second direction (counterclockwise), so that the second and third position detectors 32 and 33 detect the first and third protrusions 42 and 44 , and the first position detector 31 does not detect the second protrusion 43 of the sliding bar 40 , the controller 30 recognizes the maximum open state A of the second door 12 .
[0106] FIG. 9 is a flowchart showing an initialization operation of the door opening device 20 upon a power-on state according to the second embodiment.
[0107] As shown in FIG. 9 , if the refrigerator is powered on, the controller 30 turns on a timer 35 to set a time T of the timer to 0 (operations S 400 and S 410 ).
[0108] Then, the controller 30 determines if the time T of the timer 35 exceeds a preset time T 1 . If the time T does not exceed the preset time T 1 , the controller 30 determines if the first and second doors 11 and 12 of the refrigerator are in the waiting state. In other words, the controller 30 determines if the first and second protrusions 42 and 43 of the first sliding bar 40 are detected by the first and second position detectors 31 and 32 , and the third position detector 33 does not detect the protrusion 44 , to determine the closed state of the first and second doors 11 and 12 (operations S 420 and S 430 )
[0109] Next, if the controller 30 determines that both of the first and second doors 11 and 12 are in the waiting state when the refrigerator is powered on in operation S 430 , the controller 30 determines the operational state of the motor 38 . Accordingly, if the motor 48 is operating, the controller 30 stops the rotation of the motor 38 and terminates the initialization operation. However, if the first and second doors 11 and 12 are in the waiting state when the refrigerator is powered on, since the motor 38 has been stopped, the initialization operation is instantly terminated (operations S 450 and S 460 ).
[0110] Meanwhile, the controller 30 determines that both of the first and second doors 11 and 12 of the refrigerator are not in the waiting state in operation S 430 , the controller 30 determines if the third protrusion 44 is detected by the third position detector 33 . In other words, the controller 30 determines if the third protrusion 33 of the second sliding bar 41 is detected by the third position detector 44 .
[0111] Thereafter, the controller 30 determines that the door 12 is open if the third protrusion 44 is detected by the third position detector 33 in operation S 440 , and rotates the motor 38 in the first direction (clockwise) to move the second sliding bar 41 such that the second door 12 is closed (operation S 470 ).
[0112] Therefore, the controller 30 determines that the first door 11 is open if the third protrusion 44 is not detected by the third position detector 33 , and rotates the motor 38 in the second direction (counterclockwise) to move the first sliding bar 40 such that the first door 11 is closed in operation S 470 . In other words, the controller 30 determines that the second door 12 is open if the third protrusion 44 is detected by the third position detector 33 , and the first door 11 is open if the third protrusion 44 is not detected by the third position detector 33 according to the program stored in the memory 34 . Accordingly, the controller 30 rotates the motor 38 such that the two first and second doors 11 and 12 are regulated to be closed, that is, be in the waiting state (operation S 480 ).
[0113] If the motor 38 rotates in operations S 470 to S 480 , the controller 30 returns to operation S 420 to determine if the time T of the timer 35 exceeds the preset time T 1 . If the time T of the timer 35 does not exceed the time T 1 , the controller 30 repeats operations S 430 to S 440 . In this case, if the first and second doors 11 and 12 do not reach the waiting state until the time T of the timer 35 exceeds the time T 1 , the controller 30 stops the motor 38 , determines that the door opening device 20 is failed, and displays the failure of the door opening device 20 on the display unit 37 (operations S 490 to S 510 ).
[0114] However, if the first and second doors 11 and 12 reach the waiting state within the preset time T 1 through the above procedure, the controller 30 determines the operational state of the motor 38 and then stops the motor 38 , thereby terminating the initialization operation (operations S 450 and S 460 ).
[0115] Although few embodiments have been shown and described, it would be appreciated by those skilled in the art that changes may be made in these embodiments without departing from the principles and spirit of the invention, the scope of which is defined in the claims and their equivalents. | A refrigerator equipped with a door opening device opening doors by driving a motor and a method of controlling the same. In the method of controlling the refrigerator includes a door opening device including a plurality of sliding bars selectively opening first and second doors, a motor opening the first door or the second door by moving back and forth the sliding bars in directions opposite to each other, a plurality of position detectors detecting at least one protrusion provided at one side of the sliding bar, a switch unit inputting door opening signals, and a controller controlling operation of the first door and the second door according to the door opening signals. If door opening signals used to open the first and second doors, the door opening device is controlled so that the first and second doors are easily open/closed. | 4 |
This application is a continuation-in-part of our commonly assigned, U.S. patent application Ser. No. 08/052,456 filed Apr. 26, 1993, entitled "A Method For Reducing Fuzz In The Production Of Saturating Kraft Paper"; which is a continuation-in-part of our commonly assigned, U.S. patent application Ser. No. 07/887,697 filed May 22, 1992, now both abandoned.
FIELD OF INVENTION
The invention relates to an improvement in the art of making saturating kraft paper. In particular, the invention relates to a method for reducing the amount of fuzz generated by the production and use of saturating kraft paper. The improved saturating kraft paper is particularly useful in the production of laminated materials.
BACKGROUND OF THE INVENTION
Paper is a network of crossing fibers, more or less bonded to each other. Loose ends from some of these fibers project above the surface of the paper. As the paper proceeds through different machinery some of these fibers are pulled free, producing what is known in the industry as fuzz, dust, or lint.
Saturating kraft is a special type of absorbent paper used primarily for the core stock of decorative laminates. Fuzz released from saturating kraft has traditionally been a major problem for laminate producers. During the production of laminates, saturating kraft paper passes through a phenolic resin bath which makes the paper extremely sticky. Since loose fuzz has a tendency to agglomerate and form fuzz balls, it is common for some of these fuzz balls to collect on and stick to the resin-treated paper. As the paper proceeds through the drying process and becomes cut, sandwiched, and pressed into finished laminates, adhering fuzz balls can cause surface imperfections known as pressure marks. Because pressure-marked laminates are unsuitable for commercial use, these fuzz-induced imperfections are an important cause for the rejection of laminates.
The use of starch as a sizing agent is well known in the paper industry. In the article "Reduction of Offset Printing Rejects" TAPPI, November 1967 (pp 135A-137A) Richard F. Burtt reports the results of a study initiated to determine causes of rejection of offset printing grade paper. Among his findings Burtt reported that the addition of certain cooked starches via a size press process to a paper sheet containing about 4-5% moisture facilitated the laying down of the surface fibers of offset printing grade paper.
In U.S. Pat. No. 3,210,240, Read et al. teach a process for surface sizing newsprint, newsroto, novel news, directory, and catalog papers. In this method raw, cooked, or modified starch is dispersed in water via use of a wetting agent and compressed air to form a starch foam. The starch foam is subsequently drained of excess water and applied to the newsprint paper at a rate equivalent to 10 to 20 lbs. per ton of air dried paper.
In U.S. Pat. No. 3,639,209, Buckman et al. teach a process for making paper using cationic starch complexes. The authors disclose reacting aqueous starch with a water-soluble cationic polymeric polyelectrolyte to form a cationic starch complex. This starch complex is subsequently added at the fan pump to the furnish in order to improve the linting characteristics of newsprint paper.
In U.S. Pat. No. 3,859,108, Ware et al. teach the use of a cooked flour size (containing both the protein and the starch fractions of the flour) to seal the surface and/or body of paper or paperboard. This treatment improved the internal fiber bonding and laying of the paper's surface fibers.
In British Patent No. 1,601,282, a method for processing paper fiber webs with starch is disclosed. This method requires the heating of a starch solution almost to gelatinization of the starch particles after application of the solution to the paper.
In Canadian Patent No. 848,397, an apparatus for coating newsprint paper with either hydroxyethylated starch, modified starch, various proteins, melamine formaldehyde, urea formaldehyde, sodium alginate, carboxymethyl cellulose, or carboxyethyl cellulose is described. When used in offset lithographic printing the coated newsprint paper produced less lint than uncoated newsprint paper.
In addition to applying a variety of surface sizes to paper, the paper industry has tried other methods of addressing its fuzz problem, including varying the composition and refining level of the paper pulp and vacuuming the paper. Although each of these attempts have met with varying degrees of success, fuzz still remains an important problem in the industry.
Therefore, it is the object of this invention to provide an effective and economical method for preventing fuzz formation in the production and subsequent use of saturated kraft paper. Other objects, features, and advantages will be evident from the following disclosures.
SUMMARY OF THE INVENTION
The object of this invention is met by applying a dilute starch slurry to the surface of saturating kraft paper. This application greatly reduces subsequent fuzz production without adversely affecting the saturation and penetration properties of the saturating kraft paper.
DESCRIPTION OF THE PREFERRED EMBODIMENT
An untreated paper surface has two properties which cause liquids to penetrate it. First, there are pores in the paper web which admit the liquid. Second, paper is made of hydrophilic (water-attracting) cellulose fibers. As a result aqueous liquids move into the fiber sheet structure to penetrate the sheet. If one places a drop of water on such a sheet of paper the drop will immediately spread across the surface and penetrate into the sheet. Thus, it is a common practice in the paper industry to size certain types of paper to increase the paper's resistance to penetration by water and other liquids.
The invention taught herein requires the application of a dilute starch slurry to the surface of saturating kraft paper. It was a widely held belief in the paper industry that applying starch in this manner to saturating kraft paper would seal the pores and reduce the ability of the paper to absorb liquids, thereby making the paper unsuitable for use in producing laminates. However, the method taught herein solves that problem by improving bonding on the surface of the sheet without making the sheet repellant to liquids.
In our method starch is mixed with water to form a slurry. The desired starch concentration of the slurry will vary depending on the location and method of application to the paper.
Suitable methods for applying the starch slurry to the surface of the saturating kraft include using showers, size presses, and water boxes. For paper manufactured utilizing a traditional Fourdrinier paper making process the top (or felt) surface of paper is the source of most fuzz, while the bottom (or wire) surface generates relatively little fuzz. Thus, under these conditions it is preferred to apply the starch slurry only to the top (or felt) surface of the paper. However, the starch slurry may be applied to both surfaces of the paper if desired. The starch may be applied during the production of the saturating kraft paper or in a separate application to the produced paper. Size presses may be utilized if the starch is to be applied during the paper's drying cycle, while water boxes are used in conjunction with calendering the paper. The preferred method of application is to use a shower while the paper is still on the Fourdrinier. It is further preferred to apply the starch via a fine spray or misting shower immediately after the dry line on the paper. Each application method lightly covers the saturating kraft with the dilute starch slurry. When the spray treated paper is subsequently subjected to an iodine test, the starch application appears as mottled spotting on the face of the paper.
Either totally cooked, partially cooked, or uncooked starch may be used in this invention. However, when either partially cooked or uncooked starch is utilized it is necessary to provide proper conditions for subsequent cooking of the starch. In the dryer section the combination of high temperature and moisture cooks the starch particles causing the particles to expand, form a film, and become tacky--thereby bonding loose paper fibers to the sheet.
Of course, the temperature of the dryer section must be high enough to cook the starch, and the required minimum temperature will vary according to the type of starch employed. Suitable starches for use in this invention include any of the conventional commercially available starches such as those derived from corn, wheat, potato, tapioca, waxy maize, sago, rice, sorghum, and arrowroot.
In applying the starch to the paper a suitable application rate for the starch is in the range of about 0.01 to 1.04 pounds of dry starch per 1,000 square feet of saturating kraft produced. Where the saturated kraft has a basis weight of 156 pounds (lb.), the above-noted starch application rate is equivalent to a range of about 0.4 to 40.0 pounds of dry starch per ton of paper produced. (Of course, the starch application rate when measured in pounds of dry starch per ton of saturated kraft produced will vary according to the basis weight of the paper.) It has been found that starch application rates above about 40.0 lbs/ton results in sticking to the paper machine rolls, thereby leading to excessive paper breaks. The preferred application rate is about 0.13 to 0.21 lb/1,000 ft 2 or about 5.0 to 8.0 lbs/ton. While the retention rate of the starch is extremely difficult to measure, it is estimated that approximately 80-90% of the applied starch is actually retained by the paper. It is well within the ability of a skilled artisan to calculate the pumping rate and starch slurry concentration necessary to apply a desired amount of starch to saturating kraft via a particular method of application.
The following examples are provided to further illustrate the present invention and are not to be construed as limiting the invention in any manner.
EXAMPLE 1
A spray application of uncooked starch was applied on a Beloit Paper Machine producing a roll of 156 lb. saturating kraft paper. (This and the following examples utilize 156 lb. saturating kraft paper due to the fact that this weight paper is commonly used by industry to produce laminates. However, the procedures described herein work equally well with saturating kraft paper of other weights.) A 10% starch slurry was prepared by mixing 10 parts by weight of B-200 (an unmodified corn starch manufactured by Grain Processing Corporation) with 90 parts by weight of water at ambient temperatures until a slurry had formed. The uncooked starch slurry was applied to the top side of the paper sheet on the Fourdrinier at a position about 3 feet after the dry line using a hand held spray nozzle at a rate of about 3 gallons per minute. The showers covered approximately 30 inches of the paper and was positioned on an edge roll position of the sheet. The starch application rate was calculated to be approximately 1.0 pound of starch per 1000 square feet of paper. The temperature of the dryer section of the machine was measured to be about 150° C. The produced paper was subsequently rewound on a Black Clawson salvage rewinder.
The paper on both the paper machine and on the salvage rewinder was subjected to fuzz testing. A weighed piece of material was contacted with the surface of the paper for the amount of time required for 1,000 feet of the paper to pass under the material. The material was subsequently weighed and tared to ascertain the amount of fuzz collected. The results from the tests are listed in Table I below.
TABLE I______________________________________Fuzz Test Results of Starch-Coated Sheet Producedon a Beloit Paper Machine______________________________________Fuzz Test On Machine (g/1,000 ft.sup.2)Before starch (control) 0.16During starch application 0.04After starch (control) 0.24Fuzz Test on Salvage Rewinder (g/1,000 ft.sup.2)Starch-treated 0.07Untreated (control) 0.28Untreated (control) 0.36______________________________________
As the results indicate, the starch-treated sheets produced significantly lower amounts of fuzz than the untreated, control sheets. Saturation and penetration analysis performed on the starch-coated paper showed that the treated paper had properties comparable to those of the unstarched paper. The starch-treated paper did appear somewhat splotchy compared to the untreated paper. (However, after resin treatment the starch-treated paper looked the same as the resin-treated control paper.)
Laminates were made for evaluation purposes from both the starch-treated paper and the standard 156 lb. saturating kraft (control) paper via the following procedure. First, the paper was cut into a series of 1 foot by 1 foot squares. These paper squares were dipped into a bath of GP-4129 (a phenolic resin compound manufactured by Georgia-Pacific, Inc.) for a time sufficient to permit resin saturation of the paper in the range of about 24-28% by weight of the paper (about one minute). Subsequently, the dipped squares were placed in an explosion proof oven at a temperature of about 150° C. for a time sufficient to attain a volatile (moisture) range of about 7% in the squares (about one minute).
Laminate sandwiches were made by placing a release sheet or square on the bottom, three of the above-treated squares in the middle, and a decorative layer of melamine resin-impregnated paper (manufactured by Mead, Inc.) on the top. Thermowells were inserted in the outer and middle plates in order to monitor temperatures.
The laminate sandwiches were subsequently placed into a hydraulic laminate press and subjected to about 1,200 pounds per square inch of pressure. The temperatures of the laminates were maintained in the range of 100°-250° F. for about 23 minutes; then increased to a range of 260°-280° F. for about 17 minutes. At that time the heating was terminated and the laminates were allowed to cool down for about 16 minutes before the pressure was released and the laminates removed from the press.
The starch-treated laminates were visually examined for pressure mark surface imperfections. No pressure marks were found.
Standard industry blister time and boil test evaluations were conducted on the starch-treated laminates to determine how they compared to laminates produced from the equivalent, untreated paper. The blister times give an indication of the heat resistance of the laminate, while the boil test evaluates how much water absorption can be expected from the laminate.
The blister tests were conducted by placing 3 inch (machine direction) by 9 inch (cross direction) laminate samples (decorative side down) across a 130 volt radiant heater which had been preheated to 375° F. The time required for the laminate to blister (i.e., make a popping sound) was measured. The results are shown in Table II below.
TABLE II______________________________________Blister Time Results of Laminates Made fromStarch-Treated Saturated Kraft Blister times (sec) at 375° F.Run 1 2 3 4Laminate Type: General Purpose Postforming______________________________________Untreated Paper 76.9 77.6 68.0 68.0Treated Paper 66.5 61.4 66.0 59.0______________________________________
The results in Table II indicate that the blister times for the starch-treated laminates were slightly lower than those for the laminates made from the untreated paper. However, the starch-treated laminates' blister times were still well within the range considered acceptable by the laminate industry.
The percent swell and the water content of laminates made with the starch-treated paper and with control paper were measured by boil tests. These tests were conducted by first weighing a series of 1 inch (cross direction) by 3 inch (machine direction) laminate samples. The samples were subsequently reweighed after being oven dried at 50° C. for 12 hours. The percent weight loss was calculated and the dry thickness measured using a caliper. At this time the samples were boiled in water for 2 hours before being withdrawn. Any excess moisture was removed from the samples using cheese cloth. The wet samples were weighed and their thicknesses measured using a caliper. The results are listed in Table III below.
TABLE III______________________________________Boil Test Results of Laminatesfrom Starch-Treated Saturated Kraft % Thickness Average % Swell Water______________________________________1 untreated paper 12.20 9.81 starch-treated 9.76 8.722 untreated paper 8.54 7.66 starch-treated 5.95 7.30______________________________________
The results show that the percent swell is slightly lower for laminates made with starch-treated paper when compared to laminates made with untreated paper produced on a similar manufacturing run. This is a favorable property indicating that laminates made with starch-treated paper are somewhat more stable to humidity and water than their untreated counterparts.
EXAMPLE 2
A series of cooked starch applications was applied to a roll of 156 lb. saturating kraft paper via the use of a size press equipped with a metered film applicator (a pilot coater). Two types of starch--low-viscosity (L) starch and a low/medium-viscosity (M) starch--were used in the applications. The L starch was processed by cooking in a jet-cooker a 25% solids mixture of oxidized corn starch (manufactured by the Grain Processing Corporation) and water to gel the mixture. The M starch was processed by cooking in a jet-cooker a 25% solids mixture of medium-low viscosity hydroxyethylated corn starch (manufactured by PenFord Products, Inc.) and water to gel the mixture. Both the L starch and the M starch were diluted and applied to the kraft paper at a 6% concentration and a 2% concentration. The respective starch slurries were applied at different rates (see Table IV) to the saturating kraft paper using both a flooded size press and a metered size press.
Each starch solution was applied to the felt side of the sheet before the paper entered (felt side up) an oven heated to 500° F. for drying. After drying, the papers were subjected to a fuzz test (as described in Example 1 above). The papers were further treated with phenolic resin and subjected to standard saturation and penetration tests. Untreated 156 lb. saturating kraft paper was utilized as a control in the tests. The results are listed in Table IV below.
TABLE IV______________________________________Size StarchPress.sup.1 Type Conc. App..sup.2 Fuzz.sup.3 Sat..sup.4 Pene..sup.5______________________________________M L 6% 0.4 0.00 27.0 EqualM L 2% 0.2 0.03 29.9 MoreM M 2% 0.2 0.04 30.3 MoreM M 6% 0.3 0.01 28.8 EqualF L 6% 1.0 0.11 19.6 LessF L 2% 0.5 0.08 22.1 LessF M 6% 0.9 0.05 19.7 LessF M 2% 0.4 0.06 24.0 LessUntreated sheet -- -- 0.31 28.0 --______________________________________ .sup.1 Method of starch application: M = Metered size press F = Flooded size press .sup.2 Application Rate: Measured in pounds of starch per 1,000 square feet of paper. .sup.3 Fuzz Test: The amount of fuzz (in grams) generated by 1,000 square feet of paper. .sup.4 Saturation Test: The percentage of the phenolic resin absorbed by the paper. .sup. 5 Penetration test: A comparison of how well the resin has distributed through the thickness of the paper using untreated paper as the standard.
As the results indicate, the amounts of fuzz generated decreased significantly after each starch application. Also, the saturation and penetration results from the papers treated with a metered application were comparable to the untreated sheet. Saturability decreased at higher application levels associated with the flooded-nip application.
Further evaluations were run to ascertain the amounts of starch to be found on the papers. The results are shown in Table V below.
TABLE V______________________________________Analysis of Starch-Coated PaperSize StarchPress Type Conc. Pick-up (lb/1000 Ft.sup.2)______________________________________M L 6% 0.4M L 2% 0.2M M 2% 0.2M M 6% 0.3F L 6% 1.0F L 2% 0.5F M 6% 0.9F M 2% 0.4______________________________________
Decorative laminates were made from the cooked starch-treated paper and the unstarched paper via a conventional commercial process. The saturated kraft sheets were treated in a phenolic resin treater and oven-cured. The cured sheets were subsequently layered with a decorative sheet on the outside and pressed in a high temperature, high pressure press to produce the final laminate.
No pressure marks were found on the laminates produced from the cooked starch-treated papers. The blister time and boil test evaluations performed on the laminates indicated that the cooked starch-treated laminates were comparable to the unstarched paper laminates.
EXAMPLE 3
An uncooked starch application was applied to a roll of 156 lb. saturating kraft paper using a size press equipped with a metered film applicator (a pilot coater). Three different conditions were produced and monitored. Condition 1 was a control condition consisting of running the paper through the machine without any applications and with the oven turned off. In Condition 2 there was no treatment of the paper, but the oven was turned on and maintained at a temperature of 500° F. This condition was observed to ascertain if either the oven could be blowing loose fibers off the paper or whether the higher temperature of the paper could be affecting the fuzz tests. In Condition 3 a 2% starch solution was prepared (using the method taught in Example 1) and applied to the top side surface of the paper via the metered size press at an application rate of about 0.08 lb/l,000 ft 2 and dried in the oven at a temperature of 500° F.
At least two fuzz tests were run per each condition on the top side of the paper as it exited the oven of the pilot coater. These fuzz test results are shown in Table VI below.
TABLE VI______________________________________Fuzz EvaluationsCondition.sup.1 Fuzz.sup.2 Avg Fuzz.sup.2______________________________________1 0.19 0.22 0.23 0.252 0.22 0.22 0.223 0.04 0.05 0.05______________________________________ .sup.1 1 = Control with oven off. 2 = Control with oven on. 3 = Starchtreated paper. .sup.2 g/1,000 ft.sup.2
The fuzz tests of control Conditions 1 and 2 are the same indicating that neither the heat nor the air circulation from the oven affected the results. The starch-treated papers of Condition 3 gave clearly superior fuzz test results.
The above papers were subsequently evaluated via the use of a pilot treater. Each condition was run at two different speeds. A condition was first run on at the speed necessary to attain the resin pickup required for standard laminates, which was in the 40 to 50 feet per minute (fpm) range. Enough paper was treated at this speed so that several laminates could be produced via the method described in Example 1. Table VII shows the resin pickup (absorption) observed for the three conditions. The most important result seen in Table VII is that of Condition 3 (corresponding to the starch-treated paper), which picked up resin in the same manner as the control conditions.
TABLE VII______________________________________Resin Pickup of Starch Trial Conditions Treater SpeedCondition.sup.1 (fpm) % Resin Pickup______________________________________1 40 27 302 41 293 40 30______________________________________ .sup.1 1 = Control with oven off. 2 = Control with oven on. 3 = Starchtreated paper.
After enough paper was treated at standard conditions to make the required laminates, the speed of the treater was increased to 100 fpm for the fuzz testing. The scraper bar was cleaned and each trial condition paper was run at this speed for minutes. The scraper bar was subsequently observed for fuzz buildup. From visual observation, a light-to-medium fuzz accumulated on control Conditions 1 and 2 (no distinction in the amount of fuzz between the conditions), but no fuzz accumulated on the starch condition, Condition 3 (See Table VII).
The results of the fuzz tests on the three conditions are also given in Table VIII. Control Conditions 1 and 2 with no treatment had fuzz test values of 0.23 g/1,000 ft 2 and 0.17 g/1,000 ft 2 , respectively. The condition with the starch treatment had an average fuzz test value of 0.07 g/1,000 ft 2 .
TABLE VIII______________________________________Fuzz Evaluations on Pilot Treater Fuzz Avg Fuzz VisualCondition.sup.1 (g/1000 ft.sup.2) (g/1000 ft.sup.2) Evaluation______________________________________1 0.22 0.23 Medium fuzz 0.27 0.182 0.19 0.17 Medium fuzz 0.16 0.163 0.04 0.07 No fuzz 0.08 0.08______________________________________ .sup.1 1 = Control with oven off. 2 = Control with oven on. 3 = Starchtreated paper.
Using the method described in Example 1, laminates were produced from these trial papers, examined for pressure marks, and subjected to the standard blister time and boil test evaluations. No pressure marks were found on the laminates produced from the starch-treated papers. The results from the blister and boil tests indicated that there was no noticeable difference between the laminates made from starch-treated paper and those made from the other two (untreated) conditions.
EXAMPLE 4
A series of uncooked starch applications were conducted on a Beloit Paper Machine. A nozzled shower emitting a 36-inch-wide misting shower was manually held over the moving paper at different positions. About 2 gallons per minute of the various starch solutions were sprayed on top of the 36-inch side roll. The starch solutions were produced by following the method described in Example 2. The paper was sprayed at different positions (i.e., about a foot after the dry line and about a foot before the dry line) at different starch application rates. The starch application was controlled by using starch solutions of different concentrations. The temperature of the dryer section of the machine was about 150° C.
The first three conditions listed in Table IX were run for approximately 10 minutes each with control paper (unsprayed) being produced between conditions. Condition 4 had been running for two-to-three minutes when a break occurred on the paper machine. The break most probably occurred because starch buildup on the second press roll caused the paper to stick to the roll. Condition 4 was a very high starch application, and the uncooked starch was very difficult to disperse at this concentration.
TABLE IX______________________________________Starch Trial Conditions Starch Application StarchCondi- Shower (lb/1000 Concentrationtion Location ft.sup.2) (lb/ton) (lb starch/55 gal.)______________________________________1 After dry line 0.13 5 9 (2%)2 Before dry line 0.33 13 23 (5%)3 After dry line 0.7 27 48 (11%)4 Before dry line 1.0 38 68 (15%)______________________________________
Fuzz tests were performed on the machine for each starch condition and the control condition. Fuzz tests were later conducted on a Black Clawson salvage rewinder, and a fuzz evaluation using a commercial laboratory instrument (LI) was also conducted on samples of the final paper. The results of these evaluations, reported in Table X, are the averages of at least two tests.
Table X also describes the appearance of the paper. The paper from Conditions 1 and 2 looked like the control paper. The paper from Condition 3 looked splotchy and the paper from Condition 4 was very splotchy. When the paper from all conditions was sprayed with iodine, the spray pattern where the starch actually hit the paper was readily apparent.
TABLE X__________________________________________________________________________Fuzz Test ResultsShower Starch Fuzz (g/1000 ft.sup.2) PaperCondition Location lb/1000 ft.sup.2 Machine Sal. Rew. LI Fuzz (mg) Appearance__________________________________________________________________________Control No starch 0.13 0.46 381 * 0.13 0.03 0.09 12 Like control2 ** 0.33 0.03 0.02 3 Like control3 * 0.7 0.01 0.01 2 Splotchy4 ** 1.0 0.02 0.09 2 Very splotchy__________________________________________________________________________ *After dry line **Before dry line
Laminates were made via the procedure described in Example 1 with the control paper and paper from Conditions 1, 2, and 3. Table XI lists the saturation results, the blister times of the laminates, and the percent swell results from boil tests. Paper from the three starch conditions picked up the same amount of resin as the control paper. The blister times of the laminates were all within specifications (but they may be dropping slightly with additional starch usage). The percent swell of the laminates resulting from the boil test was the same for the three starch conditions as for the control.
TABLE XI__________________________________________________________________________Laminates Resulting from Starch Sprayed Paper Resin Blister lb/ Pickup Time %Condition Shower Location 1000 ft.sup.2 Control (%) (sec) Swell__________________________________________________________________________Control No starch 27 65 201 After dry line 0.13 1 27 66 202 Before dry line 0.33 2 27 60 203 After dry line 0.7 3 27 56 20__________________________________________________________________________
EXAMPLE 5
A series of uncooked starch spray applications to saturating kraft paper were conducted to evaluate the effect of four process variables. The four variables investigated were:
1) the application rate for starch sprayed on the paper (2.5 lb/ton v 6.0 lb/ton);
2) the mixing conditions of the starch solution (mild v robust);
3) the height of the shower; and
4) the angle of the shower impingement on the paper (straight down upon the paper v a 45° angle).
The evaluation consisted of an eight-run screening design with the four variables under investigation. The starch applications were applied over an edge roll position about one foot past the dry line via a misting shower during a 156 lb. saturating kraft run on a Beloit Paper Machine with the dryers set at a temperature of 150° C.
The low and high values of the four variables are listed in Table XII below.
TABLE XII______________________________________Variable Assignment for Example 5 Starch App. Shower Rate Mixing Shower Height AngleRun (lbs/ton) Cond..sup.(a) (inches) (degrees)______________________________________1 6.0 high 6" 90°2 6.0 high 10" 45°3 2.5 high 10" 90°4 2.5 high 6" 45°5 6.0 low 6" 45°6 6.0 low 10" 90°7 2.5 low 10" 45°8 2.5 low 6" 90°______________________________________ .sup.(a) Mixing Conditions: Low = Water temperature of 90° F., hand mixed, solution used immediately. High = Water temperature of 120° F., agitator mixed, solution used after 6 hours storage under agitation.
The variable labeled "mixing condition" refers to the temperature of the water used, the degree of agitation, and the amount of time the starch solution was stored before use. The low-mixing condition used water at ambient temperature (about 90° F.), low agitation with a paddle, and the starch solution was used immediately. Under the high-mixing condition, the water was at 120° F., the solution was agitated with a Lightnin Mixer, and the starch was stored under agitation for approximately six hours before use.
The "shower height" variable refers to the height of the shower nozzle above the paper. In both cases, the overlap between nozzles was constant.
Table XIII below lists the trial conditions in the order that they were run and the results obtained from the fuzz tests.
TABLE XIII______________________________________Fuzz Results FuzzStarch (g/1000 ft)(lb/ Mixing Shower Shower Sal LIRun ton) Cond..sup.1 Height Angle° Mach Rew (mg)______________________________________.sup.2no 0.05 0.21 32starch1 6.0 high 6" 90° 0.01 0.10 82 6.0 high 10" 45° 0.00 0.08 93 2.5 high 10" 90° 0.02 0.14 134 2.5 high 6" 45° 0.02 0.14 135 6.0 low 6" 45° 0.01 0.13 76 6.0 low 10" 90° 0.03 0.09 77 2.5 low 10" 45° 0.04 0.15 118 2.5 low 6" 90° 0.02 0.17 12______________________________________ .sup.1 Mixing Conditions: Low = Water temperature of 90° F., hand mixed, solution used immediately. High = Water temperature of 120° F., agitator mixed, solution used after 6 hours storage under agitation. .sup.2 Control: untreated 156 lb. saturating kraft paper.
The results of the fuzz tests shown above are the average of several measurements. Fuzz evaluations (fuzz) were conducted by the fuzz test described in Example 1 for both the paper as produced from the Beloit Paper Machine and the produced paper subsequently run through a Black Clawson salvage rewinder. The produced paper was also evaluated for fuzz using a commercial laboratory instrument (LI).
The data listed in Table XIII above clearly indicate that all of the trial conditions were successful in reducing fuzz. The data also show that the amount of starch sprayed on the sheet is the only variable of the four tested that had an effect on the fuzz reduction of saturating kraft during starch spray trials. A 2.5 lb/ton starch application was slightly less effective than a 6.0 lb/ton starch application in reducing fuzz. However, the fuzz reduction measured was still significant (reduction of more than half according to the LI values) at the 2.5 lb/ton starch application level.
Laminates were made from the untreated control paper and both the 2.5 lb/ton and the 6.0 lb/ton starch-containing paper produced in this trial via the methods described in both Example 1 and Example 2. The laminates were examined for pressure marks, and subjected to the standard blister time and boil test evaluations. No pressure marks were found on the laminates produced by either method using either of the starch-treated papers. Although the blister times of the laminates made from the starch-treated papers were somewhat lower than those of laminates made from the control paper, they were still well within usable specifications. The boil test results indicated no substantial differences between the laminates made from starch-treated papers and those made from the untreated control paper.
Many modifications and variations of the present invention will be apparent to one of ordinary skill in the art in light of the above teaching. It is understood therefore that the scope of the invention is not to be limited by the foregoing description but rather is to be defined by the claims appended hereto. | The invention relates to an improvement in the art of making saturating kraft paper. In particular, the invention relates to a method for reducing the amount of fuzz generated by the production and use of saturating kraft paper. The improved saturating kraft paper is particularly useful in the production of laminated materials. | 3 |
BACKGROUND OF THE INVENTION
A conventional handle lock generally used for doors of bathrooms and restrooms has a round-shaped knob, being locked without a key but with a push button in the inner knob of the lock for locking it from the inside of the door, which can be opened in an emergency from the outside by means of a coin fitted in and rotating a groove in the outside knob after when locked. However, the round knob is rather inconvenient for the invalid, the disabled or children to manipulate open. So some makers have changed the round knob into a curved handle making easy to open a door by pressing it down, and generally made by molding. But a handle made by molding is liable to break, so a handle made of copper has also been made through a wrought process, having decorative and strong feature but impossible to be combined with a handle lock with a push button locking mechanism, as those made of aluminum or steel.
SUMMARY OF THE INVENTION
This invention has an object to overcome the disadvantages of conventional handle locks mentioned above.
The handle lock in the present invention comprises an inner and an outer bearing plate fixed on the inner and the outer surface of a door, a tubular shaft combined with each of both bearing plates in a central shaft hole therein, two handles and two drive members each consisting of a coil spring and a drive plate. The two drive plates have a square hole for a square shaft to engage therein to be combined between the two drive plates. The inner bearing plate is combined with a locking rod, which can be pressed inward or pulled outward in a hole in the inner plate. When the locking rod is pressed in, the handle lock is locked, impossible to open the door from the outside, with the outer handle being stopped immovable by the locking rod.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1 is an exploded perspective view of a handle lock in the present invention.
FIG. 2 is a cross-sectional view of line 2--2 in FIG. 3.
FIG. 3 is a cross-sectional view of line 3--3 in FIG. 2.
FIG. 4 shows an operational movement of FIG. 2.
FIG. 5 is a cross-sectional view of line 5--5 in FIG. 4.
FIG. 6 is a magnified view of the part marked 6 in FIG. 4.
FIG. 7 is a cross-sectional view of line 7--7 in FIG. 4.
DETAILED DESCRIPTION OF THE INVENTION
A handle lock in the present invention, as shown in FIG. 1, comprises two handles 1, 1, two tubular shafts 2, an inner bearing plate 3, an outer bearing plate 4, two drive members 5, 5 and a locking rod 6 as main components.
The two handles are respectively shaped as double curved in opposite direction to each other, having a non-round combining hole in one end to fit with an end projection 21 of each tubular shaft 2 so that each handle 1 can rotate each tubular shaft 2.
The tubular shafts 2, 2 are adapted to fit and pass through two shaft holes 31, 41 of the inner and the outer bearing plates 3, 4, having combining projections 21, 21 in both ends to fit in the combining holes 11, 11 of two handles 1, 1, round lengthwise holes 22, 22 in both outer ends for small-diameter rod portions of caps 23, 23 to fit therein. Large diameter heads 231, 231 of the caps 23, 23 are stopped by the surrounding edges of the round holes 11, 11, of the handles 1, 1 to assemble the shafts 2, 2 with the handles 1, 1 together. The caps 23, 23 also have an annular grooves 232, 232 near the bottom ends in line with screw holes 24, 24 of the shafts 2, 2 communicating with the round holes 22, 22 for screws 25, 25 to engage therein and the annular grooves 232, 232 so that the handles 1, 1, the shafts 2, 2 and the caps 23, 23 can be combined firmly together. The shafts 2, 2 have a small-diameter portion 20 to engage the shaft holes 31, 41 of the inner and the outer bearing plates 3, 4. The small diameter portion 20 is located to protrude out of the outer sides of both the inner and the outer bearing plates 3, 4 for the drive members 5, 5 of two coil springs 51, 51 and drive plates 52, 52 to fit around, and a pair of annular grooves 26, 26 for a C ring to engage therein for preventing the springs 51, 51 and the drive plates 52, 52 from falling off and for keeping the shafts 2, 2 and the inner and the outer bearing plates 3, 4 combined together.
The inner bearing plate 3 is fixed on the inside surface of a door having a central shaft hole 31 for the inner shaft 2 to pass through, two combining holes 32, 32 for two screws 331, 331 to pass through engage two posts 42, 42 of the outer bearing plate 4, two projections 33, 33 extending from an inner side for hooking two ends of each spring 51 thereon, a locating hole 34 with a sloped inner surface for a locking rod 6 to insert therein, a screw hole 35 for a screw 36 to engage for fixing a locating plate 37, which has a hole 371 and plate 37, which has a hole 371 and a bottom side engaging a notch 61 of the locking rod 6 so as to limit the the rod 6 to move in a definite distance of the length of the notch 61.
The outer bearing plate 4 is fixed on the outer surface of a door, and combined with the outer handle 1, the outer tubular shaft 2 and one of the drive member 5, having two posts 42, 42 with female threads for the screws 331, 331 to engage so as to fix the outer and the inner bearing plates 3, 4 on the door. The outer bearing plate 4 has a small straight hole 44 in line with the locating hole 34 of the inner bearing plate 3, but may not have the screw hole 35 and the locating plate 37 the inner bearing plate 3 has.
The two drive members 5 respectively consist of a coil spring 51 and a drive plate 52 to rotate elastically each handles 1 back to its original position after the handle is rotated. Each coil spring 51 fits around small-diameter portion 20 of each tubular shaft 2, having both ends hooked on two projections 33, 33 or 45, 45 of the inner or the outer bearing plate 3, or 4. Each drive plate 52 has a square hole 521 for the square shaft 43 to pass through so that rotation of either of the handles 1, 1 can cause rotation of the square shaft 43, and two semi-circular slots 522, 522 for the wall of each tubular shaft 2 to insert there-through so as to make each shaft 2 and each drive plate 52 rotate together. Each drive plate 52 also has two bent feet 523, 523 to contact both ends of each spring 51 so that the feet 523, 523 can press the spring 51 to rotate shrinkingly and then to lengthen resiliently to make the drive plate 52 rotate back to its original position, and a notch 524 for the locking rod 6 to lie thereon.
The locking rod 6 is adapted to prevent the outer handle 1 from being rotated, fitted in a locating hole 34 of the inner bearing plate 3, with its large diameter ridges 62, 62 engaging an inner surface of the hole 34 when the rod 6 is pressed in. The hole 34 has a sloped inner surface, letting the locking rod 6 impossible to move when the rod 6 is pressed therein deep but possible to move when the rod 6 is pulled outward therein, by pressing in or pulling outward the rod 6 at the inside of the door. And the rod 6 also has a small-diameter end 64 to engage the notch 524 of the drive plate 52 of the outer bearing plate 4 for locking it immovable in case of pressing in the rod 6, and a notch 61 to engage the bottom edge of the hole 371 of the locating plate 37, keeping the rod 6 not separated from the inner bearing plate 3 when the rod 6 is pulled outward and enabling the drive plate 52 of the inner bearing plate 3 to rotate, with the notch 61 of the rod 6 positioning above the notch 524 of the drive plate 52 of the inner bearing plate 3.
FIGS. 2 and 3 show this handle lock in unlocked position, wherein the locking rod 6 is in a first position of being not pressed in in the hole 34 and the hole 371, with the small-diameter end 64 separated from the notch 524 of the drive plate 52 fixed on the outer bearing plate 4, and with the notch 61 of the locking rod 6 positioning above the drive plate 52 of the inner bearing plate 3. Consequently, both handles 1, 1 can be rotated to open the door, with the handle lock being in unlocked position.
FIGS. 4, 5, 6 show this handle lock in locked position, wherein the locking rod 6 is in a second position wherein the rod 6 is forcefully pressed in with the large-diameter portions 62,62 engaging the locating hole 34 of the inner bearing plate 3, and with the notch 61 of the rod 6 leaving away from the notch 524 of the drive plate 52 fixed on the inner bearing plate 3 and with the outer surface of the rod 6 in contact with the notch 524. In addition, as shown in FIG. 4, the small-diameter end 64 of the rod 6 is extended deep to engage the notch 524 of the drive plate 52 of the outer bearing plate 4, locking the drive plates 52, 52 immovable and subsequently also preventing both handles 1, 1 inside and outside the door from rotating for opening the door.
In emergency and when this handle lock is in locked position but the door has to be opened from the outside, a very slender bar can be used to insert through the straight hole 44 of the outer bearing plate 4 and push the locking rod 6 back to the unlocked position (the first position) shown in FIG. 2. Then the handles 1, 1 can be rotated to open the door. p Should the handles 1, 1 be altered from the right side to the left side, only the screws 25, 25 are loosened to take out the caps 23, 23 so as to interchange both handles 1, 1 and the caps 23, 23 and the screws 25, 25 are to be fixed again. | A handle lock having two handles to be symmetrically fixed on the inner and the outer bearing plate fixed on the inner and the outer side of a door, each handle assembled with a tubular shaft and a square shaft to retract a dead bolt to open the door, a locking rod combined in the inner bearing plate and being movable therein to permit the tubular shaft either to be rotated to open the door or to be prevented from being rotated by the handle either outer or inner, to lock the door. | 4 |
RELATED APPLICATION
[0001] This application is a continuation-in-part of copending, commonly-owned U.S. patent application Ser. No. 09/666,096, filed Sep. 21, 2000, entitled “Expandable Graphite and Method”, which in turn is a continuation-in-part of copending, commonly-owned U.S. patent application Ser. No. 09/633,184, filed Aug. 4, 2000, which in turn is a continuation-in-part of copending, commonly-owned U.S. patent application Ser. No. 09/015,590, filed Jan. 29, 1998, now U.S. Pat. No. 6,149,972.
FIELD OF THE INVENTION
[0002] This invention relates to intercalated graphite flake having increased exfoliation volume at temperatures as low as 600° C. and even lower.
BACKGROUND OF THE INVENTION
[0003] Graphite is a crystalline form of carbon comprising atoms bonded in flat layered planes with weaker bonds between the planes. By treating particles of graphite, such as natural graphite flake, with an intercalant of, e.g., a solution of sulfuric and nitric acid, the crystal structure of the graphite reacts to form a compound of graphite and the intercalant. The treated particles of graphite are hereafter referred to as intercalated graphite flake. Upon exposure to elevated temperatures the particles of intercalated graphite expand in dimension in an accordion-like fashion in the c-direction, i.e. in the direction perpendicular to the crystalline planes of the graphite.
[0004] Intercalated graphite flake has many useful applications. A common application is to exfoliate the intercalated graphite particles into vermicular-like structures which are then compressed into sheets of flexible graphite for use in the manufacture of gaskets or as packing material. Intercalated graphite flake is also used in a variety of products which take advantage of the high expansion characteristic of intercalated graphite flake when exposed to high temperature. One such example is for use in combination with polymer foams to form seat cushions and furniture upholstery in aircraft. Upon exposure to fire, the high temperature will cause the particles of intercalated graphite to exfoliate which minimizes or prevents the formation of toxic gases from the polymer foam and may, of itself, smother a fire.
[0005] Since it is important to suppress, i.e. retard a fire before it has begun to spread, it would be a substantial advantage for an intercalated graphite flake product to exhibit a very high degree of exfoliation upon exposure to temperatures as low as 600° C. and even lower.
[0006] It has been discovered in accordance with the present invention that the addition of an organic expansion aid to the intercalation solution and the treatment of intercalated graphite flake with an organic reducing agent, following intercalation of the graphite flake with an oxidizing intercalant solution, and while the graphite flake is covered with a coating of oxidizing intercalant solution, results in a material which exhibits enhanced exfoliation volumes at exfoliation temperatures as low as 600° C. and even lower.
SUMMARY OF THE INVENTION
[0007] The method of the present invention for forming particles of intercalated graphite flake having enhanced exfoliation volume at temperatures as low as 600° C. and even lower by:
[0008] (a) adding an organic expansion aid to an oxidizing intercalant solution;
[0009] (b) treating particles of graphite with the oxidizing intercalant solution containing the expansion aid to provide intercalated graphite flake with a surface film of oxidizing intercalant solution;
[0010] (c) contacting the surface film of the intercalated graphite flake with an organic reducing agent in the form of an organic compound selected from sugars, alcohols, aldehydes and esters which is reactive with the film of oxidizing intercalant solution at temperatures in the range of 25° C. to 125° C.; and
[0011] (d) subjecting the thus treated intercalated graphite flake to a temperature in the range of 25° C. to 125° C. to promote a reaction of the organic reducing agent with the surface film of oxidizing solution.
DETAILED DESCRIPTION OF THE INVENTION
[0012] Intercalated graphite flake is conventionally formed. by treating particles of natural graphite with agents that intercalate into the crystal structure of the graphite to form a compound of graphite and the intercalant capable of expansion in the c-direction, i.e. the direction perpendicular to the crystalline planes of the graphite, when heated to a high temperature of above 700° C. and preferably above 1000° C. The intercalated graphite flake is washed and dried prior to exfoliation. Exfoliated graphite particles are vermiform in appearance and are commonly referred to as “worms”.
[0013] A common conventional method for forming intercalated graphite flake (and for manufacturing sheets of flexible graphite from exfoliated graphite) is described in U.S. Pat. No. 3,404,061 the disclosure of which is incorporated herein by reference. As disclosed in the above mentioned patent natural graphite flake is intercalated by dispersing flakes in a solution containing an oxidizing agent, such as a mixture of nitric and sulfuric acid. After the flakes are intercalated excess solution is drained from the flakes. The quantity of intercalation solution retained on the flakes after draining is typically greater than 100 parts of solution by weight per 100 parts by weight of graphite flakes (pph) and more typically about 100 to 150 pph.
[0014] The intercalant of the present invention contains oxidizing intercalating agents known in the art. Examples include those containing oxidizing agents and oxidizing mixtures, such as solutions containing nitric acid, potassium chlorate, chromic acid, potassium permanganate, potassium chromate, potassium dichromate, perchloric acid, and the like, or mixtures, such as for example, concentrated nitric acid and chlorate, chromic acid and phosphoric acid, sulfuric acid and nitric acid, or mixtures of a strong organic acid, e.g. trifluoroacetic acid, and a strong oxidizing agent soluble in the organic acid.
[0015] In the preferred embodiment of the invention, the intercalant is a solution of sulfuric acid, or sulfuric acid and phosphoric acid, and an oxidizing agent, i.e. nitric acid, perchloric acid, chromic acid, potassium permanganate, iodic or periodic acids, or the like, and preferably also includes an expansion aid as described below. Although less preferred, the intercalant may contain metal halides such as ferric chloride, and ferric chloride mixed with sulfuric acid, or a halogen, such as bromine as a solution of bromine and sulfuric acid or bromine in an organic solvent.
[0016] In accordance with the present invention the particles of graphite flake treated with intercalant are contacted e.g. by blending, with a reducing organic agent selected from alcohols, sugars, aldehydes and esters which are reactive with the surface film of oxidizing intercalating solution at temperatures in the range of 25° C. and 125° C. Suitable specific organic agents include the following: hexadecanol, octadecanol, 1-octanol, 2-octanol, decylalcohol, 1, 10 decanediol, decylaldehyde, 1-propanol, 1,3 propanediol, ethyleneglycol, polypropylene glycol, dextrose, fructose, lactose, sucrose, potato starch, ethylene glycol monostearate, diethylene glycol dibenzoate, propylene glycol monostearate, propylene glycol monooleate, glycerol monostearate, glycerol monooleate, dimethyl oxylate, diethyl oxylate, methyl formate, ethyl formate and ascorbic acid.
[0017] Also effective are polyfunctional compounds, e.g., those having both surfactant qualities and more than one reducing function selected from the group consisting of alcohols, esters, aldehydes and the like. One example is lignin-derived compounds, such as sodium lignosulfate. The preferred compounds are preferably liquid at application temperature and essentially free of water. Among the suitable polyfunctional compounds in this group are surfactants derived from ethylene oxide and/or propylene oxide and a compound capable of contributing a hydrophobic group to the compound, e.g., polymers of ethylene oxide and nonylphenol available as Tergitol NP detergents, products formed by the reaction of linear secondary alcohols with ethylene oxide available as Tergitol 15-S- detergents, and various alkylaryl polyether alcohols prepared by the reaction of octylphenol with ethylene oxide as are available as Triton X detergents. Examples are presented below of materials effective as reducing organic agents that can improve both free and compressed expansion.
[0018] The amount of organic reducing agent is suitably from about 0.5 to 4% by weight of the the particles of graphite flake. The use of an expansion aid applied prior to intercalation or during intercalation can also provide improvement. Among these improvements can be reduced exfoliation temperature, and increased expanded volume (also referred to as “worm volume”).
[0019] An expansion aid in this context will be an organic material sufficiently soluble in the intercalant solution to achieve an improvement in expansion. More narrowly, organic materials of this type that contain carbon, hydrogen and oxygen, preferably exclusively, may be employed. Carboxylic acids have been found effective in this invention. A suitable carboxylic acid as the expansion aid can be selected from aromatic, aliphatic or cycloaliphatic, straight chain or branched chain, saturated and unsaturated monocarboxylic acids, dicarboxylic acids and polycarboxylic acids which have at least 1 carbon atom, and preferably up to about 10 carbon atoms, which is soluble in the aqueous intercalant solution employed according to the invention in amounts effective to provide a measurable improvement of one or more aspects of exfoliation. Preferred products are characterized by an intumescent temperature of below about 200° C. According to some observations, exfoliation can be initiated at temperatures as low as 160°. Suitable water-miscible organic solvents can be employed to improve solubility of an organic expansion aid in the intercalant solution.
[0020] Representative examples of saturated aliphatic carboxylic acids are acids such as those of the formula H(CH 2 ) n COOH wherein n is a number of from 0 to about 5, including formic, acetic, propionic, butyric, pentanoic, hexanoic, and the like. In place of the carboxylic acids, the anhydrides or reactive carboxylic acid derivatives such as alkyl esters can also be employed. Representative of alkyl esters are methyl formate and ethyl formate. Sulfuric acid, nitric acid and other known aqueous intercalants have the ability to decompose formic acid, ultimately to water and carbon dioxide. Because of this, formic acid and other sensitive expansion aids are advantageously contacted with the graphite flake prior to immersion of the flake in aqueous intercalant.
[0021] Representative of dicarboxylic acids are aliphatic dicarboxylic acids having 2-12 carbon atoms, in particular oxalic acid, fumaric acid, malonic acid, maleic acid, succinic acid, glutaric acid, adipic acid, 1,5-pentanedicarboxylic acid, 1,6-hexanedicarboxylic acid, 1,10-decanedicarboxylic acid, cyclohexane-1,4-dicarboxylic acid and aromatic dicarboxylic acids such as phthalic acid or terephthalic acid. Representative of alkyl esters are dimethyl oxylate and diethyl oxylate. Representative of cycloaliphatic acids is cyclohexane carboxylic acid and of aromatic carboxylic acids are benzoic acid, naphthoic acid, anthranilic acid, p-aminobenzoic acid, salicylic acid, o-, m- and p-tolyl acids, methoxy and ethoxybenzoic acids, acetoacetamidobenzoic acids and, acetamidobenzoic acids, phenylacetic acid and naphthoic acids. Representative of hydroxy aromatic acids are hydroxybenzoic acid, 3-hydroxy-1-naphthoic acid, 3-hydroxy-2-naphthoic acid, 4-hydroxy-2-naphthoic acid, 5-hydroxy-l-naphthoic acid, 5-hydroxy-2-naphthoic acid, 6-hydroxy-2-naphthoic acid and 7-hydroxy-2-naphthoic acid. Prominent among the polycarboxylic acids is citric acid.
[0022] The intercalant solution will be aqueous and will preferably contain an amount of expansion aid of from about 1 to 10%, the amount being effective to enhance exfoliation. In the embodiment wherein the expansion aid is contacted with the graphite flake prior to immersing in the aqueous intercalant solution, the expansion aid can be admixed with the graphite by suitable means, such as a V-blender, typically in an amount of from about 0.2% to about 10% by weight of the graphite flake. After intercalating the graphite flake with an intercalating solution, preferably containing an expansion aid, and following the blending of the intercalant coated intercalated graphite flake with the organic reducing agent, the blend is exposed to temperatures in the range of 25° to 125° C. to promote reaction of the reducing agent and intercalant coating. The heating period is up to about 20 hours, with shorter heating periods, e.g., at least about 10 minutes, for higher temperatures in the above-noted range. Times of one half hour or less, e.g., on the order of 10 to 25 minutes, can be employed at the higher temperatures.
EXAMPLE 1
[0023] Twenty-five grams of a (+50 mesh) natural graphite flake were intercalated with twenty-five grams of intercalant consisting of 86 parts by weight of 93% sulfuric acid and 14 parts by weight of 67% nitric acid. After mixing for three minutes, 1.0 grams of decanol were blended into the flakes. The flakes were then placed in a 90° C. oven for 20 minutes. The intercalated flakes were then washed with four aliquots of 200 ml of water. After each washing the flakes were filtered by vacuum through a Teflon screen. After the final wash the flakes were dried for 1 hour in a 115° C. oven.
[0024] The expansion of the intercalated flakes was measured by placing exactly 1.00 g into a 250 ml crucible. The cold crucible was placed into a 600° C. oven for 2 minutes. The volume and weight of the expanded flakes were measured after carefully funneling them into a 250 ml graduated cylinder. The expansion volume was 222 cc/g.
[0025] The expansion or exfoliation volume of the intercalated flakes was also measured by heating the intercalated graphite flakes in a 845° C. preheated metal crucible over a Bunsen burner flame, and measuring the bulk volume of the resulting exfoliated flakes. The volume and weight of the expanded flakes were measured after carefully financing them into a 250 ml graduated cylinder. The expansion volume was 566 cc/g.
Comparative Example 1 (A)
[0026] Twenty -five grams of a (+50 mesh) natural graphite flake were intercalated for 20 minutes with 25 grams of intercalant consisting of 86 parts by weight of 93% sulfuric acid and 14 parts by weight of 67% nitric acid. No reducing agent and no external heat and digestion period were applied to the intercalated flakes. The intercalated flakes were then washed with four aliquots of 200 ml of water. After each washing the flakes were filtered by vacuum through a Teflon screen. After the final wash the flakes were dried for 1 hour in a 115° C. oven.
[0027] The expansion of the intercalated flakes was measured by placing exactly 1.00 g into a 250 ml crucible. The cold crucible was placed into a 600° C. oven for 2 minutes. The volume and weight of the expanded flakes were measured after carefully funneling them into a 250 ml graduated cylinder. The expansion volume was only 32 cc,/g. The expansion was inferior to that obtained in example (1) since neither a reducing agent nor ,a high temperature digestion period was employed.
[0028] The expansion or exfoliation volume of the intercalated flakes was also measured by heating the intercalated graphite flakes in a 845° C. preheated metal crucible over a Bunsen burner flame, and measuring the bulk volume of the resulting exfoliated flakes. The volume and weight of the expanded flakes were measured after carefully funneling them into a 250 ml graduated cylinder. The expansion volume was only 110 cc/g. The expansion was inferior to that obtained in example (1) since neither a reducing agent nor a high temperature digestion period were employed.
Comparative Example 1 (B)
[0029] Twenty -five grams of a (+50 mesh) natural graphite flake were intercalated for 3 minutes with 25 grams of intercalant consisting of 86 parts, by weight of 93% sulfuric acid and 14 parts by weight of 67% nitric acid. No reducing agent was applied to the intercalated flakes. The flakes were then placed in a 100° C. oven for 20 minutes. The intercalated flakes were then washed with four aliquots of 200 ml of water. After each washing the flakes were filtered by vacuum through a Teflon screen. After the final wash the flakes were dried for 1 hour in a 115° C. oven.
[0030] The expansion of the intercalated flakes was measured by placing exactly 1.00 g into a 250 ml crucible. The cold crucible was placed into a 600° C. oven for 2 minutes. The volume and weight of the expanded flakes were measured after carefully funneling them into a 250 ml graduated cylinder. The expansion volume was only 26 cc/g. The expansion was inferior to that obtained in example (1) since no reducing agent was employed with the process.
[0031] The expansion or exfoliation volume of the intercalated flakes was also measured by heating the intercalated graphite flakes in a 845° C. preheated metal crucible over a Bunsen burner flame, and measuring the bulk volume of the resulting exfoliated flakes. The volume and weight of the expanded flakes were measured after carefully funneling them into a 250 ml graduated cylinder. The expansion volume was only 147 cc/g. The expansion was inferior to that obtained in example (1) since no reducing agent was employed with the process.
EXAMPLE 2
[0032] Twenty -five grams of a (+50 mesh) natural graphite flake were intercalated with 25 grains of intercalant consisting of 86 parts by weight of 98% sulfuric acid and 14 parts by weight of 67% nitric acid. After mixing for three minutes, 2 grams of hexadecanol were blended into the flakes. The flakes were then placed in a 90° C. oven for 20 minutes. The intercalated flakes were then washed with four aliquots of 200 ml of water. After each washing the flakes were filtered by vacuum through a Teflon screen. After the final wash the flakes were dried for 1 hour in a 115° C. oven.
[0033] The expansion of the intercalated flakes was measured by placing exactly 1.00 g into a 250 ml crucible. The cold crucible was placed into a 600° C. oven for 2 minutes. The volume and weight of the expanded flakes were measured after carefully funneling them into a 250 ml graduated cylinder. The expansion volume was 178 cc/g.
[0034] The expansion or exfoliation volume of the intercalated flakes was also measured by heating the intercalated graphite flakes in a 845° C. preheated metal crucible over a Bunsen burner flame, and measuring the bulk volume of the resulting exfoliated flakes. The volume and weight of the expanded flakes were measured after carefully funneling them into a 250 ml graduated cylinder. The expansion volume was 531 cc/g.
Comparative Example 2
[0035] Twenty -five grams of a (+50 mesh) natural graphite flake were intercalated for 20 minutes with 25 grams of intercalant consisting of 86 parts by weight of 98% sulfuric acid and 14 parts by weight of 67% nitric acid. No reducing agent and no external heat were applied to the intercalated flakes. The intercalated flakes were then washed with four aliquots of 200 ml of water. After each washing the flakes were filtered by vacuum through a Teflon screen. After the final wash the flakes were dried for 1 hour in a 115° C. oven.
[0036] The expansion of the intercalated flakes was measured by placing exactly 1.00 g into a 250 ml crucible. The cold crucible was placed into a 600° C. oven for 2 minutes. The volume and weight of the expanded flakes were measured after carefully funneling them into a 250 ml graduated cylinder. The expansion volume was only 30 cc/g. The expansion was inferior to that obtained in example (2) since no reducing agent and no external heat were applied to the intercalated flakes.
[0037] The expansion or exfoliation volume of the intercalated flakes was also measured by heating the intercalated graphite flakes in a 845° C. preheated metal crucible over a Bunsen burner flame, and measuring the bulk volume of the resulting exfoliated flakes. The volume and weight of the expanded flakes were measured after carefully funneling them into a 250 ml graduated cylinder. The expansion volume was only 142 cc/g. The expansion was inferior to that obtained in example (2) since no reducing agent and no external heat were applied to the intercalated flakes.
EXAMPLE 3
[0038] Twenty -five grams of a (+50 mesh) natural graphite flake were intercalated with 25 grams of intercalant consisting of 90 parts by weight of 93% sulfuric acid and 10 parts by weight of 67% nitric acid. After mixing for three minutes, 0.75 grams of 1-octanol were blended into the flakes. The flakes were then placed in a 100° C. oven for 20 minutes. The intercalated flakes were then washed with four aliquots of 200 ml of water. After each washing the flakes were filtered by vacuum through a Teflon screen. After the final wash the flakes were dried for 1 hour in a 115° C. oven.
[0039] The expansion of the intercalated flakes was measured by placing exactly 1.00 g into a 250 ml crucible. The cold crucible was placed into a 600° C. oven for 2 minutes. The volume and weight of the expanded flakes were measured after carefully funneling them into a 250 ml graduated cylinder. The expansion volume was 203 cc/g.
[0040] The expansion or exfoliation volume of the intercalated flakes was also measured by heating the intercalated graphite flakes in a 845° C. preheated metal crucible over a Bunsen burner flame, and measuring the bulk volume of the resulting exfoliated flakes. The volume and weight of the expanded flakes were measured after carefully funneling them into a 250 ml graduated cylinder. The expansion volume was 634 cc/g.
Comparative for Examples 3 to 8
[0041] Twenty -five grams of a (+50 mesh) natural graphite flake were intercalated for 20 minutes with 25 grams of intercalant consisting of 90 parts by weight of 93% sulfuric acid and 10 parts by weight of 67% nitric acid. No reducing agent and no external heat were applied to the intercalated flakes. The intercalated flakes were then washed with four aliquots of 200 ml of water. After each washing the flakes were filtered by vacuum through a Teflon screen. After the final wash the flakes were dried for 1 hour in a 115° C. oven.
[0042] The expansion of the intercalated flakes was measured by placing exactly 1.00 g into a 250 ml crucible. The cold crucible was placed into a 600° C. oven for 2 minutes. The volume and weight of the expanded flakes were measured after carefully funneling them into a 250 ml graduated cylinder. The expansion volume was only 29 cc/g. The expansion was inferior to that obtained in examples (3 to 8) since no reducing agent and no external heat were applied to the intercalated flakes.
[0043] The expansion or exfoliation volume of the intercalated flakes was also measured by heating the intercalated graphite flakes in a 845° C. preheated metal crucible over a Bunsen burner flame, and measuring the bulk volume of the resulting exfoliated flakes. The volume and weight of the expanded flakes were measured after carefully funneling them into a 250 ml graduated cylinder. The expansion volume was only 188 cc/g. The expansion was inferior to that obtained in examples (3 to 8) since no reducing agent and no external heat were applied to the intercalated flakes.
EXAMPLE 4
[0044] Twenty -five grams of a (+50 mesh) natural graphite flake were intercalated with 25 grams of intercalant consisting of 90 parts by weight of 93% sulfuric acid and 10 parts by weight of 67% nitric acid. After mixing for three minutes, 0.50 grams of 1-propanol were blended into the flakes. The flakes were then placed in a 100° C. oven for 20 minutes. The intercalated flakes were then washed with four aliquots of 200 ml of water. After each washing the flakes were filtered by vacuum through a Teflon screen. After the final wash the flakes were dried for 1 hour in a 115° C. oven.
[0045] The expansion of the intercalated flakes was measured by placing exactly 1.00 g into a 250 ml crucible. The cold crucible was placed into a 600° C. oven for 2 minutes. The volume and weight of the expanded flakes were measured after carefully funneling them into a 250 ml graduated cylinder. The expansion volume was 94 cc/g.
[0046] The expansion or exfoliation volume of the intercalated flakes was also measured by heating the intercalated graphite flakes in a 845° C. preheated metal crucible over a Bunsen burner flame, and measuring the bulk volume of the resulting exfoliated flakes. The volume and weight of the expanded flakes were measured after carefully funneling them into a 250 ml graduated cylinder. The expansion volume was 439 cc/g.
EXAMPLE 5
[0047] Twenty -five grams of a (+50 mesh) natural graphite flake were intercalated with 25 grams of intercalant consisting of 90 parts by weight of 93% sulfuric acid and 10 parts by weight of 67% nitric acid. After mixing for three minutes, 0.375 grams of 1,3-propanediol were blended into the flakes. The flakes were then placed in a 100° C. oven for 20 minutes. The intercalated flakes were then washed with four aliquots of 200 ml of water. After each washing the flakes were filtered by vacuum through a Teflon screen. After the final wash the flakes were dried for 1 hour in a 115° C. oven.
[0048] The expansion of the intercalated flakes was measured by placing exactly 1.00 g into a 250 ml crucible. The cold crucible was placed into a 600° C. oven for 2 minutes. The volume and weight of the expanded flakes were measured after carefully funneling them into a 250 ml graduated cylinder. The expansion volume was 83 cc/g.
[0049] The expansion or exfoliation volume of the intercalated flakes was also measured by heating the intercalated graphite flakes in a 845° C. preheated metal crucible over a Bunsen burner flame, and measuring the bulk volume of the resulting exfoliated flakes. The volume and weight of the expanded flakes were measured after carefully funneling them into a 250 ml graduated cylinder. The expansion volume was 381 cc/g.
EXAMPLE 6
[0050] Twenty -five grams of a (+50 mesh) natural graphite flake were intercalated with 25 grains of intercalant consisting of 90 parts by weight of 93% sulfuric acid and 10 parts by weight of 67% nitric acid. After mixing for three minutes, 0.500 grams of 1, 10 decanediol were blended into the flakes. The flakes were then placed in a 100° C. oven for 20 minutes. The intercalated flakes were then washed with four aliquots of 200 ml of water. After each washing the flakes were filtered by vacuum through a Teflon screen. After the final wash the flakes were dried for 1 hour in a 115° C. oven.
[0051] The expansion of the intercalated flakes was measured by placing exactly 1.00 g into a 250 ml crucible. The cold crucible was placed into a 600° C. oven for 2 minutes. The volume and weight of the expanded flakes were measured after carefully funneling them into a 250 ml graduated cylinder. The expansion volume was116 cc/g.
[0052] The expansion or exfoliation volume of the intercalated flakes was also measured by heating the intercalated graphite flakes in a 845° C. preheated metal crucible over a Bunsen burner flame, and measuring the bulk volume of the resulting exfoliated flakes. The volume and weight of the expanded flakes were measured after carefully funneling them into a 250 ml graduated cylinder. The expansion volume was 511 cc/g.
EXAMPLE 7
[0053] Twenty -five grams of a (+50 mesh) natural graphite flake were intercalated with 25 grams of intercalant consisting of 90 parts by weight of 930% sulfuric acid and 10 parts by weight of 67% nitric acid. After mixing for three minutes, 1.00 grams of decylaldehyde were blended into the flakes. The flakes were then placed in a 100° C. oven for 20 minutes. The intercalated flakes were then washed with four aliquots of 200 ml of water. After each washing the flakes were filtered by vacuum through a Teflon screen. After the final wash the flakes were dried for 1 hour in a 115° C. oven.
[0054] The expansion of the intercalated flakes was measured by placing exactly 1.00 g into a 250 ml crucible. The cold crucible was placed into a 600° C. oven for 2 minutes. The volume and weight of the expanded flakes were measured after carefully funneling them into a 250 ml graduated cylinder. The expansion volume was 156 cc/g.
[0055] The expansion or exfoliation volume of the intercalated flakes was also measured by heating the intercalated graphite flakes in a 845° C. preheated metal crucible over a Bunsen burner flame, and measuring the bulk volume of the resulting exfoliated flakes. The volume and weight of the expanded flakes were measured after carefully funneling them into a 250 ml graduated cylinder. The expansion volume was 521 cc/g.
EXAMPLE 8
[0056] Twenty -five grams of a (+50 mesh) natural graphite flake were intercalated with 25 grams of intercalant consisting of 90 parts by weight of 93% sulfuric acid and 10 parts by weight of 67% nitric acid. After mixing for three minutes, 1.0 grain of the ester, ethylene glycol monostearate, was blended into the flakes. The flakes were then stirred on a hot plate for 10 minutes temperature increasing to 90° C. to dissolve the ethylene glycol monostearate). The mixture was then placed in a 100° C. oven for 20 minutes. The intercalated flakes were then washed with four aliquots of 200 ml of water. After each washing the flakes were filtered by vacuum through a Teflon screen. After the final wash the flakes were dried for 1 hour in a 115° C. oven.
[0057] The expansion of the intercalated flakes was measured by placing exactly 1.00 g into a 250 ml crucible. The cold crucible was placed into a 600° C. oven for 2 minutes. The volume and weight of the expanded flakes were measured after carefully funneling them into a 250 ml graduated cylinder. The expansion volume was 124 cc/g.
[0058] The expansion or exfoliation volume of the intercalated flakes was also measured by heating the intercalated graphite flakes in a 845° C. preheated metal crucible over a Bunsen burner flame, and measuring the bulk volume of the resulting exfoliated flakes. The volume and weight of the expanded flakes were measured after carefully funneling them into a 250 ml graduated cylinder. The expansion volume was 379 cc/g.
EXAMPLE 9
[0059] Twenty -five grams of a (+50 mesh) natural graphite flake were intercalated with 25 grams of intercalant consisting of 90 parts by weight of 93% sulfuric acid and 10 parts by weight of 67% nitric acid. After mixing for three minutes, 0.375 grams of sucrose were blended into the flakes. The flakes were then stirred on a hot plate for 10 minutes (temperature increasing to 90° C. to dissolve the sucrose). The mixture was then placed in a 100° C. oven for 20 minutes. The intercalated flakes were then washed with four aliquots of 200 ml of water. After each washing the flakes were filtered by vacuum through a Teflon screen. After the final wash the flakes were dried for 1 hour in a 115° C. oven.
[0060] The expansion of the intercalated flakes was measured by placing exactly 1.00 g into a 250 ml crucible. The cold crucible was placed into a 600° C. oven for 2 minutes. The volume and weight of the expanded flakes were measured after carefully funneling them into a 250 ml graduated cylinder. The expansion volume was 73 cc/g.
[0061] The expansion or exfoliation volume of the intercalated flakes was also measured by heating the intercalated graphite flakes in a 845° C. preheated metal crucible over a Bunsen burner flame, and measuring the bulk volume of the resulting exfoliated flakes. The volume and weight of the expanded flakes were measured after carefully funneling them into a 250 ml graduated cylinder. The expansion volume was 342 cc/g.
Comparative for Example 9
[0062] Twenty -five grams of a (+50 mesh) natural graphite flake were intercalated with 25 grams of intercalant consisting of 90 parts by weight of 93 % sulfuric acid and 10 parts by weight of 67% nitric acid. After mixing for three minutes, 0.375 grams of sucrose were blended into the flakes. The flakes were then stirred and blended at room temperature (20°) for 20 minutes. The intercalated flakes were then washed with four aliquots of 200 ml of water. After each washing the flakes were filtered by vacuum through a Teflon screen. After the final wash the flakes were dried for 1 hour in a 115° C. oven.
[0063] The expansion of the intercalated flakes was measured by placing exactly 1.00 g into a 250 ml crucible. The cold crucible was placed into a 600° C. oven for 2 minutes. The volume and weight of the expanded flakes were measured after carefully funneling them into a 250 ml graduated cylinder. The expansion volume was only 31 cc/g. The expansion was inferior to that obtained for Example (9) since the sample was blended with sucrose at 20° C. for only 20 minutes.
[0064] The expansion or exfoliation volume of the intercalated flakes was also measured by heating the intercalated graphite flakes in a 845° C. preheated metal crucible over a Bunsen burner flame, and measuring the bulk volume of the resulting exfoliated flakes. The volume and weight of the expanded flakes were measured after carefully funneling them into a 250 ml graduated cylinder. The expansion volume was only 156 cc/g. The expansion was inferior to that obtained in example (9) since no external heat was applied to the intercalated flakes.
EXAMPLE 10
[0065] Twenty -five grams of a (+50 mesh) natural graphite flake were intercalated with 25 grams of intercalant consisting of 90 parts by weight of 93% sulfuric acid, 10 parts by weight of 67% nitric acid, and 3.5 pph of oxalic acid. After mixing for three minutes, 0.25 grams of polypropylene glycol were blended into the flakes. The flakes were then placed in a 100° C. oven for 20 minutes. The intercalated flakes were then washed with four aliquots of 200 ml of water. After each washing the flakes were filtered by vacuum through a Teflon screen. After the final wash the flakes were dried for 1 hour in a 115° C. oven.
[0066] The expansion of the intercalated flakes was measured by placing exactly 1.00 g into a 250 ml crucible. The cold crucible was placed into a 600° C. oven for 2 minutes. The volume and weight of the expanded flakes were measured after carefully funneling them into a 250 ml graduated cylinder. The expansion volume was 260 cc/g.
EXAMPLE 11
[0067] Twenty -five grams of a (+50 mesh) natural graphite flake were intercalated with 25 grams of intercalant consisting of 90 parts by weight of 93% sulfuric acid, 10 parts by weight of 67% nitric acid, and 3.5 pph of oxalic acid. After mixing for three minutes, 0.625 grams of ascorbic acid were blended into the flakes. The flakes were then placed in a 100° C. oven for 20 minutes. The intercalated flakes were then washed with four aliquots of 200 ml of water. After each washing the flakes were filtered by vacuum through a Teflon screen. After the final wash the flakes were dried for 1 hour in a 115° C. oven.
[0068] The expansion of the intercalated flakes was measured by placing exactly 1.00 g into a 250 ml crucible. The cold crucible was placed into a 600° C. oven for 2 minutes. The volume and weight of the expanded flakes were measured after carefully funneling them into a 250 ml graduated cylinder. The expansion volume was 270 cc/g.
EXAMPLE 12
[0069] Twenty -five grams of a (+50 mesh) natural graphite flake were intercalated with 25 grams of intercalant consisting of 90 parts by weight of 93% sulfuric acid, 10 parts by weight of 67% nitric acid, and 3.5 pph of oxalic acid. After mixing for three minutes, 0.50 grams of sodium lignate were blended into the flakes. The flakes were then placed in a 100° C. oven for 30 minutes. The intercalated flakes were then washed with four aliquots of 200 ml of water. After each washing the flakes were filtered by vacuum through a Teflon screen. After the final wash the flakes were dried for 1 hour in a 115° C. oven.
[0070] The expansion of the intercalated flakes was measured by placing exactly 1.00 g into a 250 ml crucible. The cold crucible was placed into a 600° C. oven for 2 minutes. The volume and weight of the expanded flakes were measured after carefully funneling them into a 250 ml graduated cylinder. The expansion volume was 290 cc/g.
EXAMPLE 13
[0071] Twenty -five grams of a (+50 mesh) natural graphite flake were intercalated with 25 grams of intercalant consisting of 90 parts by weight of 93% sulfuric acid, 10 parts by weight of 67% nitric acid, and 4.0 pph of succinic acid. After mixing for three minutes, 1.00 grams of decanol were blended into the flakes. The flakes were then placed in a 100° C. oven for 30 minutes. The intercalated flakes were then washed with four aliquots of 200 ml of water. After each washing the flakes were filtered by vacuum through a Teflon screen. After the final wash the flakes were dried for 1 hour in a 115° C. oven.
[0072] The expansion of the intercalated flakes was measured by placing exactly 1.00 g into a 250 ml crucible. The cold crucible was placed into a 600° C. oven for 2 minutes. The volume and weight of the expanded flakes were measured after carefully funneling them into a 250 ml graduated cylinder. The expansion volume was 355 cc/g.
EXAMPLE 14
[0073] A series of polyfunctional reducing agents was evaluated for their effect on both cold crucible expansion and compressed expansion. For each run, graphite flake was intercalated as in Example 12 and then subjected to expansion testing as in that example to obtain a value for cold crucible expansion. A value for compressed expansion was obtained by varying the above test by using a special test device that employs a 400 gram weight to rest upon 5 grams of the graphite flake placed in a 2.54 cm diameter cylinder and exert a pressure on the flake during heating and expansion. The results are summarized in the following table:
Cold Crucible Compressed Grams Expansion at Expansion Reagent Reagent 600° C., cc/g height at 600° C., mm Triton X-100 1 0.225 298 72.8 Tergitol NP-10 2 0.225 293 76.5 Tergitol 15-S-7 3 0.225 339 73.4 Polypropylene Glycol 4 0.25 260 60
[0074] In each of the above cases, the polyfunctional surfactant reducing additive increases both cold crucible and compressed expansion compared to a nonsurfactant polyfunctional reducing additive, polypropylene glycol. | Intercalated graphite flake which has enhanced exfoliation volume characteristics at relatively low exfoliation temperatures, e.g., 600° C. and even lower, is made by adding an organic expansion aid to the intercalant solution and heating a blend of intercalated particles and an organic reducing agent in the temperature range of 25° to 125° C. | 2 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to a beamwidth adjustment device, and more particularly, to a beamwidth adjustment device for adjusting a beamwidth formed by a feedhorn.
[0003] 2. Description of the Prior Art
[0004] Satellite communication is distinguished in wide coverage and terrestrial interference avoidance, and is widely used in military, probe, and commercial communication services, such as satellite navigation, satellite voice broadcasting, and satellite television broadcasting. A conventional satellite communication receiving device consists of a dish reflector and a low noise block down-converter with feedhorn (LNBF). The LNBF is disposed on the focus of the dish reflector, and is used for receiving radio signals reflected via the dish reflector, down-converting the radio signals to middle band, and then transmitting the radio signals to a backend satellite signal processor for signal processing, thereby enabling the playing of satellite television programs.
[0005] The LNBF is composed of a feedhorn, a waveguide and a low noise block down-converter (LNB). The feedhorn is used for collecting signals reflected by a satellite antenna to the waveguide, to output to the LNB. Except receiving satellite signals, the feedhorn can transmit signals (reflected via the dish reflector) to the satellite for different applications.
[0006] The reception quality of the satellite antenna is significant related to the placed position of the feedhorn. For example, the feedhorn radiates electromagnetic waves from a focal position of the satellite antenna, and thereby the electromagnetic waves are reflected to the satellite via the dish reflector. A number of signals that can be received by the satellite antenna is decreased when the feedhorn is deviated from the focal position. In practice, the focal position is represented by a focal length to diameter ratio (F/D) of the dish. Note that, the reception efficiency of the satellite antenna is affected by whether the focal length to diameter ratio (hereafter called F/D value) of the dish matches a beamwidth formed by the feedhorn. In other words, different F/D design requires different values of the beamwidth, so that the beams emitted from the feedhorn can be efficiently received by the satellite antenna. For example, a dish with F/D=0.6 requires a narrower beamwidth compared to a dish with F/D=0.4. If the beamwidth does not conform the F/D design of the dish (e.g. too wide or too narrow), reception efficiency of the satellite antenna is affected, thereby lowering the reception quality of the satellite antenna.
[0007] However, a device for adjusting the beamwidth formed by the feedhorn has never been provided in the current market, so that the beamwidth formed by the feedhorn may not match the dish perfectly. In addition, in the beginning of product design, manufacture companies take much effort to reduce size of products, toward compact products and low cost. Therefore, under reduction of an opening size of the feedhorn, how to match the beamwidth and the dish is a topic for discussion.
SUMMARY OF THE INVENTION
[0008] Therefore, the present invention provides a beamwidth adjustment device for a feedhorn, for adjusting a beamwidth formed by the feedhorn, so as to perfectly match the beamwidth with a dish of a satellite antenna.
[0009] The present invention discloses a beamwidth adjustment device for a feedhorn comprising an opening and a ring encircling the opening. The beamwidth adjustment device comprises a conductor for adjusting beamwidth formed by the feedhorn according to a characteristic of a dish of a satellite antenna corresponding to the feedhorn, and a fixing element for fixing the conductor to the feedhorn, wherein the satellite antenna is used for receiving signals from the feedhorn.
[0010] These and other objectives of the present invention will no doubt become obvious to those of ordinary skill in the art after reading the following detailed description of the preferred embodiment that is illustrated in the various figures and drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] FIG. 1 is a schematic diagram of a beamwidth adjustment device used for a feedhorn according to an embodiment of the present invention.
[0012] FIG. 2-FIG . 5 are schematic diagrams of beamwidth adjustment devices according to embodiments of the present invention.
[0013] FIG. 6 is a schematic diagram of a waterproof component with the beamwidth adjustment device of FIG. 1 .
[0014] FIG. 7 is a schematic diagram of a beam emitted from the feedhorn without a beamwidth adjustment device according to an embodiment of the present invention.
[0015] FIG. 8 is a schematic diagram of a beam emitted from the feedhorn of FIG. 1 .
[0016] FIG. 9 is a schematic diagram of a beam emitted from the feedhorn of FIG. 3 .
[0017] FIG. 10 is a comparison table of beamwidths in FIG. 7-FIG . 9 .
DETAILED DESCRIPTION
[0018] Please refer to FIG. 1 , which is a schematic diagram of a beamwidth adjustment device 10 according to an embodiment of the present invention. The beamwidth adjustment device 10 is used in a feedhorn 100 . The feedhorn 100 includes an opening 102 and a ring 104 encircling the opening 102 . In FIG. 1 , the beamwidth adjustment device 10 is composed of a conductor used for adjusting beamwidth formed by the feedhorn 100 according to a characteristic of a dish of a satellite antenna (not shown in FIG. 1 ) corresponding to the feedhorn 100 . The characteristic of the dish is a focal length to diameter radio (F/D). Note that, a shape of the conductor of the beamwidth adjustment device 10 can be a symmetric geometrical shape, such as orthogonal cross, concentric circle, spot eccentric circle, or radiative distribution, etc., and the conductor is placed above, below or in the same plane of the opening 102 of the feedhorn 100 by a fixed component (shown in FIG. 1 ). The fixed component is mainly used for fixing the conductor at the feedhorn 100 , as other components and methods obtaining the same objective belong to the claimed invention. For example, the fixed component is a weld, so that the conductor can be welded at the outer rim of the opening 102 or the inner surface of the ring 104 of the feedhorn, or is a pillar extending from the ring 104 to the opening 102 , so that the conductor can be installed on the top of the pillar, so as to reach the goal of fixing the conductor at the feedhorn 100 . In brief, the beamwidth is modified according to a size, a shape, or a position of the conductor placed at the feedhorn 100 . Therefore, the present invention can adjust a width of abeam emitted from the feedhorn 100 to the satellite antenna through the beamwidth adjustment device 10 , thereby increasing signal reception efficiency of the satellite antenna, so as to enhance the reception quality. Furthermore, the present invention can perfectly match the feedhorn 100 to different satellite antennas (e.g. different F/D design).
[0019] In FIG. 1 , the beamwidth adjustment device 10 is a design of orthogonal polarization, and is capable of reflecting to extend an electric field feedback path and gather current so that the directionality of the beam can be enhanced, to reach the goal of gathering beams, thereby avoiding that a part of beams with wider beamwidth cannot be received, so as to increase reception efficiency of the satellite antenna. The design of the orthogonal polarization can be symmetrical or asymmetrical orthogonal (e.g. length, width or height). In addition, a size of the opening of the feedhorn 100 can be decreased without affecting a match with the dish when the beamwidth is decreased by the beamwidth adjustment device 10 , so as to reduce the manufacture cost.
[0020] As can be seen, when the size of the opening of the feedhorn 100 is fixed, the feedhorn 100 can match the dish perfectly with the beamwidth adjustment device 10 , so as to increase the reception quality. On the other hand, when the opening size of the feedhorn 100 is decreased, the beamwidth can be maintained or optimized via the beamwidth adjustment device 10 of the present invention. Therefore, the area of the opening of the feedhorn 100 can be reduced efficiently, to increase a feasibility of installation with multiple satellite antennas.
[0021] Note that, the beamwidth adjustment device 10 of the present invention can be applied into any kind of feedhorns, such as conical, pyramidal, corrugated, dielectric-load, lens-corrected, dielectric or array, etc., or into different shapes of the opening, such as a square, circle, rectangle, rhombus or ellipse, etc.
[0022] Therefore, the feedhorn 100 can obtain an optimization antenna gain through different shapes of the beamwidth adjustment devices. For example, please refer to FIG. 2-5 , which illustrate schematic diagrams of beamwidth adjustment devices 20 - 50 according to embodiments of the present invention. In FIG. 2 , the conductor of the beamwidth adjustment device 20 and the opening 102 are not located in the same plane and formed as a radiative circularity. In FIG. 3 , the conductor of the beamwidth adjustment device 30 and the opening 102 are located in the same plane and formed as a concentric circularity. In FIG. 4 , the conductor of the beamwidth adjustment device 40 and the opening 102 are located in the same plane and formed as a non-continuous circularity. In FIG. 5 , the conductor of the beamwidth adjustment device 50 and the opening 102 are not located in the same plane and formed as an eccentric circularity. Therefore, the beamwidth adjustment devices 30 , 40 of FIG. 3 and FIG. 4 , can make high frequencies match the electric field reflection, so as to maintain the beam pattern. On the other hand, the beamwidth adjustment devices 20 , 50 of FIG. 2 and FIG. 5 , can adjust the beamwidth according to different frequencies, such as low, intermediate, or high frequency, to obtain a beamwidth appropriated for the design of the dish, so as to reduce antenna loss and obtain the optimization antenna gain. In addition, the beamwidth adjustment devices 10 , 20 , 30 , 40 , 50 of the present invention can be utilized for impedance match improvement, to reduce the return loss of the antenna.
[0023] From the above, except installation in the same plane of the opening 102 of the feedhorn 100 , the beamwidth adjustment device of the present invention can be installed above or below the opening 102 as well. For example, in FIG. 6 , the beamwidth adjustment device 10 is installed in a waterproof component 200 for covering the feedhorn 100 , such as a feed cap. Furthermore, the beamwidth adjustment device 10 can be electroplated on the waterproof component 200 with a form of conductive film, be included in the water proof component 200 upon injection molding, or be installed on the waterproof component 200 with a metal foil form made of cupronickel oxide. Note that, except the beamwidth adjustment device 10 , the beamwidth adjustment devices 20 , 30 , 40 , 50 can be applied into the waterproof component 200 as well.
[0024] Please refer to FIG. 7-9 , which are schematic diagrams of beams emitted from the feedhorn 100 operated in a frequency of 10.7 GHz without any beamwidth adjustment device, with the beamwidth adjustment device 10 , and with the beamwidth adjustment device 30 respectively. As can be seen in FIG. 7-9 , the beamwidth formed by the feedhorn 100 without the beamwidth adjustment device is wider than the beamwidth formed by the feedhorn 100 with the beamwidth adjustment device 10 . Compared to FIG. 8-9 , the beamwidth formed by the beamwidth adjustment device 10 with the shape of orthogonal cross is narrower than the beamwidth formed by the feedhorn 100 with no beamwidth adjustment device at 10 dB, and the beamwidth formed by the beamwidth adjustment device 30 with the shape of concentric circle is wider than the beamwidth formed by the feedhorn 100 with no beamwidth adjustment device at 10 dB. Please refer to FIG. 10 , which is a comparison table of the beamwidths of FIG. 7-9 . As can be seen in FIG. 10 , the beamwidth of the feedhorn 100 without the beamwidth adjustment device is 80.22 degree (an average of the beamwidth measured in horizontal, vertical and 45 degree direction), whereas the beamwidth of the feedhorn 100 with beamwidth adjustment device 10 is 69.35 degree, so as to match the dish with F/D=0.6. On the other hand, the beamwidth of the feedhorn 100 with the beamwidth adjustment device 30 is 92.66 degree, thereby matching the dish with F/D=0.4. As can be seen, the beamwidth at 10 dB formed by the feedhorn 100 can be adjusted plus and minus 15 degree by the beamwidth adjustment device. Note that, the present invention can adjust the beamwidth to conform the characteristic of the satellite antenna without modification of the opening size of the feedhorn or a mold size.
[0025] In conclusion, in the prior art, the beamwidth can not be adjusted to match the dish perfectly, causing poor reception quality. In comparison, in the present invention a required beamwidth can be obtained for different dish designs (e.g. different F/D values) without modification the size of the feedhorn, so as to increase reception quality. Furthermore, with decrease opening size of the feedhorn, the beamwidth adjustment device of the present invention can maintain the same beamwidth to match the dish, so as to reduce cost efficiently.
[0026] Those skilled in the art will readily observe that numerous modifications and alterations of the device and method may be made while retaining the teachings of the invention. | A beamwidth adjustment device, which is used for a feedhorn comprising an opening and a ring encircling the opening, comprises a conductor used for adjusting beamwidth formed by the feedhorn according to a characteristic of a dish of a satellite antenna corresponding to the feedhorn, and a fixing element used for fixing the conductor to the feedhorn, wherein the satellite antenna is used for receiving signals from the feedhorn. | 7 |
CROSS-REFERENCE TO RELATED APPLICATIONS
The present invention is related to U.S. patent application Ser. No. 11/297,490 entitled “Electric Drives System for Vehicle, Electric Control System for Vehicle, Electric Drive Method for Vehicle”, filed on Dec. 9, 2005.
BACKGROUND OF THE INVENTION
The present invention relates to an AC drive apparatus, a vehicle control apparatus, a power conversion method, and a vehicle control method.
With the advance of power electronics, a vehicle drive system, for example, has increasingly employed an AC motor instead of a DC motor. In such a system which employs an AC motor, electric energy is supplied to the motor for use as motive energy upon startup of the system, and a so-called rheostatic brake is employed for forcing the motor to operate as a generator upon braking such that electric energy generated thereby is consumed by a resistor to produce a braking force. Such a system is shown, For example, in JP-A-6-46505.
SUMMARY OF THE INVENTION
However, the foregoing system cannot produce the braking force if the rheostatic brake fails. While a mechanical brake is often provided together with an electric brake to enable the production of a braking force by applying a friction force to an axil, the rheostatic brake tends to produce a larger braking force and requires less maintenance operations than the mechanical brake, so that the mechanical brake is used only during low-speed operations or for a final stop. Therefore, the rheostatic brake has been requested to improve the reliability. It is an object of the present invention to provide an AC drive apparatus which has a reliable rheostatic brake, a vehicle control apparatus, a power conversion method, and a vehicle control method.
To achieve the above object, an AC drive apparatus of the present invention includes a plurality of electric brakes each including a resistor for consuming an electromotive force regenerated by a motor, and a switch for connecting the resistor. If the consumption of the electromotive force is impeded in one of electric brakes including any of the plurality of resistors, the electromotive force Is consumed by electric brakes including the remaining resistors.
More specifically, the AC drive apparatus has a plurality of rheostatic brakes, each brake is connected to DC section through a switch, and the DC section is configured between a rectifier of which power is from a prime mover and the bidirectional converter of which power is from AC motor.
According to the present invention, the AC drive apparatus realized thereby comprises reliable electric brakes More specifically, an electromotive force regenerated as DC power through the bidirectional converter is consumed by a plurality of rheostatic brakes to produce a braking force. Also, when some of the plurality of rheostatic brakes fails, the failed rheostatic brake is disconnected, such that a vehicle operator can still continue a vehicle decelerating operation, or can keep enough time to transit to a mechanical bake because an entire braking force is not lost, though the braking force becomes lower than when all the rheostatic brakes are sound. Generally, in recent years, a forced cooling scheme based on an electric fan Is employed in the rheostatic brake with the intention of improving the utilization factor and reducing the size and weight. For this reason, opportunities of failure are increasing, so that the present invention is also effective as means which responds to the need for both the reduction in size and weight and the improvement in reliability.
Other objects, features and advantages of the invention will become apparent from the following description of the embodiments of the invention taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block circuit diagram illustrating a method of implementing an AC drive system which comprises a prime mover as a power source, and a plurality of rheostatic brake circuits (First Embodiment);
FIG. 2 is a graph showing an exemplary AC voltage control characteristic;
FIG. 3 is a graph showing an exemplary control characteristic of a DC voltage versus switch on/off duty;
FIG. 4 is a block circuit diagram illustrating a method of implementing an AC drive system which comprises a trolley as a power source, and a plurality of rheostatic brake circuits (Second Embodiment);
FIG. 5 is a block circuit diagram illustrating a method of implementing an AC drive system which comprises a prime mover and a trolley as power sources, and a plurality of rheostatic brake circuits (Third Embodiment); and
FIGS. 6A , 6 B, 6 C are diagrams illustrating a cooling unit in detail.
DETAILED DESCRIPTION OF THE EMBODIMENTS
In the following, embodiments of the present invention will be described with reference to the accompanying drawings in the order of a first to a third embodiment.
First Embodiment
An AC drive system of the present invention comprises a plurality of rheostatic brakes connected in parallel to achieve the object of avoiding a loss of an overall braking force due to a failure of a rheostatic brake. FIG. 1 illustrates the AC drive system according to a first embodiment of the present Invention. An AC generator 2 (or called the “main generator 2 ,” which is also applied to the following description) driven by a prime mover 1 feeds an AC output to a rectifier 3 . The rectifier 3 outputs a DC voltage which includes ripples reduced by a smoothing capacitor 4 . For setting the DC voltage to a required value which Is calculated by a controller 7 , a field regulator 17 controls an exciting current of the generator 2 . This DC voltage is fed to a motor 9 through a bidirectional converter 8 which converts the DC voltage to an AC voltage at art arbitrary frequency. Output values of an output current detector 14 associated with the bidirectional converter 8 and a speed detector 16 are fetched into a controller 7 which determines a switching state of the bidirectional converter 8 together with a motor output torque setting unit 5 and a voltage across a smoothing capacitor, and outputs a switching pulse to the bidirectional converter 8 . With these operations, a vehicle equipped with the AC drive system conducts acceleration/deceleration control.
When the vehicle is accelerated, a torque is determined based on an accelerator unit 5 trodden state and output values of the current detector 14 associated with the bidirectional converter 8 and the speed detector 16 . To provide the determined torque to the motor, the controller 7 controls the rotation speed of the prime mover 1 by using the values of the output current detector 14 , speed detector 16 and DC voltage detector 15 in a relationship as shown in FIG. 2 . Likewise, to determine a switching state of the bidirectional converter 8 , the output values of the output current detector 14 , the speed detector 16 , the torque setting unit 5 and the voltage across the smoothing capacitor are supplied to the controller 7 . Since the motor 9 generates an increasingly larger torque as the bidirectional converter 8 supplies an AC current at a higher frequency, the vehicle is accelerated.
When the vehicle is decelerated, the motor 9 enters a regenerative mode to convert motive energy of the vehicle to AC electric energy. This AC electric energy is converted to DC power by the bidirectional converter 8 . In this event, a DC voltage outputted by the bidirectional converter 8 is controlled to a higher value than a DC voltage which is outputted by the generator 2 through the rectifier 3 . The controller 7 determines a time for which a resistor a ( 12 a ) of an electric brake a ( 10 a ) and a resistor b ( 12 b ) of an electric brake b ( 10 b ) are connected to a DC section, ie., a duty in accordance with the values of the DC voltage detector 15 and a braking force setting unit 6 , as well as a difference between the two values. Switches 11 a , 11 b for connecting the resistors a ( 12 a , b ( 12 b ) to the DC section, which comprise semiconductor devices or the like, start an on/off operation when the DC voltage value exceeds a set value a (2,000 volts by way of example), for example, as shown in FIG. 3 , and repeat the on/off operation such that the DC voltage value falls within a set value b (3,000 volts by way of example). In this event, in a range of 100 to 2,000 volts, the switches 11 a , 11 b remain off.
Further, the on/off duty is increased as the DC voltage value is increased, and the on/off duty is set to 100% when the DC voltage value reaches a set value b, for example, as shown in FIG. 3 (i.e., the switches 11 a, 11 b remain on).
The controller 7 detects currents passing through the resistors a, b by current detectors 18 a and 18 b , and calculates the power consumed by the resistors a, b such that the electric energy generated by the motor 9 is entirely consumed by the resistors a, b. With these operations, the vehicle equipped with the AC drive system is decelerated.
If one of the rheostatic brakes 10 a , 10 b fails during the decelerating operation, the electric energy generated by the motor 9 cannot be entirely consumed. Thus, if the same electric energy as that before the failure was continuously regenerated to the DC section, the DC voltage would continue to rise and eventually exceed the withstanding voltage level of each device, so that, for preventing this inconvenience, the regenerated energy must be limited. Since the regenerated energy is limited by the capacity of a sound rheostatic brake, a conventional vehicle equipped only with a single rheostatic brake results in a temporary loss of an entire braking force However, the AC drive system according to the present invention illustrated in FIG. 1 comprises a plurality of rheostatic brakes, so that even it the electric brake 10 a (also called the “rheostatic brake 10 a ”) fails, the switch a is made inoperative, and the second electric brake 10 b (also called the “rheostatic brake 10 b ”) can continue the braking operation though the braking force is reduced to one-half as much as when the whole system is sound.
Referring now to FIGS. 6A , 6 B, 6 C, a detailed description will be given of the structure of a cooling unit composed of the resistor a ( 12 a ) and a cooling fan a ( 13 a ) (an area surrounded by a one-dot chain line within the electric brake 10 a ), and a cooling unit composed of the resistor b ( 12 b ) and a cooling fan b ( 13 b ) (an area surrounded by a one-dot chain line within the electric brake 10 b ). Since the former cooling unit is substantially identical in configuration to the latter cooling unit, the following description will focus on the cooling unit composed of the resistor a ( 12 a ) and cooling fan a ( 13 a ) in FIG. 1 .
As illustrated in FIG. 6A , a housing comprises a cylinder housing and a square pillar housing connected thereto, both of which are made of metal (preferably, a steel plate). The cooling fan a ( 13 a ) is stored in the cylindrical housing. The cooling fan a ( 13 a ) rotates to feed cooling air in a direction indicated by arrows in the figure. The cooling air passes through the square pillar housing, flowing as indicated by the right-hand arrow in the figure, and is emitted from the square pillar housing by an air blasting action of the cooling fan a ( 13 a ).
As illustrated in FIG. 6B , resistor elements 12 a - 1 - 12 a - 7 , which make up the resistor a ( 12 a ), are arranged side by side within the square pillar housing in the air blasting direction. The cooling air fed by the cooling fan a ( 13 a ) sequentially cools down the resistor elements 12 a - 1 - 12 a - 7 . Each of the resistor elements 12 a - 1 - 12 a - 7 is composed of an upper metal plate and a lower metal plate which are connected by four metal plates for example. Electric couplers are attached to both ends of the upper metal plate.
The foregoing electric couplers are electrically connected to each other to make up an electric circuit as illustrated in FIG. 6C .
Here, as illustrated in FIG. 6A , a temperature sensor 22 a is mounted halfway in the cylindrical housing in the air passing direction. The temperature sensor 22 a detects the temperature within the cylindrical housing to send a temperature signal to the controller 7 . Also, a pressure sensor 23 a is mounted near the rear end of the cylindrical housing in the air passing direction. The pressure sensor 23 a detects the pressure to find the fan working soundly near the exit of the cylindrical housing to send a pressure signal to the controller 7 , so as to increase reliability of the electric brake.
The controller 7 monitors the temperature signal and pressure signal, and determines an abnormal temperature or an abnormal pressure if one (or both) of these signals reaches a predetermined value or higher to bring the switches 11 a, 11 b into a disconnected state. Alternatively, the controller 7 controls the switches 11 a, 11 b such that they remain off for a longer time in their on/off operations.
Second Embodiment
An AC drive system according to a second embodiment comprises a trolley which is substituted for the components of the first embodiment for connecting the AC output of the AC generator 2 driven by the prime mover 1 to the rectifier 3 to supply DC power in the first embodiment. In a system which comprises a trolley 20 that does not have a capacity large enough to absorb regenerated power, a vehicle itself must consume the regenerated power. Therefore, when a braking force is required, the trolley is disconnected from the AC drive system by a trolley connector 19 upon detection of a positive output from the braking force setting unit 6 , in order to prevent the power from flowing from the trolley to the resistors 11 a, 11 b of the rheostatic brakes 10 a, 10 b. In this way, the AC rive system of the second embodiment can perform similar operations to those of the first embodiment.
Third Embodiment
An AC drive system according to a third embodiment comprises both means for connecting the AC output of the AC generator 2 driven by the prime mover 1 to the rectifier 3 to supply DC power in the first embodiment, and means for supplying DC power by a trolley 20 in the second embodiment. A special vehicle system such as an electric truck may be provided with the power through a trolley 20 , but must operate even in a place where the trolley is not installed. Thus, the AC drive system continues to operate while switching the power source by a trolley/motor switching unit 21 between the power generated by the prime mover 1 and the power supplied through the trolley 2 . In this way, the AC drive system of the third embodiment can perform similar operations to those of the first and second embodiments.
The configurations of the first to third embodiments can also be applied to an electric propeller ship which employs a grid resistor for a speed restraining operation.
It should be further understood by those skilled in the art that although the foregoing description has been made on embodiments of the invention, the invention is not limited thereto and various changes and modifications may be made without departing from the spirit of the invention and the scope of the appended claims. | A motor is driven with variable frequency AC power converted from DC power, and an AC output power from the motor is converted to DC. In the conversion, an electromotive force regenerated by the motor is consumed by a plurality of resistors. When the consumption of the electromotive force is impeded in any of systems including any of the plurality of resistors, the electromotive force is consumed by the systems including the remaining resistors. Even if a system including any of the plurality of resistors fails, the electromotive force can by consumed by the other systems including the remaining resistors, thus providing a reliable rheostatic brake. | 8 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a test circuit for logic circuits which fetches data from a register connected to an interface circuit. The semiconductor circuit performs logical operations and stores results in the register.
2. Description of the Prior Art
FIG. 1 is a block diagram showing a conventional semiconductor circuits such as, a one-chip microcomputer. The semiconductor circuit includes logic circuits for receiving data from a register connected to an interface circuit. An operation is performed, the result of which is stored in the register.
In the figure, numeral 1 denotes an input terminal. An instruction code 101 is input on input terminal 1 by control of a CPU, (not shown).
An instruction decoder 2 decodes the instruction code 101 input from the input terminal 1. A decoded result of instruction decoder 2 is input to a register control circuit 3 and interface control circuit 4 as a control signal 102.
The register control circuit 3 outputs a control signal 103 for controlling data transmissions between a register 5 and an internal bus 8. These data transmitted are controlled according to the control signal 102 received from the instruction decoder 2.
The interface control circuit 4 outputs a control signal 104 which controls an interface circuit 6. Control of interface circuit 6 is determined according to the control signal 102 received from the instruction decoder 2.
The register 5 is connected to the internal bus 8 and controlled by the control signal 103 received from the register control circuit 3. The data stored in register 5 is output to the internal bus 8. Further, data on internal bus 8 can be stored in register 5. Register 5 is connected to an internal logic circuit 20 as such as an ALU.
The internal logic circuit 20 fetches data stored in the register 5. A prescribed logical operation is performed on the data and the result is again stored in the register 5.
The interface circuit 6 is connected to the internal bus 8 and controlled by the control signal 104 received from the interface control circuit 4. Depending upon the state of control signal 104, data is either input from an external terminal 7 to the internal bus 8, or output from the interface circuit 6 to the external terminal 7.
Operations of a semiconductor circuit including such conventional logic circuits are as follows.
When the instruction code 101 is input to the input terminal 1, the instruction code is decoded by the instruction decoder 2 from which the control signal 102 is output.
Now, suppose that the instruction code 101 is a data transfer instruction code. In that case the instruction code stores data in the register 5 from the external terminal 7 of the interface circuit 6 via the internal bus 8. Alternatively, register 5 may output the data to the external terminal 7 via the internal bus 8 and interface circuit 6.
The control signal 102 is input to the register control circuit 3 and interface control circuit 4. The register control circuit 3 outputs the control signal 103 in response to receiving the control signal 102 to the register 5. The interface control circuit 4 outputs the control signal 104 responsive to the control signal 102 to the interface circuit 6.
The instruction code 101 input to the input terminal 1 may be an instruction for outputting data to the external terminal 7 from the register 5. In that case, register 5 outputs the data to the internal bus 8 according to the control signal 103 input from the register control circuit 3. The interface circuit 6 fetches the data from the internal bus 8 and outputs to the external terminal 7 according to the control signal 104 received from the interface control circuit 4. Likewise, the instruction code input to the input terminal 1 may be an instruction for setting data to the register 5 from the external terminal 7. In this case, the interface circuit 6 fetches the data from the external terminal 7 and outputs it to the internal bus 8 according to the control signal 104 received from the interface control circuit 4. The register 5 fetches and stores the data from the internal bus 8 according to the control signal 103 received from the register control circuit 3. The data stored in the register 5 is input to the internal logic circuit 20.
The conventional semiconductor circuit including the logic circuit has the configuration described hereinabove. It may used for checking, for example, the operation of internal logic circuit 20 or for determining whether the operating function is normal. To perform checking it is necessary to execute a prescribed program in the CPU, (not shown), to transfer the dat to the internal logic circuit 20 from the external terminal 7 of the interface circuit 6. The result is output to the external terminal 7 of the interface circuit 6 from the internal logic circuit 20.
In other words, the instruction code of data transfer is input to the input terminal 1 at each time to execute the data transfer to the register 5 from the interface circuit 6 and to the interface circuit 6 from the register 5.
In view of above circumstances, inventions disclosed in Japanese Patent Application Laid-Open Nos. 208476 (1984), 168051 (1986) and 132182 (1987) have been proposed.
In Japanes Patent Application Laid-Open No. 208476 (1984), "a test circuit is described for forming a test mode signal. The test circuit receives serial data and supplies a test pattern signal directly to the internal logic circuit from a predetermined input terminal. The circuit also sends out a signal of an internal logic circuit to a predetermined output terminal. The test circuit is incorporated to improve the test effect without increasing the number of external terminals". In the same invention, "the inputted serial data is set at a signal level higher than the ordinary signal level so as" not to increase the level on the external terminals.
Thus, in the invention disclosed in Japanese Patent Application Laid-Open No. 208476 (1984), the test circuit requires various parts such as a level detecting circuit for detecting a level of the serial data to be inputted, a shift register for holding it and a decoder. However, since the test circuit is built in the semiconductor circuit for use in the supplier side, and for users, it consumes just an actual capacity of the semiconductor circuit. Therefore, a test circuit which is too complicated with too many component parts is not preferable.
The invention disclosed in Japanese Patent Application Laid-Open No. 168051 (1986) relates to a test circuit of a RAM of single-chip microcomputer. Therefore, for checking whether the operation result of the logic circuits such as ALU etc. is normal, a specific address of the RAM must be accessed at a suitable timing to take out the data.
The invention of Japanese Patent Application Laid-Open No. 132182 (1986) relates to a test circuit of a large scale integrated circuit, which is divided into a plurality of blocks so as to be tested separately respectively. Thus, it is not suitale for checking whether the operation result of a specific logic circuit is correct.
SUMMARY OF THE INVENTION
The present invention has been designed in view of the aforesaid circumstances. Therefore, it is a primary object thereof to provide a test circuit for logic circuits capable of testing whether various logic circuits included in a semiconductor circuit such as a one-chip microcomputer and the like are functioning properly by a simple operation.
The test circuit for logic circuits according to the present invention is constructed with a register for storing data. The register is operated by the logic circuits and an interface circuit is connected to the register through an internal bus. The register, the logic circuits, and the interface circuit are controlled from external terminals. The data to be operated by the logic circuits is set in the register directly from the interface circuit. The operation result data stored in the register are outputted to the external source directly from the interface circuit. By having such a configuration, the data to be operated by the logic circuits can be transferred from the interface circuit to the register, and the operation result data stored in the register can be transferred to the interface circuit without executing a data transfer instruction. This the test can be performed easily.
The above and further objects and features of the invention will be more fully apparent from the following detailed description with accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram showing a configuration of a conventional semiconductor circuit including logic circuits, and
FIG. 2 is a block diagram showing a configuration of a semiconductor circuit including a test circuit for logic circuits according to the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The present invention will be described in detail as follows with reference to the drawings showing its embodiment.
FIG. 2 is a block diagram showing a configuration of a semiconductor circuit including a test circuit for logic circuits according to the present invention.
In the figure, numeral 1 denotes an input terminal. Instruction code 101 is input on this terminal by control of a CPU (not shown).
An instruction decoder is indicated generally at 2 whereby the instruction code 101 inputted from the input terminal 1 is decoded. A decoded result from the instruction decoder 2 is given to a register control circuit 3 and an interface control circuit 4 as a control signal 102.
The register control circuit 3 outputs a control signal 103 for controlling data transmission between a register 5 and internal bus 8. Control is determined according to the control signal 102 received from the instruction decoder 2. The control signal 103 constitutes one input of a 2-input multiplexer 9 to be described later.
The interface control circuit 4 outputs a control signal 104 for controlling an interface circuit 6 according to the control signal 102 received from the instruction decoder 2.
The register 5 is connected to the internal bus 8 and controlled by the control signal 103 input from the register control circuit 3. Register 5 outputs data stored therein to the internal bus 8 and stores the data input from the internal bus 8. An internal logic circuit 20 of, for example, an ALU to be tested by the test circuit of the present invention is also connected to register 5.
The internal logic circuit 20 fetches the data stored in the register 5 to execute a predetermined logical operation and stores its result again in the register 5.
The interface circuit 6 is connected to the internal bus 8 and is controlled by the control signal 104 input from the interface control circuit 4. Interface circuit 6 outputs the data input from the external terminal 7 to the internal bus 8, and fetches the data from the internal bus 8 to be output to the external terminal 7.
The control signal 103 output from the register control circuit 3 constitutes one input of the 2-input multiplexer 9. A register control signal 108 for test is output from a test circuit 10 and constitutes the other to multiplexer 9. Furthermore, a signal which selects an output signal 110 of the multiplexer 9, either as the control signal 103 or the register control signal 108 for test, is input from the test circuit 10 as a control signal switching signal 105. The output signal 110 of the multiplexer 9, namely, either the control signal 103 or register control signal 108 for test, is input to the register 5.
The test circuit 10 of the present invention includes a first external input terminal 12. A first signal is input on this terminal switching a mode or a whole circuit to either an ordinary operating state or a testing state. Second external inut terminals 11a, 11b, 11c, 11d etc. are connected to receive the control signal (second signal) at testing state for the multiplexer 9 and interface circuit 6. Test includes 4 outputs: circuit 10. First, register control signal 108 for test; second control signal switching signal 105 for the register control circuit 3; third there are an interface circuit control signal 109 for test; and fourth, a control signal switching signal 106 for the interface circuit 6 to be controlled by either the control signal 104 from the interface control circuit 4 or the aforesaid interface circuit control signal 109 for test.
Operations of the semiconductor circuit including such test circuit 10 for logic circuits of the present invention are as follows.
First, when a low level signal is given to the first external input terminal 12 of the test circuit 10, an ordinary operation is performed. That is, when the low level signal is input to the first external input terminal 12, both the control signal switching signal 105 for the register control circuit 3 and the control signal switching signal 106 for the interface circuit 6 are at a low level. Furthermore, the control signal 103 output from the register control circuit 3 is input to the register 5 and the control signal 104 output from the interface control circuit 4 is input to the interface circuit 6.
Thus, in such a case, the operation is similar to the prior art described above.
When the instruction code 101 is input to the input terminal 1, it is decoded by the instruction decoder 2 and the control signal 102 is output from the instruction decoder 2. Supposing that the instruction code 101 is one of either a data transfer instruction code, an instruction code which stores data in the register 5 from the external terminal 7 of the interface circuit 6 through the internal bus 8, or an instruction code which outputs the data to the external terminal 7 from the register 5 through the internal bus 8 and interface circuit 6.
The control signal 102 is input to the register control circuit 3 and interface control circuit 4. The register control circuit 3 outputs the control signal 103 responsive to the control signal 102 to the register 5. The interface control circuit 4 outputs the control signal 104 responsive to the control signal 102 to the interface circuit 6.
When the instruction code 101 input to the input terminal 1 is the instruction for data outputting to the external terminal 7 from the register 5, the register 5 outputs the data to the internal bus 8 according to the control signal 103 given from the register control circuit 3. At the same time, the interface circuit 6 fetches the data from the internal bus 8 and outputs it to the external terminal 7 according to the control signal 104 given from the interface control circuit 4. When the instruction code input to the input terminal 1 is an instruction for setting data to the register 5 from the external terminal 7, the interface circuit 6 fetches the data from the external terminal 7 and outputs it to the internal bus 8 according to the control signal 104 given from the interface control circuit 4. The register 5 fetches the data from the internal bus 8 and stores it therein according to the control signal 103 given from the register control circuit 3. The data stored in the register 5 are given to the internal logic circuit 20.
When a high level signal (the first signal) is given to the first external input terminal 12 of the test circuit 10, a testing state is attained. That is, when a high level signal is input to the first external input terminal 12, both the control signal switching signal 105 for the register control circuit 3 and control signal switching signal 106 for the interface circuit 6 are turned into the high level. The register control signal 108 for test output from the test circuit 10 is input to the register 5, and the interface circuit control signal 109 for test output from the test circuit 10 is given to the interface circuit 6.
When the data (the second signal) signifying the instruction to set data in the register 5 from the external terminal 7 of the interface circuit 6 through the internal bus 8 is input to the second external input terminals 11a, 11b, 11c, 11d of the test circuit 10, the test circuit 10 outputs the register control signal 108 for test. At the same time, test circuit 10 outputs interface circuit control signal 109 for test according to the data input to the second external input terminals 11a, 11b, 11c and 11d.
The interface circuit 6 fetches the data from the external terminal 7 and outputs it to the internal bus 8 according to the interface circuit control signal 109 for test given from the test circuit 10. Depending on the register control signal 108 for test input from the test circuit 10, register 5 fetches the data output already to the internal bus 8 from the interface circuit 6 and stores it. The data stored in the register 5 is input to the internal logic circuit 20 to execute a predetermined logical operation. The operation result data by the internal logic circuit 20 is stored again in the register 5.
When the data (the second signal) signifying the instruction to output the operation result data by the internal logic circuit 20 stored in the register 5 to the external terminal 7 from the interface circuit 6 through the internal bus 8 is input to the second external input terminals 11a, 11b, 11c and 11d of the test circuit 10, the test circuit 10 outputs the register control signal 108 for test and interface circuit control signal 109 for test according to the data input to the second external input terminals 11a, 11b, 11c and 11d.
Depending on the register control signal 108 for test input from the test circuit 10, register 5 outputs the data stored therein or the operation result data of the logic circuit 20 connected thereto to the internal bus 8. Depending on the interface circuit control signal 109 for test input from the test circuit 10, interface circuit 6 fetches the data output already to the internal bus 8 from the register 5 from the internal bus 8 and outputs it to the external terminal 7.
Thus, processes for inputting data from the external terminal 7 of the interface circuit 6 to set it in the register 5, storing the operation result of the internal logic circuit 20 with respect to this data again in the register 5, and transferring it to the interface circuit 6 to output it from the external terminal 7, are executed directly by the control of test circuit 10 without inputting the instruction code of the data transfer instruction to the input terminal 1. By checking the data output from the external terminal 7 it can be determined the logic circuits are operating normally and testing can be conducted promptly with relatively simple processings.
As particularly described hereinabove, according to the present invention, whether respective logic circuits included in the semiconductor circuit are operating normally can be tested promptly with relatively simple processings.
This invention may be embodied in several forms without departing from the spirit of essential characteristics thereof. The present embodiment is therefore illustrative and not restrictive and the scope of the invention is defined by the appended claims rather than by the description preceding them. All changes that fall within the meets and bounds of the claims, or equivalence of such meets and bounds thereof are therefore intended to be embraced by the claims. | A test circuit for logic circuits of the present invention is constructed with a register for storing data to be operated in the logic circuits and its operation results and interface circuit is connected to the register through an internal bus and is controlled from external terminals. The data to be operated on by the logic circuits is set in the register directly from the interface circuit for operation, and the operation result data stored in the register are outputted to the external source directly from the interface circuit. By adopting such a configuration, since the data to be operated in the logic circuits can be transferred from the interface circuit to the register, and data of the operation result stored in the register can be transferred to the interface circuit without executing a data transfer instruction, the logic circuits can be tested readily by giving the data to the logic circuits from the external and outputting its operation results to the external. | 6 |
FIELD OF THE INVENTION
[0001] This invention relates to a method for prevention and remediation of water block and condensate block in oil and/or gas producing subterranean formations. In particular, the invention relates to contacting such subterranean formations with a composition comprising a low molecular weight fluorinated copolymer thereby modifying the wettability of the rock within the subterranean formation and removing and preventing water block and condensate block therein.
BACKGROUND OF THE INVENTION
[0002] Typically, hydrocarbon extraction involves drilling a wellbore into an oil and/or gas containing subterranean formation. Hydrocarbon extraction is facilitated by a vast number of interconnected pore throats which form channels within the subterranean formation thereby allowing flows of oil and/or gas to the wellbore. The ease of hydrocarbon extraction is dependent upon characteristics of the subterranean formation such as resistivity flow and capillary pressure, both of which are highly dependent upon the number, size, and distribution of unblocked pore throats within the subterranean formation. A common problem encountered during typical oil and/or gas extraction, is the decrease of productivity resulting from the blockage of pore throats by: 1) water, commonly referred to as “water block”; and/or 2) condensed hydrocarbons, commonly referred to as “condensate block”.
[0003] Water block occurs in oil and gas wells when pore throats are blocked by an accumulation of water which may be result of filtrate water from drilling mud, cross flow of water from water-bearing zones, water from completion or workover operations, water from hydraulic fracturing, and water from emulsions. Condensate block occurs in gas wells when pore throats are blocked by an accumulation of liquid hydrocarbons which may be the result of oil-based drilling mud, hydrocarbon liquids used in workover operations, and the use of oil-based fracturing fluids. Additionally, the pressure during the extraction of gas often drops below the dew point pressure of the gas causing the gas to condense into liquid hydrocarbons also resulting in condensate block. Water blocks and condensate blocks may occur together or independently, leading to a decrease in well productivity and, in certain instances, to complete halt in production.
[0004] One method for the prevention or remediation of water blocks and/or condensate blocks involves modifying the wettability of the rock within the subterranean formation wherein the rock is contacted by a wettability modifier such that the rock's wettability is modified from an initially oil or water wet state to an intermediate or gas wet state. Proposed wettability modifiers include non-polymeric and fluorinated polymers, both of which are disclosed by Panga et al., in U.S. Patent Application with Pub. No. 2007/0029085.
[0005] Unfortunately, previously disclosed non-polymeric surfactants are disadvantageous for use as wettability modifiers because they suffer from low durability and tend to be easily washed away, therefore requiring repeated treatments. Previously disclosed fluorinated polymers are also disadvantageous for use as wettability modifiers because: 1) they have a high average molecular weight, typically about 140,000 g/mol or above; and 2) they have perfluoro alkyl moieties which are C 8 or longer. This combination of high molecular weight and long perfluoro alkyl moieties translates to a high fluorine content and higher costs.
[0006] It would be desirable to discover a fluorinated polymer which can act as a wettability modifier without the aforementioned disadvantages.
BRIEF SUMMARY OF THE INVENTION
[0007] The present invention provides a fluorinated copolymer which can act as a wettability modifier for the prevention and remediation of water block and condensate block in oil and/or gas producing subterranean formations without the disadvantages of previously disclosed fluorinated polymers. In particular, the invention provides a fluorinated copolymer having an average molecular weight from about 5,000 gram/mol to 50,000 gram/mol, preferably less than about 20,000 g/mol, more preferably less than about 10,000.g/mol, and even more preferably less than 2,000 g/mol. Furthermore, the invention provides a fluorinated copolymer having perfluoro alkyl moieties which are no longer than C 6 . This combination of low molecular weight and shorter perfluoro alkyl moieties translates to a lower fluorine content and lower costs for use as wettability modifiers for the prevention and remediation of water block and condensate block in oil and/or gas producing subterranean formations.
[0008] The present invention comprises a method for preventing or removing water block and/or condensate block in a subterranean formation penetrated by a well bore comprising the step of contacting the formation with an aqueous composition comprising a fluorinated copolymer copolymerized from monomers comprising (preferably consisting of):
[0009] (a) from about 30% to about 90% of at least one monomer of formula I:
[0000] R f -Q-A-C(O)—C(R)═CH 2 I
[0000] wherein
[0010] R f is a straight or branched-chain perfluoroalkyl group of from 2 to 6 carbon atoms,
[0011] R is H or CH 3 ,
[0012] A is O, S or N(R′), wherein R′ is H or an alkyl of from 1 to about 4 carbon atoms,
[0013] Q is alkylene of 1 to about 15 carbon atoms, hydroxyalkylene of 3 to about 15 carbon atoms, —(C n H 2n )(OC q H 2q ) m —, —SO 2 —NR′(C n H 2n )—, or
[0014] —CONR′(C n H 2n )—, wherein R′ is H or an alkyl of from 1 to about 4 carbon atoms, n is 1 to about 15, q is 2 to about 4, and m is 1 to about 15;
[0015] (b) from about 10 wt. % to about 70 wt. % of at least one monomer or a mixture of monomers is selected from formula IIA, formula IIB, and formula IIC:
[0000] (R 1 ) 2 N—(CH 2 ) r -Z-C(O)—C(R 2 )═CH 2 IIA
[0000] (O)(R 3 )(R 4 )N—(CH 2 ) r -Z-C(O)—C(R 2 )═CH 2 IIB
[0000] X − (R 5 )(R 4 )(R 3 )N + —(CH 2 ) r -Z-C(O)—C(R 2 )′CH 2 IIC
[0000] wherein
[0016] Z is —O— or —NR 5 —; R 1 is an alkyl group of from 1 to about 3 carbon atoms; R 2 is H or an alkyl radical of 1 to about 4 carbon atoms; R 3 and R 4 are each independently an alkyl of 1 to 4 carbon atoms, hydroxyethyl, benzyl, or R 3 and R 4 together with the nitrogen atom form a morpholine, pyrrolidine, or piperadine ring; R 5 is H or an alkyl of 1 to 4 carbon atoms, or R 3 , R 4 and R 5 together with the nitrogen atom form a pyridine ring; r is 2 to 4; provided that for formula IIA the nitrogen is from about 40% to 100% salinized; and
[0017] (c) from 0% to about 7% of a monomer of the formula III or IV, or a mixture thereof:
[0000] CH 2 (O)CH 2 —CH 2 —O—C(O)—C(R 2 )═CH 2 III;
[0000] Cl—CH 2 —CH(OH)CH 2 —O—C(O)—C(R 2 )═CH 2 IV;
[0000] (R 6 )OC(O)C(R 6 )═CH 2 V;
[0000] or
[0000] CH 2 ═CCl 2 VI
[0000] wherein
[0018] each R 2 is independently H or an alkyl radical of 1 to about 4 carbon atoms, and each R 6 is independently H or an alkyl of 1 to about 8 carbon atoms.
[0019] Preferably, the fluorinated copolymer of the present invention has an average molecular weight less than about 10,000 g/mol, more preferably less than about 5,000 g/mol, and most preferably less than about 2,000 g/mol.
[0020] Preferably, the fluorinated copolymer of the present invention is copolymerized from a monomer of formula I which is represented by CF 3 CF 2 (CF 2 ) x C 2 H 4 OC(O)—C(H)═CH 2 wherein x=0, 2, 4, and 6.
[0021] Preferably, the fluorinated copolymer of the present invention incorporates a monomer selected from formula IIA wherein the monomer selected is 2-methyl, 2-(diethylamino)ethyl ester.
[0022] Preferably, the fluorinated copolymer of the present invention monomer selected from formula V wherein the monomer selected is 2-propenoic acid.
DETAILED DESCRIPTION OF THE INVENTION
[0023] Herein, trademarks are shown in upper case.
[0024] The term “(meth)acrylate”, as used herein, indicates either acrylate or methacrylate.
[0025] Another advantage of using fluorinated copolymer of the present invention as a wettability modifier for the prevention and remediation of water block and condensate block in oil and/or gas producing subterranean formations is that the fluorinated copolymer's hydrophilic and oleophobic properties can be varied over a wide range for different applications and for different subterranean formations by simply varying the relative amounts of monomers (a) of formula I and (b) of formula IIA and/or IIB, while still maintaining its properties as an effective water repellent and liquid hydrocarbon (oil) repellent.
[0026] Preferably monomer (b) of formula IIA is derived from diethylaminoethyl methacrylate by partial or full salinization. The free amine portions of the resulting copolymer is then reacted with a salinizing agent such as acetic acid, resulting in the conversion of part or all of the amine moieties to the corresponding acetate. It must be at least about 40% salinized for adequate solubilizing effect, but may be as high as 100%. Preferably the degree of salinization is between about 50% and about 100%. Alternatively, the salinization reaction is carried out on the amine group before the polymerization reaction with equally good results. The salinizing group is an acetate, halide, sulfate, tartarate or other known salinizing group.
[0027] The proportion of monomer (b) of formula IIA, IIB, IIC or a mixture thereof must be at least about 10% for adequate solubilization. While a copolymer with proportions of this monomer (b) above about 70%, such a proportion will produce polymers with very high viscosity, making processing and handling difficult. Preferably the proportion of monomer (b) of formula IIA, IIB, IIC or a mixture thereof in the copolymer is between about 15% and about 45% by weight for the best balance of hydrophilicity, oleophobicity and viscosity in currently envisioned applications. Other proportions may be more desirable for other applications. All weight percentages are based on the monomer weight as quaternized.
[0028] They are prepared by reacting the aforesaid acrylate or methacrylate ester or corresponding acrylamide or methacrylamide with conventional oxidizing agents such as hydrogen peroxide or peracetic acid.
[0029] The quaternary ammonium monomers of formula IIC are prepared by reacting the acrylate or methacrylate esters or corresponding acrylamide or methacrylamide with a di-(lower alkyl) sulfate, a lower alkyl halide, trimethylphosphate or triethylphosophate. Dimethyl sulfate and diethyl sulfate are preferred quaternizing agents.
[0030] The presence of monomer (c) of formula III, IV, V, or VI is optional, depending on the particular application for the copolymer. While not wishing to be bound by this theory, it is believed that monomer (c) of formula III and IV acts as a reactive site for the polymer to covalently bond to the substrate surface. The monomers of formula III, IV, V and VI are prepared by conventional methods known in the art.
[0031] The polymerization of comonomers (a), (b) and (c) is carried out in a solvent such as acetone, methylisobutyl ketone, ethyl acetate, isopropanol, and other ketones, esters and alcohols. The polymerization is conveniently initiated by azo initiators such as 2,2′-azobis(2,4-dimethylvaleronitrile). These initiators are sold by E. I. du Pont de Nemours and Company, Wilmington, Del., commercially under the name of VAZO 67, 52 and 64, and by Wako Pure Industries, Ltd., Richmond, Va., under the name “V-501.”
EXAMPLES
[0032] Examples are carried out using the Berea cores from Cleveland Quarries (Amherst, Ohio) and reservoir sandstone cores from the subsurface from the Middle East. The Berea and reservoir core have the same diameter D of about 2.5 cm, while the length L of Berea is about 15 cm and the length L of reservoir core is about 10 cm. The permeability of Berea is in a range of 600 mD to 1000 mD. While the permeability of reservoir core is about 2 to about 6 mD. The porosity Φ describes the fraction of void space defined by the ratio:
[0000] φ= V p /V, (1)
[0033] where V p is the volume of void-space and V is the total or bulk volume of the porous material, including the solid arid void space. The porosity of Berea (0.21-0.22) is about twice that of the reservoir core (0.11-0.13).
[0000] The unit of “PV” (pore volume) is defined as the void volume of a single core. The porosity can be alternatively expressed based the bulk density ρ and particle density ρ p :
[0000] φ=1−ρ/ρ p (2)
[0034] Table 1 shows the relevant data of the cores used in this work. The sandstone particle density calculated from Eq. (2) is about 2.44 g/cm 3 for Berea and about 2.61 g/cm 3 for reservoir core respectively. Prior to the experiments, the cores are cleaned by rinse and injection of water, followed by drying in the oven.
[0000]
TABLE 1
Relevant data of the cores
Core type
Designation
D [cm]
L [cm]
W [g]
φ
Berea
BYR
2.58
15.1
163.93
0.224
B1
2.58
15.1
153.56
0.220
B2
2.52
14.9
151.69
0.205
B3
2.52
14.8
149.49
0.205
B4
2.42
14.5
134.53
0.224
B5
2.41
14.7
133.90
0.224
B6
2.39
14.7
131.89
0.224
B7
2.45
14.6
138.27
0.224
B8
2.43
14.6
135.35
0.224
B9
2.43
14.4
133.95
0.224
B10
2.43
14.3
128.88
0.224
B11
2.43
14.1
131.14
0.214
B12
2.42
12.8
118.95
0.217
B13
2.44
14.2
132.09
0.217
B14
2.45
14.4
136.94
0.222
B15
2.45
14.6
138.27
0.225
B16
2.45
14.1
134.35
0.221
B17
2.45
14.7
139.87
0.224
B18
2.45
14.1
134.90
0.222
B20
2.44
14.04
132.52
0.223
B21
2.44
14.26
133.79
0.224
B22
2.46
14.26
136.95
0.217
B23
2.48
14.67
144.18
0.209
B24
2.46
13.10
128.53
0.208
B25
2.46
13.70
134.10
0.208
B18
2.45
14.1
134.90
0.222
Reservoir
R1
2.48
9.72
105.50
0.131
R2
2.48
9.75
106.04
0.134
R3
2.48
10.48
118.52
0.111
R4
2.48
10.44
118.56
0.105
R5
2.48
10.45
117.16
0.109
[0035] The treatments are carried out by injecting chemical solution into cores and aging at high temperature and high pressure. The wettability modification of cores is evaluated by measurement of contact angle and imbibition test. The liquid mobility is examined by the flow in two-phase state. By the term “imbibition” as used herein is meant a process in which a wetting phase displaces a non-wetting phase in a porous medium.
[0036] Mobility in a core is examined via single-phase gas flow, and two-phase liquid displacing the gas phase. The flow parameters of porous media with respect to different fluids are calculated. Applying the Forchheimer equation in the steady-state gas flow:
[0000]
M
g
(
p
1
2
-
p
2
2
)
2
μ
g
ZRTLj
g
=
β
j
g
μ
g
+
1
k
g
,
(
3
)
[0000] where p 1 and p 2 are the inlet and outlet pressure; M g , μ g , and j g are molecular weight, viscosity, and mass flux of the gas, respectively; R and Z are the gas constant and the gas deviation factor; T is temperature and L is the core length. The absolute permeability, k g , and high velocity-coefficient, β, are determined from the intercept and slope in the plot of M g (p 1 2 −p 2 2 )/(2μ g ZRTLj g ) vs. j g /μ g .
[0037] The absolute permeability and high-velocity coefficient are measured. In the unsteady-state gas-liquid flow with gas displaced by liquid injection, the effective and relative permeability of liquid is calculated at the final steady state using the Darcy expression to the quasi steady-state:
[0000]
Δ
p
=
Q
μ
l
k
el
L
A
,
(
4
)
[0038] to describe the pressure drop, Δp, as a function of the volume flow rate, Q, with the parameters of liquid viscosity, μ l , core length, L, cross section area, A, and the effective liquid permeability, k el . It is the so-called ‘effective’ because the core is not 100% saturated with liquid even the pressure drop has reached steady state. The effectiveness of the wettability modification from the change of fluid flow parameters after chemical treatment is measured.
[0039] The liquid relative permeability k rl is calculated by the ratio of the liquid effective permeability to the absolute permeability obtained from single-phase gas flow:
[0000]
k
rl
=
k
el
k
g
,
(
5
)
[0040] Examples are carried out using the Berea cores (B1-B18) from Cleveland Quarries (Amherst, Ohio) and reservoir sandstone cores from the subsurface from the Middle East. Prior to the tests, the cores are cleaned by rinse and injection of water or normal decane, followed by drying in the oven. Air is the gas phase in contact angle measurement and imbibition tests. The model liquid is either water or normal decane (oil). The water is either pure water or brine (1.0 wt % NaCl dissolved in tap water).
[0041] 2-propenoic acid, 2-methyl-3,3,4,4,5,5,6,6,7,7,8,8,8-tridecafluorooctyl ester (CAS 2144-53-8), 2-propenoic acid, 2-methyl-, 2-(diethylamino)ethyl ester, acetate (CAS 2397-53-7), and 2,2′-azobis(2-methylbutyronitrile) (CAS 13472-08-7) are available from E. I. du Pont de Nemours and Company, Wilmington, Del. Other reagents are commercially available, For example, from Aldrich Chemical Co., Milwaukee, Wis.
Method I Chemical Treatment
[0042] The wettability of the core was modified by chemical treatment at 140° C. and 1.5×10 6 Pa (200 psig). The chemical solution of 5 PV is injected in the nitrogen-saturated core, followed by aging overnight of about 15 h. About 20 PV of pure water was then injected to displace the chemical solution and wash the core. The injection of chemical solution or washing water was carried out at a flow rate of4 cm 3 /min in Berea. Then, nitrogen (˜30 PV) was injected to drain the liquids from the core at Δp about 6.9×10 4 Pa (10 psia) for Berea. The purpose of water washing was to have an indication of durability of chemical treatment at high temperature through the examination of the contact angle.
Method 2 Permanency of Treatment
[0043] The reaction between rocks and chemicals was studied by analyzing liquid streams before they enter the rock and after contact with the rock. Qualitative analyses were made by color change in the cores and the solutions. The chemical adsorption was measured from the gain in the core weight after treatment. The pH of chemical solutions was measured by the pH meter (OAKTON, Model pHTestr 30). The automatic temperature compensation was built into the pH meter. Through its temperature sensor, the measurement error caused by the change in the electrode sensitivity due to alterations in the temperature was compensated to give the actual pH reading of the sample. The surface potential of the glass electrode exhibited non-linear behavior vs. the concentration of H+ or OH− ions in the acid and alkali regions. Three professional pH buffer solutions at pH=4, 7, 10 (Fisher Scientific), covering the pH range of the experimental solutions, were used to calibrate the pH meter. The reproducibility of the pH measurements for the aqueous solution was about 0.02 units. However due to the low dissociation of H + ion in the IPA solution, the pH reading of chemical in IPA solutions had fluctuations (errors) of about 0.5. The refractive index, density and viscosity of chemical solutions were measured by refractometer (Abbe C-10, accuracy=0.0003), pycometer (Moore-Van Slyke specific-gravity bottle, 2 mL), and viscometer (Ubbelohde capillary, size OB), respectively.
[0044] The composition of chemical solutions was analyzed using gas chromatography-mass spectrometry (GCMS) and inductively coupled plasma-mass spectrometry (ICPMS).
Method 3. Contact Angle Measurements
[0045] A pipette was used to place a liquid drop on the surface of the air-saturated core at room temperature of about 20° C. The configuration-of a sessile liquid drop on the core surface in the ambient air was magnified on a monitor screen. Snapshots of the drop image were taken by a digital camera under the proper illumination of light source. The air-liquid-rock three-phase-contact angle was measured through the liquid phase using the goniometry tool of the software Image Pro Analyzer. In Berea, the liquid drop of water or N-decane (oil) imbibed instantly into the liquid-wetting untreated core, indicating a contact angle of 0°. As the rock wettability was modified by chemical treatment to liquid-non-wetting (gas-wetting), the water contact angle, θ w , increased to 120°-135° and N-decane (nC 10 ) contact angle, θ o , increased to 45°-80°.
Method 4 Spontaneous Imbibition Test
[0046] Spontaneous liquid imbibition into the air-saturated cores was monitored at room temperature of about 20° C. It was performed by immersing the air-saturated core in the liquid while hanging under an electronic balance. The dynamic process of liquid imbibitions into the core was studied by recording the core weight gain with time. The liquid saturation was calculated as the ratio of the amount of liquid imbibed into the core to the core pore volume:
[0000]
S
w
=
Δ
W
l
/
ρ
l
V
p
,
(
6
)
[0000] where ΔW l is the weight gain due to liquid imbibition and ρ l is the liquid density. The effect of wettability modification was evaluated by comparing the liquid saturation vs. time before and after treatment. The imbibition rate decreased as the wettability is modified from liquid-wetting to non-wetting.
Method 5 Fluid Flow Test
[0047] Fluid flow tests were conducted to evaluate the effect of wettability modification. FIG. 3 shows the setup. An overburden pressure of 6.9×10 6 Pa (1000 psig) was applied by the syringe pump (ISCO, D series) on the core inside the core holder (Temco, type HCH). The temperature of the system was maintained by a universal oven (Memmert). Gas was injected from the compressed nitrogen cylinder or liquid injection from the inlet pump. The inlet pressure and pressure drop were measured by the pressure transducers (Validyne Engineering), with the accuracy of ˜1.4 kPa (0.2 psia) after calibration by the deadweight tester (Ametek). A backup pressure regulator was used to adjust the pressure drop while measuring the gas flow rate by a flow meter in the range of 1-80 cm 3 /sec with the accuracy of about 0.5%. The liquid flow rate was fixed using the inlet pump while maintaining the outlet pressure by the receiver pump.
[0048] In single-phase gas flow, the inlet and outlet pressures at various gas flow rates were recorded at the steady state. In the two-phase flow when liquid displaced gas, the liquid was injected at a fixed flow rate into the gas-saturated core. The transient pressure drop was recorded until the steady state was reached.
Example 1
Preparation of Compound A
[0049] A vessel fitted with a stirrer, thermometer, and reflux condenser was charged with 64.0% by weight of fluoromonomer (a) 2-propenoic acid, 2-methyl-3′,3,4,4,5,5,6,6,7,7,8,8,8-tridecafluorooctyl ester (CAS 2144-53-8); 33.7% by weight of monomer (b), 2-propenoic acid, 2-methyl-, 2-(diethylamino)ethyl ester, acetate (CAS 2397-53-7) in methyl isobutyl ketone (MIBK). The charge was purged with nitrogen at 40° C. for 30 minutes. VAZO 67 (0.5% by weight), or 2,2′-azobis (2,4-dimethylbutyronitrile) available from E. I. du Pont de Nemours and Company, Wilmington, Del., was then added to initiate polymerization and the charge was stirred for 16 hours at 70° C. under nitrogen. A mixture of water and acetic acid (0.6% by weight) at room temperature was added to the above copolymer mixture at 70° C. The reflux condenser was replaced with a distillation column and the MIBK was removed at reduced pressure. A copolymer solution of perfluoroalkylethyl methacrylate, having a weight average molecular weight of approximate 10 3 gram/mol, was obtained, which was designated as Compound A and was used in the following tests.
Example 2
Preparation of Compound B
[0050] The same procedure described above for the preparation of Compound A was employed, but using of fluoromonomer (a) having the formula:
[0000] CF 3 CF 2 (CF 2 ) x C 2 H 4 OC(O)—C(H)═CH 2 ,
[0051] wherein x=0, 2, 4, and 6. A copolymer solution of perfluoroalkylethyl methacrylate, having a weight average molecular weight of approximate 10 4 gram/mol, was obtained, which was designated as Compound B and was used in the following tests.
Example 3
Preparation of Compound C
[0052] The same procedure described above for the preparation of Compound A and Compound B was employed, but using of fluoromonomer (a) having the formula:
[0000] CF 3 CF 2 (CF 2 ) x C 2 H 4 OC(O)—C(H)═CH 2 ,
[0053] wherein x=0, 2, 4, and 6, with the change in the distribution of fluoromonomer (a) from which used in the preparation of Compound B. A copolymer solution of perfluoroalkylethyl methacrylate, having a weight average molecular weight of approximate 10 4 gram/mol, was obtained, which was designated as Compound C and was used in the following tests.
Example 4
Preparation of Compound D
[0054] Compound D is a fluorinated polydimethylsiloxane fluid, which WACKER 65000 VP grafted with 1-perfluorohexyl-ethylene-2-sulfonylchloride: 50 gram WACKER 65000 VP, which is available from Wacker Chemie AG, Munich, Germany, reacted with 25 gram of 1-perfluorohexyI-ethylene-2-sulfonylchloride in 80 gram methyl isobutyl ketone (MIBK), at 14° C. A solution of fluorinated polydimethylsiloxane, having a weight average molecular weight of approximate 10 3 gram/mol, was obtained. Compound D was used in the following tests.
Example 5
Preparation of Compound E
[0055] Compound E is a blend of 5% active ingredient of Compound A prepared above and 0.25% active ingredient of ZONYL FS-610, a fluorinated telomer based phosphate ammonium salt in isopropanol, which is available from E. I. du Pont de Nemours and Co., Wilmington, Del. Compound E was used in the following tests.
Example 6
Preparation of Compound F
[0056] Compound F is a blend of 5% active ingredient of Compound A prepared above and 0.25% active ingredient of ZONYL FS-200, a fluorinated telomer based amine salt in isopropanol, which is available from E. I. du Pont de Nemours and Co., Wilmington, Del. Compound F was used in the following tests.
Comparative Example 1
Preparation of Comparative Compound A
[0057] ZONYL 8740, a polysubstituted methacrylic copolymer, having a weight average molecular weight of approximate 10 5 gram/mol, which is available from E. I. du Pont de Nemours and Co., Wilmington, Del., was used as the Comparative Compound A in the flowing tests.
Comparative Example 2
Preparation of Comparative Compound B
[0058] ZONYL 8867L, a polysubstituted methacrylic copolymer, having a weight average molecular weight of approximate 10 5 gram/mol, which is available from E. I. du Pont de Nemours and Co., Wilmington, Del., was used as the Comparative Compound B in the flowing tests.
Preparation of Aqueous Compositions
[0059] The fluoropolymers in Examples 1-6 and Comparative Examples 1-2 were dissolved in isopropanol to a dilution of about 1% wt to about 5% wt. The 1% wt aqueous solutions of Compound A, Compound B, Compound C, Compound D, Compound E, Compound F, and Comparative Compound.
Contact Angle
[0060] FIG. 9. Contact angle of water and nC 10 on Berea (A) before and (B) after treatment with Compound E solution (1.05 wt % polymer), and on Berea (C) before and (D) after treatment with Compound F solution (1.05 wt % polymer).
[0061] The effect of wettability modification was evaluated by measuring the gas-liquid-rock contact angle before and after treatment according to the Method 3. Contact angle data at the core inlet before and after treatment with Compound A-D and Comparative Compound A are shown in Table 2. As the table shows, there seems to be an effect of concentration on the increase of the contact angle. The experimental error of the measured contact angle was about ˜5°. The increase of water contact angle was 120°-150° from treatment in Berea; but the increase for the reservoir core is only 25°-65°. The nC 10 contact angle increase was from 0°-80° for the treated Berea and from 27°-45° for the reservoir core. The treatment with Compound C (2 wt %) and Compound A (1 wt %-5 wt %) increases contact angle the most for water and nC 10 in Berea, respectively.
[0062] Contact angle data at the core inlet before and after treatment with Compound E-F are shown in Table 3. As the table shows, there seems to be an effect of concentration on the increase of the contact angle. The experimental error of the measured contact angle was ˜5°. The increase of water contact angle was 120°-135° from treatment in Berea. The nC 10 contact angle increase was 45°-80° for the treated Berea. The contact angle for water was uniform across the core while for nC 10 ; the contact angle change was limited to the inlet of the treated core. The treatment with Compound E solution of 3.15 wt % polymer resulted in a higher contact angle measurement for nC 10 in Berea, than Compound F. The Compound E-F induced contact angle increase in the treated Berea cores for water and nC 10 , similar to the Compound A-D reported in Table 6.
[0000]
TABLE 2
Contact angle data at 23° C.
Contact angle of water and nC 10
Before
After
Chemical
treatment
treatment
Change
Core
Sample
Conc.
θ w
θ o
θ o
Δθ w
Δθ o
Type
Designation
Name
Designation
[wt %]
[°]
[°]
θ w [°]
[°]
[°]
[°]
Berea
B11
Comparative
0.25
0
0
135
0
+135
0
B4
Compound A
1
0
0
120
0
+120
0
B10
0
0
130
0
+130
0
B12
0
0
135
0
+135
0
BYR
2
0
0
135
0
+135
0
B2
0
0
135
30
+135
+30
B6
0
0
135
0
+135
0
B9
3
0
0
135
45
+135
+45
B15
Compound B
1
0
0
135
75
+135
+75
B16
Compound C
1
0
0
135
55
+135
+55
B7
2
0
0
150
50
+150
+50
B13
Compound D
1
0
0
135
0
+135
0
B14
Compound A
1
0
0
140
80
+140
+80
B17
3
0
0
140
80
+140
+80
B18
5
0
0
140
80
+140
+80
Reservoir
R1
Comparative
1
70
0
110
40
+40
+40
R3
Compound A
110
5
135
45
+25
+40
R2
2
70
0
135
45
+65
+45
R4
Compound A
1
80
3
135
30
+55
+27
R5
3
70
3
135
40
+65
+37
[0000]
TABLE 3
Contact angle data (~20° C.)
Contact angle of water and nC 10
Chemical solution
Before
After
Polymer
treatment
treatment
Change
Sample
Conc
Chemical
θ w
θ o
θ w
θ o
Δθ w
Δθ o
Core
Name
Solvent
[wt %]
adsorption
[°]
[°]
[°]
[°]
[°]
[°]
B25
IPA
IPA
0.00
N/A
0
0
120
0
120
0
B22
Compound E
1.05
0.63
0
0
135
60
135
60
B24
3.15
2.02
0
0
135
80
135
80
B23
Compound F
1.05
1.08
0
0
135
70
135
70
Imbibition
[0063] The results of imbibitions for various new chemicals in Table 4. The final water saturation in spontaneous imbibitions decreases by 81% to 93% by treatment with both TLF chemicals. The chemical treatment (with polymer concentration <3.15 wt %) has little effect on oil imbibition (the imbibition change <6%).
[0000]
TABLE 4
Imbibition data (~20° C.)
Final saturation of water and nC 10
Chemical solution
Before
After
Polymer
treatment
treatment
Change
Conc.
Chemical
S w
S o
S w
S o
ΔS w /S w
ΔS o /S o
Core
Sample Name
Solvent
[wt %]
adsorption
[%]
[%]
[%]
[%]
[%]
[%]
B25
IPA
IPA
0.00
N/A
63
67
48
70
25
5
B20
Comparative
IPA
0.33
N/A
57
65
50
69
12
6
Compound A
B22
Compound E
IPA
1.05
0.63
60
66
11
70
81
5
B24
3.15
2.02
62
66
4
64
93
3
B23
Compound F
IPA
1.05
1.08
59
65
8
68
86
4
Permeability
[0064] The absolute permeability and high-velocity coefficient before and after treatment were measured according to Method 5. The dependence of pressure drop on gas flow rate is studied using the Forchheimer expression from Eq. (4) at 140° C. The pressure drop, Δp=p 1 −p 2 , and the average pressure, p =(p 1 +p 2 )/2 across the core were p about 3.9×10 5 Pa and Δp about 1.6×10 5 Pa for Berea, and p about 4.7×10 5 Pa and Δp about 7.1×10 5 Pa for the reservoir core. The measurements of absolute permeability and high-velocity coefficient before and after treatment were presented in Table 5 and Table 6. There was a reduction of absolute permeability, and an increase in high-velocity coefficient from treatment. Generally, the permeability reduction increased and high-velocity coefficient decreased with increasing chemical concentration. In Table 5, the treatment for Berea with Compound A (1 wt %-5 wt %) seemed to have a negligible effect on permeability. A permeability reduction of 10% and a high-velocity coefficient increased by factor of two would have a negligible effect in two phase performance. Among all the chemicals, Compound D had the best performance in single-phase gas flow.
[0065] In Table 6, the permeability reduction increases and high-velocity coefficient decrease with increasing Compound E concentration. The treatment for Berea with Compound E with 1.05 wt % polymer seemed to have a negligible effect on permeability. A permeability reduction below 10% and a high-velocity coefficient increase by factor of two will have a negligible effect in two-phase performance. Between Compound E and Compound F, Compound E with the least permeability reduction performed the best in single-phase gas flow, and is comparable to the best one of Compound A.
[0000]
TABLE 5
Absolute gas permeability and high-velocity coefficient data at 140° C.
Absolute permeability and high-velocity
coefficient
Before
After
Chemical
treatment
treatment
Change
Core
Sample
Conc.
k g
β
k g
β
Δk g /k g
Δβ/β
Type
Designation
Name
Designation
[wt %]
[mD]
[10 6 cm −1 ]
[mD]
[10 6 cm −1 ]
(%)
(%)
Berea
B11
Comparative
0.25
747
0.10
681
0.42
9
319
B10
Compound A
1
957
0.33
811
0.78
15
136
B6
2
911
0.26
723
0.49
21
86
B9
3
984
0.27
722
0.57
27
11
B15
Compound B
1
670
0.37
639
0.34
5
8
B16
Compound C
1
843
0.27
765
0.26
9
4
B7
2
875
0.25
681
0.42
22
69
B13
Compound D
1
677
0.29
651
0.31
4
7
B14
Compound A
1
708
0.28
682
0.32
4
14
B17
3
693
0.33
677
0.42
2
26
B18
5
721
0.31
702
0.48
3
53
Reservoir
R1
Comparative
1
4.82
253
4.71
708
2
180
R3
Compound A
2.36
3605
2.20
8746
7
143
R4
Compound A
1
2.50
2415
2.46
3334
1
38
R5
3
2.23
3440
2.06
2966
7.5
14
[0000] TABLE 6 Absolute gas permeability and high-velocity coefficient data (140° C.) Absolute permeability and high-velocity coefficient Chemical solution Before Polymer treatment After treatment Change Sample Conc. k g β k g β Δk g /k g Δβ/β Core Name Solvent [wt %] [mD] [10 6 cm −1 ] [mD] [10 6 cm −1 ] (%) (%) B25 IPA 0.00 667 0.23 570 0.28 14 23 B22 Compound E IPA 1.05 687 0.22 698 0.23 2 4 B24 Compound F IPA 3.15 640 0.18 598 0.31 6 79 B23 1.05 614 0.14 550 0.18 10 23
FIG. 15. Pressure drop vs. pore volume before and after treatment with chemicals: Berea, 140° C. (A) Compound E and Compound F (B) Compound A, E, F and Comparative compound A.
[0066] Two-phase flow testing by water displacement of gas was performed. Water was injected into the nitrogen-saturated cores at a fixed flow rate of 6 cm 3 /min for Berea at 140° C. and the outlet pressure of 1.5×10 6 Pa (200 psig). The pressure drop across the untreated and treated core was monitored with time.
[0067] The effective and relative permeability were calculated from steady-state pressure drop using the Darcy law. The results are shown in Table 7 and Table 8. The chemical treatment decreased the pressure drop, and increased the effective and relative permeability for both the Berea and reservoir cores. The treatment effectiveness was evaluated by calculating the changes in the effective permeability and relative permeability. Both Δk ew /k ew and Δk rw /k rw decreased with increasing Comparative Compound A concentration, but Compound A had an optimum concentration at 3 wt %. Among all the chemicals, Compound D had the best performance in increasing the water effective permeability in Berea, followed by Compound A. Compound D was the only chemical containing siloxane, which was perhaps contributing to its superior performance to repel water. However for the reservoir core, Comparative Compound A was more effective than Compound A. Between Compound E and Compound F, Compound E (1.05 wt % polymer) with the largest Δk ew /k ew and Δ k rw /k rw performed the best in water injection test. All the results for k rw in Table 7 and Table 8 provided a strong indication that the chemical treatment changed the core surface from hydrophilic to hydrophobic resulting in an increase in water mobility.
[0000]
TABLE 7
Effective water permeability and relative permeability data at 140° C.
Effective and relative permeability
Before
After
Chemical
treatment
treatment
Change
Core
Sample
Conc.
k ew
k ew
Δk ew /k ew
Δk rw /k rw
Type
Designation
Name
Designation
[wt %]
[mD]
k rw
[mD]
k rw
(%)
(%)
Berea
B10
Comparative
1
197
0.21
393
0.48
100
136
B6
Compound A
2
223
0.24
334
0.46
50
89
B9
3
261
0.27
365
0.51
40
90
B15
Compound B
1
208
0.30
331
0.52
59
70
B16
Compound C
1
214
0.25
415
0.54
94
114
B7
2
262
0.30
366
0.54
40
80
B13
Compound D
1
152
0.22
376
0.58
147
157
B14
Compound A
1
176
0.25
379
0.56
116
124
B17
3
153
0.22
415
0.61
142
148
B18
5
219
0.30
390
0.56
78
82
Reservoir
R1
Comparative
1
1.33
0.28
2.00
0.42
50
53
R3
Compound A
0.77
0.32
0.91
0.41
19
28
R4
Compound A
1
0.96
0.38
1.01
0.41
5
6
R5
3
0.93
0.42
1.09
0.53
17
27
[0000]
TABLE 8
Effective water permeability and relative permeability data (140° C.)
Effective and relative
water permeability
Chemical solution
Before
After
Polymer
treatment
treatment
Change
Sample
Conc.
k ew
k ew
Δk ew /k ew
Δk rw /k rw
Core
Name
Solvent
[wt %]
[mD]
k rw
[mD]
k rw
(%)
(%)
B25
IPA
0.00
266
0.40
320
0.56
20
41
B22
Compound E
IPA
1.05
252
0.37
441
0.63
75
72
B24
3.15
259
0.41
382
0.64
47
57
B23
Compound F
IPA
1.05
247
0.40
341
0.62
38
54
[0068] In summary, the examples demonstrated the wettability modification of various rock samples from liquid-wetting to intermediate gas-wetting by the method of the present invention wherein the rock samples are contacted with a composition comprising a low molecular weight fluorinated copolymer in accordance with the invention. The wettability modification increased the contact angle of liquid drops on the core, and decreased the spontaneous imbibition. The effect of wettability modification on liquid mobility was pronounced in the gas-water system. The adsorption of the fluorochemical onto the core surface has negligible effect on the absolute permeability for the chemicals with small molecular weight. | A method of removing and preventing water and condensate blocks in wells by contacting a subterranean formation with a composition comprising a low molecular weight fluorinated copolymer having perfluoro alkyl moieties which are no longer than C 6 . | 2 |
BACKGROUND OF THE INVENTION
The invention relates to a feeder mechanism for single or folded sheets of paper or similar flexible sheets and serves for supplying sheets to a rapidly operating production machine in the paper processing and printing industry. Such feeding mechanisms are used, for example, for collating machines, folding machines, stapling machines, leaf insertion machines and end-paper gluing machines. One or several of these machines are used in each case for handling discrete sheets and for transporting them to the processing machinery.
Such feeder mechanisms are usually constructed in such a manner as to be replenishable from the top, by hand or otherwise, while the individual items are pulled off cyclically at the bottom. Such a manner of operation insures uninterrupted production.
The singularization of the sheets is generally performed by suction cups which first adhere to the lowermost sheet or the lowermost page of a folded item, generally at one edge, and serve to bend that item away from the remaining stack by a certain angle. Subsequently, the released sample is grasped by grippers or is caught between pull-off rollers and is pulled from beneath the remaining stack. Subsequently, the suction cups again go into operation to remove the following sheet or folded material, etc.
All feeding mechanisms operate in this way, with the exception of those feeding cardboard whose thickness makes it possible to pull off single items by means of stepped slides. If the material is sufficiently thick or is a multi-layer product, there may, in some cases, be present only a stepped slide without suction cups. However, the single sheet removal by means of suction cups is far and away the most commonly used method of operation of paper feed mechanisms.
Feeder mechanisms available at the present time and using vacuum for operation permit operating speeds of only approximately 15,000 items per hour. This limit is due to the fact that the suction device which is used for separating a sheet can be moved into position to grasp the following sheet only after the first item has been completely pulled out from under the remaining stack, because otherwise it would cover the contact point of the suction cup.
As a consequence, the return stroke of the suction cup toward the stack cannot take place at an earlier time. Only after the complete removal of a sheet is it possible to build up the vacuum in the suction cup and to initiate the strip-off motion. It is clear that the common manner of operation for all of the feeder mechanisms serves to limit the speed of operation. In addition to this disadvantage regarding the operating speed, there are of course other factors which also act to reduce the operating speed. These are, e.g., the long control lines from the vacuum controlled valves to the suction cups which require a change of the vacuum in dependence on operating speed, as well as the solenoid valves for controlling the vacuum and the many reciprocating motions of retainer devices, splitting wedges, pull-off mechanisms, or, if rotating pull-off drums are used, the extremely rapid motion of the grippers, which is opposite the direction of rotation, which hold the separated item on the pull-off drum and may tear it because the item is accelerated very rapidly from zero speed to the pull-off speed, and all these are only a few of the many disadvantages inherent in the known mechanisms. All of these mechanisms have one or several of these disadvantages and all of them pull off the single items with distinct separations between them. Certain feeder mechanisms for uninterrupted operation, such as used especially in large sheet-printing machines, may also employ a pull-off and singularization process that uses several conveyor speeds, but in these cases the singularization of the sheets occurs from the top of the stack and the stack cannot be refilled without certain supplementary manipulations which may, in fact, require stopping the machine.
Finally, one should mention the so-called round stack feeders in which the paper sheets can be supplied uninterruptedly and which are deflected and stacked in staggered form so that a suction roller is able to pull them off one by one. But in this machine also, the suction roller can pull off a sheet only after the previous sheet has been completely pulled out of the stack, which again entails the above-described velocity-limiting disadvantage. Furthermore, such round stack feeders are not usable for a folded material. Purely rotating feeders in which the suction cups are also rolling beneath the stack so as to peel off an individual item from beneath the stack have been found to produce no substantial velocity increase.
The operating speed of production machinery, especially of so-called insertion machinery, which inserts advertising copy into newspapers for example, far exceeds the operating speed of the feeder mechanisms known at the present time so that feeder mechanisms with increased operating speed are extremely desirable.
OBJECT AND SUMMARY OF THE INVENTION
It is a principal object of the invention to provide a high performance feeder mechanism for individual sheets as well as for folded sheets of paper or similar material, whose speed is a multiple of the operating speed of such feeders at the present time and which furthermore does not exhibit the above-mentioned disadvantages which are inherent in known feeder mechanisms.
This and other objects are attained by the invention by providing a pair of suction devices operating in opposite phase for a preliminary separation of an individual item in the stack of items to be processed and further by providing a conveyor wheel with several recesses wherein individual items are grasped and delivered to a conveyor mechanism which pulls the individual item out of the stack. The conveyor wheel bends an item away from the stack so that, long before that item is actually removed from the stack, the other suction device is able to move to the next item in the sequence and pull it from the stack so that the individual items come to lie on top of one another in staggered fashion. A complete singularization then takes place by subsequent accelerator mechanisms. It will be noted that the individual items are pulled from the stack at a relatively low velocity initially so that the final velocity is not imparted to the material in a single accelerating process but rather in stepwise manner. The substantial increase in the operating speed is due primarily to the presence of double sets of suction cups which operate in opposite cyclic phase and which are able to pull items from the stack initially in staggered array. A further operating speed increase is obtained by including the vacuum control mechanism in the pivoting suction mechanism, thereby producing a very short path from the control valve to the suction cup. The alternating motion of the suction cups is performed by a simple lever drive which operates without exhibiting any torque peaks.
The supply rack for the apparatus according to the invention is similar to an accumulator belt which brings the advantage that it may be refilled by hand but may also be connected directly to a conveyor belt which supplies the product in staggered array which permits the direct connection to, for example, a rotating newsprint machine without any intermediate handling and restacking.
Accordingly, this high performance feeder mechanism is able to fulfill the main requirement for a rapidly running insertion machine which is used in newspaper processing. A prototype of the feeder mechanism according to this invention has already achieved operating speeds of 40,000 items per hour.
The invention will be better understood as well as further objects and advantages thereof become more apparent from the following detailed description of a preferred embodiment taken in conjunction with the drawing.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a side elevational view of the feeder mechanism according to the invention;
FIG. 2 is a detailed illustration of the suction cup operating mechanism and one conveyor wheel; and
FIG. 3 is an end elevational view of the apparatus according to the invention; and
FIG. 4 shows the structure of FIG. 3 and the connection between a source of vacuum and one of the suction device.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The feeder mechanism according to the invention is illustrated in an exemplary embodiment in FIG. 1 which shows a main frame 1 including an oblique rail 2 on which there is displaceably located a serving platform 3 on which stacks or staggered arrays of the items (individual sheets, folded sheets, etc.) may be placed either by hand or automatically for eventual individual removal. A main drive shaft 5 acts through a crank and a connecting rod 6 to power a group of adjacently disposed conveyor belts 7 in discrete steps with free-wheeling operation so that the items placed on the conveyors are transported in discrete, stepwise motions to the feeder platform 8 where they are automatically erected to assume an inclined position in such a way that their upper edges extend beyond a reversing roller 9 and are located in positions in which they are accessible to the suction cups. The height of the serving platform is so adjusted that the upper edge of each of the items to be processed will extend to the same height in each case.
The main drive shaft 5 also drives conveyor belts 10 in the direction of the arrow 11 and furthermore, via chains or drive belts (not shown) it drives two conveyor wheels 12 in the direction of the arrow. The suction cup drive shaft 13 is also driven in the direction of the arrow and a belt drive 14 powers accelerator rollers 15 which cooperate with counter-pressure rollers 16. In the exemplary embodiment shown, the conveyor wheels 12 have eight uniformly distributed recesses so that these wheels 12 complete 1/8 of a revolution per operating cycle. The suction cup drive shaft 13 includes two eccentric bearings 17, 18 mutually displaced by 180°, each of which acts as the drive crank for a four-jointed linkage that moves the suction cups back and forth. The four-jointed linkage for the foremost suction-operated sheet withdrawing device or cup 22 in FIG. 2 includes the eccentric crank 17, a connecting rod or support 19 and a lever 20 which latter is able to pivot around a locally fixed axis 21. In FIG. 2, the suction cup 22 is disposed rotatably about the axis of a coupling pin 23 behind the connecting rod 19 and is held in its normal position adjacent a surface of the connecting rod 19 24 by a compression spring 23a (see FIG. 4). While the suction cup 22 moves along the curve or path 25 traced by the connecting rod 19, it is supplied with vacuum when in the vicinity of the first sheet to be removed so that it adheres to that sheet by suction. During the further motion, the suction cup is forced to rotate about the axis of the coupling pin 23 in the direction of the arrow 26 while the compression spring 23a yields, and it thus bends the upper edge or the upper fold of the first item from the stack. Subsequently, an upper corner 27 on each of the conveyor wheels 12 engages the upper edge of the sheet and thus pulls the bent sheet over the reversing roller 9 in the downward direction until it is pinched between the conveyor wheels 12 and the reversing roller and is gradually pulled further out of the stack. During this process, however, the second suction cup 29 has arrived at the bottom surface of the stack and is already engaged in removing the second item in the stack in the same manner so that, when the next recesses in the conveyor wheels 12 arrive, the respective corners 27 engage the second sheet and cause it to be pinched between the conveyor wheels and the reversing roller. The relatively close sequencing of the recesses in the conveyor wheels 12 results in a staggered array of the individual items taken from the stack which are then pulled further apart by the accelerator rollers 15 cooperating with their counter-rollers 16.
Since the second suction cup 29 is driven by a mirror image mechanism at 180° phase displacement, the shaft 13 executes 1/2 revolution per operating cycle. The connecting rod of each of the linkages is made relatively large so that it is possible to use the bearing which carries the two connecting rods to serve at the same time as the vacuum control mechanism and by letting the motion of the connecting rods themselves cause the opening and closing of the valve and thereby control the admission of vacuum to the respective suction cups. For this purpose, the bearing 30 is provided with a source 30A of vacuum (see FIG. 4) and a lateral air evacuating bore 30B in suitable locations through which the air evacuating slots 19A and bores 19B of the two connecting rods may be coupled with vacuum for a short time during part of their motion, namely, whenever the particular suction cup begins to engage the stack and bends the first item thereof in a downward direction. The above-described construction of the suction mechanism provides very short paths for air flow from the vacuum control valve which, in this case, is formed by the bearing 30, to the individual suction cup.
Since the two suction cups 22 and 29 operate in alternate manner, it is unnecessary to have a separate retainer mechanism for the remaining stack because a particular item is pulled from the stack only after the other suction cup has already arrived at the stack and holds its respective item in a fixed manner just at the time when the previous item is being accelerated between the conveyor wheels 12 and the reversing roller 9. Accordingly, there are present no mechanisms which would require additional reciprocating drive means so that, during one cycle, the driving torque exhibits no particular fluctuations or peaks which would necessitate the presence of a more powerful motor drive. Accordingly, the power required for driving the high performance feeder mechanism according to the present invention is relatively small.
The foregoing pertains to a preferred exemplary embodiment of the invention, it being understood that many modifications thereof are possible within the spirit and scope of the invention, the latter being defined by the appended claims. | A feeder mechanism for feeding single sheets, folios or multiple-ply material of paper or the like to subsequent processing machinery. A stack of sheets is partially tilted and edge portions of the front sheet are grasped and bent over by alternately approaching suction devices. While one of the suction devices engages the edge portion of one sheet, the previously detached sheet is being engaged by a conveyor wheel which pulls it completely from the stack. | 1 |
[0001] This application is a Continuation of, and claims priority under 35 U.S.C. § 119 to, International application number PCT/IB03/03004, filed 4 Jul. 2003, and claims priority under 35 U.S.C. § 119 to German application number 102 31 879.4, filed 12 Jul. 2002, the entireties of both of which are incorporated by reference herein.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The invention relates to a method for influencing and monitoring the oxide layer on metallic components of hot CO 2 /H 2 O cycle systems, in particular of CO 2 /H 2 O gas turbines.
[0004] 2. Brief Description of the Related Art
[0005] CO 2 /H 2 O gas turbine systems having a largely closed CO 2 gas turbine cycle are known. A gas turbine system of this type comprises at least one compressor, at least one combustion chamber, at least one turbine, at least one heat sink and a water separator. In the combustion chamber, the fuel (hydrocarbon, e.g. natural gas with methane CH 4 as its main component) reacts with the oxygen of the atmosphere prepared from O 2 , CO 2 and if appropriate H 2 O.
[0006] The components CO 2 and H 2 O formed as a result of the combustion, as well as any inert gases introduced with the oxygen or the natural gas, are removed on an ongoing basis, so that a cycle with a substantially constant composition of the working medium is maintained.
[0007] Unlike in conventional gas turbine systems, in which the exhaust gases still contain a high level of O 2 , the working medium in a cycle process of this type, predominantly comprising CO 2 and H 2 O, may have reducing properties. Consequently, at the high temperatures which usually prevail in the combustion chamber and in the turbine, the protective oxide layer on the metal surfaces of the components that are subject to thermal load may disadvantageously be worn away. These components are then corroded quickly and can lead to undesirable premature failure.
SUMMARY OF THE INVENTION
[0008] It is an aspect of the invention to avoid the abovementioned drawbacks of the prior art. One aspect of the present invention includes developing a method for influencing and monitoring the oxide layer on components of hot CO 2 /H 2 O cycle systems, in particular of CO 2 /H 2 O gas turbines. The method is to be as simple as possible to implement.
[0009] According to principles of the present invention, an exemplary method in accordance therewith, to protect the oxide layer of the components which are under thermal load, an excess of oxygen is used, the level of which is dependent on the current state of the oxide layer, this state of the oxide layer being determined by periodic and/or continuous measurements.
[0010] Advantages of the invention include that with the method according to the present invention it is possible to prevent undesirable removal of the protective oxide layer on the surfaces of the metallic components that are subject to thermal load, and therefore to counteract corrosive damage and premature failure of the corresponding components.
[0011] It is advantageous for the state of the oxide layer of the components which are under thermal load to be determined using specimens with a pre-calibrated surface condition by said sensors being introduced into the hot flow, being exposed to this flow for a certain time and then being removed and examined periodically. This method is relatively simple to implement.
[0012] However, it is also possible for the state of the oxide layer on at least one component that is subject to thermal load to be monitored on-line. The on-line monitoring is exemplarily based on an emission measurement with on-line reference or on an analysis of reflection spectra.
[0013] Furthermore, it is advantageous if the information obtained from the monitoring of the state of the oxide layer is combined with information obtained from the measurement results of a λ sensor. It is then possible to implement a system operating mode which is oriented to the state of the oxide layer and is optimized with regard to power and efficiency.
[0014] It is expedient if information about the local composition of the combustion gas in the turbine is additionally taken into account. Information of this type can be obtained, for example, with the aid of spectral emission analysis.
[0015] Finally, methods according to the invention can also advantageously be used in cycle systems in which the working medium is liquefied through dissipation of heat and a pump is used instead of the compressor, or in systems in which an integrated membrane reactor replaces the combustion chamber.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] Four exemplary embodiments of the invention are illustrated in the drawing, in which:
[0017] FIG. 1 shows a circuit diagram of a gas turbine system operating in accordance with the method of the invention in a first variant embodiment;
[0018] FIG. 2 shows a circuit diagram of a gas turbine system operating in accordance with the method of the invention in a second variant embodiment;
[0019] FIG. 3 shows a circuit diagram of a system operating in accordance with the method of the invention in a third variant embodiment, and
[0020] FIG. 4 shows a circuit diagram of a gas turbine system operating in accordance with the method of the invention with an integrated membrane reactor.
[0021] In the figures, identical parts are in each case provided with identical reference symbols. The direction of flow of the media is indicated by arrows.
DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS
[0022] The invention is explained in more detail below on the basis of exemplary embodiments and FIGS. 1 to 4 .
[0023] FIG. 1 illustrates a largely closed CO 2 gas turbine cycle. It substantially comprises a compressor 1 , a combustion chamber 2 , a turbine 3 , a heat sink 4 , a water separator 5 and a CO 2 removal location 6 . The cycle involves internal combustion of a hydrocarbon, for example a natural gas, which predominantly comprises methane CH 4 , in an atmosphere prepared from O 2 , CO 2 and if appropriate H 2 O. The components CO 2 and H 2 O formed as a result of the combustion, as well as any inert gases supplied with the oxygen or natural gas, are removed on an ongoing basis, so that a cycle with a substantially constant composition of the working medium is maintained.
[0024] Unlike in conventional gas turbines, in which the exhaust gases still contain a high level of oxygen, the working medium in a cycle process of this type, which predominantly comprises CO 2 and H 2 O, may have reducing properties. This can cause the protective oxide layer on the metal surfaces to be worn away at the high temperatures which prevail in the combustion chamber and the turbine. To counteract this phenomenon, according to the invention the combustion is now operated with a suitable excess of oxygen. The excess of oxygen is monitored, for example, by a λ sensor arranged in the exhaust-gas stream of the turbine.
[0025] Since the relationships between the excess of oxygen and the build-up and degradation of the oxide layer may be highly complex, it is advantageous if information about the state of the oxide layer on the components which are at risk of being damaged by high temperatures is additionally used to set the level of the oxygen excess. In accordance with FIG. 1 , this is achieved by a specimen 7 having a pre-calibrated surface condition being arranged at at least one exposed location in the combustion chamber 2 , being removed periodically and its surface state examined. This specimen 7 characterizes the state of the component which is subject to thermal load and is used as a basis for setting the level of the oxygen excess.
[0026] FIG. 2 shows a further exemplary embodiment of the invention. Unlike in the first exemplary embodiment, illustrated in FIG. 1 , this embodiment does not use specimens 7 which have been calibrated in terms of their surface state, but rather in this case the state of the oxide layer on the components that are subject to high thermal loads, for example the guide vane of the turbine 3 , is determined continuously by using an optical measurement method 8 which is known per se and is based on analysis of reflection spectra for on-line measurement of the surface state. Then, the level of oxygen excess required is determined and set on the basis of these measurements. In a further exemplary embodiment, the on-line monitoring may be based, for example, on an emission measurement with on-line reference.
[0027] The on-line oxide layer monitoring is based on using a suitably constructed optical (reflection) sensor to determine whether there is an oxide layer on a metal surface.
[0028] Oxidized and unoxidized surfaces differ in two main respects:
[0029] 1. The emissivity from an oxidized surface is very high, for example for a typical Ni-base superalloy in the near IR it is>0.8. For an unoxidized surface of the same material, the emissivity under the same conditions is significantly lower (<0.5). The result of this is that at a given temperature without active illumination, the oxidized surface emits significantly more radiation than the unoxidized surface. In the event of illumination with an external source, the oxidized layer reflects less than the unoxidized surface.
[0030] 2. The spectral emission characteristics, i.e. the radiated (or reflected) signal as a function of the wavelength, changes in the oxidized state compared to the unoxidized state.
[0031] If the radiation characteristic in the relevant temperature range does not change significantly, by way of example a purely passive sensor can determine the surface condition from the relative ratio of the emitted IR radiation at two or more suitable wavelengths. The relative measurement has the advantage of being insensitive to losses in the optical path (e.g. dust on viewing window), provided that these losses manifest themselves equally at both wavelengths.
[0032] Methods with active, broad-band illumination are more robust. In this case, the surface is irradiated over a broad band, for example with the light from a halogen lamp, and the reflected light is analyzed spectrally. By comparison with the illumination signal, it is possible to determine the reflectivity for each wavelength, and the formation of a quotient at different wavelengths provides information about the surface condition.
[0033] An example which may be mentioned is the alloy Hastelloy X, for which a quotient from two optical bandpasses, around 1.6 μm (λ 1 ) and around 2.1 μm (λ 2 ), is recommended for the analysis. In the case of an unoxidized surface, the reflection is greater at λ 2 than at λ 1 , whereas precisely the reverse is true if an oxide layer is present. Light of both wavelengths can be flexibly transmitted via optical waveguides. To determine the bandpasses and illumination strategy, the optical properties of the combustion chamber material must be known or have been determined beforehand.
[0034] It is advantageous if the information obtained from the monitoring of the state of the oxide layer is combined with information obtained from the measurement results of a λ sensor in order to set a system operating mode which is oriented to the state of the oxide layer and is optimized with regard to power and efficiency. Furthermore, by way of example, information about the local composition of the combustion gas in the turbine can be taken into consideration, it being possible for this information to be obtained, for example, with the aid of emission analysis.
[0035] A further exemplary embodiment is illustrated in FIG. 3 . Unlike in the exemplary embodiment illustrated in FIG. 1 , the working medium is liquefied through dissipation of heat in a CO 2 liquefier 10 , and a pump 9 , which transfers the liquid working medium to the combustion chamber 2 , is used instead of the compressor.
[0036] In this example, stepped compression and expansion processes with intervening supply or dissipation of heat can be provided in order to limit the maximum operating pressure.
[0037] A final exemplary embodiment is illustrated in FIG. 4 . In this case, CH 4 is reacted with O 2 in a membrane reactor 11 supplied with compressed air by a compressor 1 , one side of the membrane being purged with a sweep gas 13 which comprises the hot CO 2 /H 2 O mixture described above with a low O 2 content. The membrane reactor 11 is thereby integrated in the sweep cycle of the gas turbine system, which also includes a flow-splitting control valve 14 . The control valve 14 is used to control what proportion of the sweep gas 13 is fed to the downstream sweep turbine 15 and what proportion remains in the sweep cycle. The hot air with a reduced oxygen content 12 which emerges from the membrane reactor 11 is expanded in the turbine 3 .
[0038] In particular the membrane reactor 11 , the sweep turbine 15 and any additional heat exchangers (not shown) in this example have to be protected against corrosion, and consequently on-line measurements 8 of the surface state of the thermally loaded component are carried out at these locations.
[0039] Of course, the invention is not restricted to the exemplary embodiments described. By way of example, the measurements can be carried out at a plurality of locations, or both continuous on-line measurements and periodic measurements on calibrated specimens 7 can be performed.
[0040] List of Designations
[0041] 1 Compressor
[0042] 2 Combustion chamber
[0043] 3 Turbine
[0044] 4 Heat sink, for example cooler or heat recovery utilization
[0045] 5 Water separator
[0046] 6 CO 2 removal location
[0047] 7 Specimen
[0048] 8 On-line measurement
[0049] 9 Pump
[0050] 10 CO 2 liquefier
[0051] 11 Membrane reactor
[0052] 12 Hot air with reduced O 2 content
[0053] 13 Sweep gas
[0054] 14 Flow-splitting control valve
[0055] 15 Sweep turbine
[0056] While the invention has been described in detail with reference to exemplary embodiments thereof, it will be apparent to one skilled in the art that various changes can be made, and equivalents employed, without departing from the scope of the invention. Each of the aforementioned documents is incorporated by reference herein in its entirety. | A method for influencing and monitoring the oxide layer on metallic components of hot CO 2 /H 2 O cycle systems, in particular of CO 2 /H 2 O gas turbine installations, in which a hydrocarbon-containing fuel is burnt with oxygen, and the excess CO 2 and H 2 O formed is removed from the cycle system at a suitable location. To protect the oxide layer of the components which are under thermal load, an excess of oxygen is used, the level of which is dependent on the current state of the oxide layer, the state of the oxide layer being determined by periodic and/or continuous measurements. | 5 |
CROSS REFERENCE TO RELATED APPLICATIONS
This application is a Continuation-in-Part of application Ser. No. 494,208 Filed Jun. 23, 1995; now abandoned.
FIELD OF THE INVENTION
This invention relates to composite materials having reduced permeability to small molecules, such as air, and which have enhanced mechanical properties. More particularly this invention relates to layered silicates intercalated with a polymer.
BACKGROUND OF THE INVENTION
Layered clay minerals such as montmorillonite are composed of silicate layers with a thickness of about 1 nanometer. Dispersions of such layered materials in polymers are frequently referred to as nanocomposites.
Recently, there has been considerable interest in forming nanocomposites as a means to improve the mechanical properties of polymers. Incorporating clay minerals in a polymer matrix, however, does not always result in markedly improved mechanical properties of the polymer. This may be due to the lack of affinity between the layered silicate materials and the organic polymers. Thus it has been proposed to use ionic interactions as a means of incorporating clay minerals in a polymer. In this regard, see for example U.S. Pat. No. 4,889,885 and U.S. Pat. No. 4,810,734. This type of approach, unfortunately, has limited usefulness. Indeed, a more direct, simple, and economic approach to preparing nanocomposites is highly desirable.
One object of the present invention is to provide a latex comprising a layered silicate intercalated with a polymer.
Another object of the present invention is to provide a composite material formed from a latex of a layered silicate and a polymer which material has reduced permeability to small molecules such as air, and improved mechanical properties.
These and other objects, features and advantages of the present invention will become more apparent from the description which follows.
SUMMARY OF THE INVENTION
In one embodiment of the present invention, a latex is provided comprising water and a layered material, such as a layered mineral, intercalated with a polymer.
Another embodiment of the present invention provides a nanocomposite comprising a layered material intercalated with a polymer.
Another aspect of the present invention comprises a blend of a nanocomposite composed of a layered material intercalated with a polymer, and a second polymer.
One process for producing the latex of the present invention comprises forming a dispersion of a layered material in water including a surfactant such as an onium salt; adding a polymerizable monomer or monomers, such as an olefin or diene, and a polymerization initiator to the dispersion; and thereafter polymerizing the monomer or monomers to form the latex. The preparation of this latex comprises yet another embodiment of the present invention. This process is advantageous where polymerization can proceed in the presence of water.
Some technologically important polymers, for example butyl rubber and polyolefins, cannot be formed from monomers in the presence of polar liquids like water. In order to form these polymers, a second process for producing the latex of the present invention must be used whereby the latex is formed from bulk polymer. These polymers are referred to as pre-formed polymers because the polymerization from the monomer occurs in a separate procedure before the formation of the latex. In this process a surfactant is added to a mixture of polymer and non-polar liquid thereby forming an emulsion or micro-emulsion. Polar liquids have molecules with an electric dipole moment. A layered material is added to an emulsion or micro-emulsion and then subjected to shearing forces sufficient to form a latex containing a nanocomposite.
A composite material formed from the latex of the present invention prepared by either method has improved mechanical properties and reduced permeability to small molecules such as air. These materials are therefore particularly useful in a range of applications, particularly as a tire inner liner and as inner tubes, barriers, films, coatings and the like.
DETAILED DESCRIPTION
The methods below describe the formation of a solid nanocomposite intercalated with a polymer. A solid nanocomposite is a solid material containing molecules selected from the group consisting of anionic, cationic, and nonionic surfactants having a hydrophilic head group and at least one oleophilic tail wherein the tails are selected from the group of alkyl, alkenyl, and alkynyl groups having about 4 to about 30 carbon atoms, and layered material intercalated with a polymer, the layered material having an average number of layers between about 150 and about 300 layers, and an average interlayer separation in the range of about 20 to about 40 Å. The layered material intercalated with a polymer is in the form of nano-scale particles dispersed throughout the solid nanocomposite material. Often the nano-scale particles are called nanocomposite particles. Each individual nanocomposite particle has at least 10 layers.
The solid nanocomposite material is formed from a latex. A latex is a two phase material that has a continuous liquid phase such as water and a second phase comprising micelles of 0.5 microns in average size or larger dispersed in the continuous phase. The latex is prepared by one of two methods, depending on the type of polymer to be intercalated in the layered material.
In-situ polymerization in a mixture of surfactant, layered material, monomer, and a liquid is used in cases where the polymerization can occur in the presence of a polar liquid. In this method polymers can be formed by either emulsion or micro-emulsion polymerization methods. This process results in a latex containing a layered material intercalated with a polymer.
In another method, a mixture of pre-formed polymer, surfactant, and a polar liquid is processed to form an emulsion or micro-emulsion. Layered material is then added and shearing forces are applied to the mixture to produce a latex containing a layered material intercalated with a polymer.
The following is a detailed description of the formation of a solid nanocomposite material intercalated with a polymer prepared in-situ.
Any natural or synthetic layered mineral capable of being intercalated may be employed; however, layered silicate minerals are preferred. The layered silicate minerals that may be employed in the present invention include natural and artificial minerals capable of forming intercalation compounds. Non limiting examples of such minerals include smectite clay, montmorillonite, saponite, beidellite, montronite, hectorite, stevensite, vermiculite, kaolinite and hallosite. Of these montmorillonite is preferred.
The surfactant used is any compound capable of derivatizing the layered mineral. Representative surfactants include anionic, cationic, and nonionic surfactants having a hydrophilic head group and at least one oleophilic tail wherein the tails are selected from the group of hydrogen, alkyl, alkenyl, and alkynyl groups having about 4 to about 30 carbon atoms. Representative surfactants include quaternary ammonium, phosphonium, maleate, succinate, molecules having carboxyl containing groups, acrylate, benzylic hydrogens, benzylic halogens, aliphatic halogens, and oxazoline.
It will be readily appreciated that some of the above mentioned surfactants are also emulsifying agents. However, in those instances when the surfactant is not an emulsifying agent preferably an emulsifying agent will be employed in carrying out the polymerization. Optionally, of course, another emulsifying agent may be used even when the surfactant has emulsifying properties. In either event, the emulsifying agent will be one typically used in emulsion or microemulsion polymerization processes.
The polymers and copolymers referred to herein as emulsion polymers are those formed by emulsion polymerization techniques, and those referred to herein as microemulsion polymers are those formed by microemulsion techniques. In both techniques micelles containing monomer and surfactant are present in a solvent, and the polymerization occurs within the micelles resulting in the formation of latex particles. In microemulsion polymerization the latex particles range in average size from about 50 Å to about 0.2 microns. In emulsion polymerization, on the other hand, the latex particles range in average size from about 0.2 to about 100 microns. While the average latex particle size of microemulsions and emulsions fall into distinct ranges, the actual sizes of the latex particles present in either case vary over a wide range of sizes. There is sufficient overlap in actual particle size that even in the case on an emulsion some latex particles smaller than 100 Å in size are present. While not wishing to be bound by any theory, it is believed that polymerization occurs in the presence of a layered material when latex particles that have a size less than or equal to the average separation distance of the layers are present in the liquid. This separation depends on the relative concentrations of the layered material and surfactant in the solvent, as well as on other factors such as the type of layered material employed. Polymerization can occur by either microemulsion or emulsion polymerization methods because there is an overlap in latex particle size range between the emulsions and microemulsions on the order of the interlayer distances employed in this invention.
Some polymers useful in the practice of this invention are polymers based on one or more water immiscible, free radical polymerizable, monomers such as olefinic monomers and especially styrene, paramethyl styrene, butadiene, isoprene, and acrylonitrile. Particularly preferred are styrene rubber copolymers and styrene acrylonitrile rubber copolymers, i.e., copolymers having styrene, butadiene, isoprene and acrylonitrile. Especially preferred, in the practice of the present invention are homopolymers and copolymers having a glass transition temperature less than about 25° C., a number average molecular weight above about 5,000 g/mole and especially about 15,000g/mole. Also, the preferred polymer will contain some unsaturation or other reactive sites for vulcanization.
These methods are especially useful for forming nanocomposite materials having polymers with a Tg below about 100° C. Particularly preferred polymers have Tg in the range of about -50° C. to about 100° C.
The latex of an intercalatable mineral having an emulsion or microemulsion polymer intercalated in the mineral is prepared by forming a dispersion of the layered mineral in a polar liquid such as water and including a surfactant. Typically, the mineral is first dispersed in water by adding from about 0.01 to about 80 grams of mineral to 100 grams of water and preferably, about 0.1 to about 10.0 g of mineral to 100 g of water, and then vigorously mixing or shearing the mineral and water for a time sufficient to disperse the mineral in the water. Then a surfactant such as a hydrocarbyl onium salt is added to the dispersion, preferably as a water solution, and with stirring.
The amount of surfactant used in the process of the present invention depends on the type of layered material and monomers used as well as process conditions. In general, however, the amount of surfactant used will be in the range from about 100% to about 2,000% of the cationic exchange capacity (C.E.C) of the layered mineral. Generally, an amount of surfactant in the range of about 1000% to about 2,000% C.E.C. is used when the formation of a microemulsion is desired.
Next, the polymer latex is formed by adding to the mineral dispersion an emulsifying agent, if desired or necessary, the appropriate monomer or monomers, and a free radical initiator under emulsion polymerization or microemulsion conditions. For example, styrene and isoprene are polymerized in the mineral dispersion using a free radical polymerization initiator while stirring the reactants. The copolymerization typically is conducted at a temperature in the range of about 25° C. to about 100° C. and for a time sufficient to form the polymer latex, followed by termination of the reaction.
In cases where polymerization cannot occur in the presence of the liquid present in the emulsion or microemulsion, the latex is formed by a process that uses pre-formed polymers. Pre-formed polymers are polymers that are formed prior to the formation of the latex. The layered materials, surfactants, and liquids described above for production of the in-situ polymer latex are all suitable for the production of a pre- formed polymer latex.
Pre-formed polymers are based on one or more of the monomers selected from the group consisting of styrene, paramethyl styrene, butadiene, isoprene, chloroprene, ethylene, propylene, vinyl chloride, vinyl acetate, nitriles such as acrylonitrile, butene, hexene, heptene, isobutylene, octene, maleic anhydride, succinic anhydride, dienes, and acrylates, and having molecular weights that range from about 1,000 gram per mole to about 10 7 gram per mole. Often it is desirable that the polymer be functionalized. Preferably the polymer contains from about 0.01 to about 900 milliequivalents of functionalization per 100 grams of polymer, and more preferably from about 0.01 to about 200 milliequivalents of functionalization per 100 grams of polymer. Representative functionalization groups are quaternary ammonium, phosphonium, maleate, succinate, molecules having carboxyl containing groups, acrylate, benzylic hydrogens, benzylic halogens, aliphatic halogens, and oxazoline.
To form the latex containing a nanocomposite material intercalated with a polymer, the pre-formed polymer is mixed with a surfactant, a polar liquid, and, optionally, a co-solvent. Typical liquids are water or dimethylformamide. Typical co-solvents are aliphatic alcohols, aliphatic alkanes, esters, and ethers. Preferred concentration ranges are about 0.1% to about 70 wt% surfactant, and 0.1% to about 63 wt % polymer, with the balance being solvent, or solvent and optional co-solvent. The wt % is based on the total weight of polymer, surfactant, liquids, and optional co-solvent when present. After mixing is complete layered material is added to the solution. Layered material concentration in the solution ranges from about 0.2% to about 4 wt %, based on the total weight of polymer, surfactant, liquid, optional co-solvent when present, and layered material. Shearing forces are then applied to the mixture, preferably resulting from ultrasonic vibration and high speed blenders, for a time sufficient to form the latex.
The latex produced by either method described above can be used to form a solid nanocomposite where the layered material ranges from about 0.1 wt % to 90 wt. % of the total weight. These nanocomposites can be formulated into coatings or films following standard techniques employed for forming such materials. Additionally, the nanocomposite of the layered silicate mineral and the polymer may be recovered by coagulating the latex, and drying the solid composite. The solid nanocomposite can then be formed into tire inner-liners or inner tubes using conventional processing techniques such as calendaring or extrusion followed by building the tire and molding.
In one embodiment of the present invention the nanocomposite is dispersed with a second polymer, such as a styrene-rubber copolymer by blending on a rubber mill or in an internal mixer. Preferably the nanocomposite will be blended with a polymer formed from the same monomer or monomers used in forming the nanocomposite. The amount of nanocomposite in the blend typically will be in the range of about 0.1 to about 99.9 wt %, based on the total weight of the blend.
In producing tire inner liners the polymer blended with the nanocomposite of this invention preferably will have a molecular weight of greater than about 10,000 and some unsaturation or other reactive sites so that it can be vulcanized or cross-linked in the bulk state.
The invention will be more clearly understood by reference to the following examples.
Example 1
Samples of 0.2, 0.8, 1.1, 1.2, 4, and 8 wt % montmorillonite in water were prepared. The results of small angle X-ray scattering measurements are shown in Table 1. Results of the measurements of the 0.2 through 1.2 wt % samples are characteristic of slightly deformed silicate layers completely dispersed in the water. The absence of any (001) Bragg reflections indicates that at these concentrations the solution is a suspension of individual silicate layers 9.6 Å thick isotropically oriented with respect to each other, and therefore having no average layer repeat distance. The results of the 4 wt % and 8 wt % samples are characteristic of a disordered aggregation of silicate layers with an average layer repeat distance of about 80 Å. Dodecyl trimethyl ammonium bromide surfactant was added to all but the 1.1 wt % sample in an amount equal to 100% of the cation exchange capacity of the montmorillonite in each sample. All those cases exhibit an average layer repeat distance of about 20 Å. See Table 1.
The surfactant was then added to the 1.1 wt % sample above to make a solution of 1.1 wt % clay and 3.5 wt % surfactant in water. This amount of surfactant corresponds to 1140% cation exchange capacity. X- ray scattering measurements of this sample revealed (001) Bragg reflections corresponding to an average layer repeat distance of about 30 Å. See Table 1.
Table 1 shows that at high clay concentrations the addition of surfactant causes a contraction of the interlayer separation. At lower clay concentrations, below about 4 wt %, the addition of surfactant in an amount equal to about 100% of the cation exchange capacity of the layered material initially causes the aggregation of the silicate layers into a layered structure having a measurable interlayer separation. Expansion of the interlayer separator is observed for surfactant concentration of approximately 1140% of the cation exchange capacity of the clay.
Example 2
A layered silicate, montmorillonite clay (18 g), was slurried with water (450 g) which had been degassed by sparging with nitrogen. The slurry was stirred overnight at 23° C. The clay was dispersed in the water in a Waring blender for three minutes and then degassed further. Dodecyl trimethyl ammonium bromide surfactant (25.7 g) was dissolved in degassed water (250 g) and added to the clay slurry. Isoprene (35 g), styrene (15 g), and azobisisobutyronitrile (AIBN) (0.25 g) as initiator were blended and then added to the clay slurry. The mixture was mechanically stirred for 20 hours at 23° C. and for 26 hours at 65° C. at which time polymerization was terminated with a 5 g aliquot of a mixture of(0.24 g) 2,6-di-tert-butyl-4-methylphenol, (1.6 g) hydro-quinone, (0.8 g) tetrakis methylene(3,5-di-tert-butyl-4-hydroxyhydrocinnamate)! methane and 200 ml methanol. The net result was the formation of an emulsion containing a layered silicate having a styrene-isoprene copolymer latex intercalated in the layered mineral. While not wishing to be bound by any theory, it is believed that the surfactant at this concentration causes the layers to aggregate parallel to each other. Polymeric intercalation would not be possible if the layers were not oriented parallel to each other, instead an isotropic mixture of polymer and individual silicate layers would result.
Example 3
A solid nanocomposite was formed from the latex of Example 2 by adding an excess of methanol to the latex, separating the solid from the liquid aqueous phase and washing the solid six times with methanol, followed by drying for about 18 hours at 60° C. under vacuum and for 48 hours at 23° C. in vacuum. Information obtained from electron micrographs of this sample are summarized in Table 3. That table shows that the number of silicate layers in each nanocomposite particle is at least 10, with an average number of layers of about 260. Additionally, the interlayer separation was measured to be about 36 Å. The micrographs also showed that the maximum number of layers in each nanocomposite particle is about 1000.
Example 4
A portion of the solid nanocomposite (20 grams) of Example 3 was then melt blended at 130° C. in a Brabender mixer for 5 minutes with a styrene-isoprene copolymer (20 grams) that was synthesized identically but had no clay. The blend of nanocomposite and the clay-free styrene-isoprene copolymer was cross-linked by roll milling the blend with stearic acid (1 phr), zinc oxide (3.9 phr), and tetramethyl thiuram disulfide (accelerator)) (1 phr) at 55° C. for ten minutes. Then the blend was hot pressed into 20 mil films for 20 minutes at 130° C. The films were tested on a Mocon 2/20 for oxygen transmission at 30° C. The results are given in Table 3 below. Also shown in Table 3 were the results obtained with a film formed from a styrene-isoprene copolymer that had been synthesized identically but had no clay. (Comparative Example 1)
Uniaxial tensile properties were also measured on mini-tensile film specimens using an Instron tester. The stress-strain measurements were performed at room temperature and at an extension rate of 0.51 mm/min and the results are shown in Table 4 below. Also shown in Table 4 and labeled as Comparative Example 1 are the tensile properties obtained for a polystrene-isoprene copolymer that was synthesized identically to that in Examples 2,3, and 4 but had no clay.
Example 5
Triethylammonium functionalized paramethyl styrene -co-isobutylene-co-isoprene, bromine neutralized ionomer, 5.6 g was dissolved in 100 g tetrahydrofuran overnight. 300g of water, 1 g poly(oxy 1,2-ethanediel, a-sulfo-w-nonyl phenoxy sodium) surfactant (Witco D-51-51), and 1 g hexadecanol were added to the polymer solution and stirred at 23° C. overnight, then at 65° C. for 2 hours. Subsequently, 2 g sodium montmorillonite was added and stirred at 65° C. for 2 hours. Ultrasonic vibration was then applied to the mixture at 65° C. using a W-225R Ultrasonic Inc. sonicator for 4 minutes at 50% duty cycle. The resultant was filtered then dried at 60° C. for 12 hours in vacuum, and 48 hours at 23° C. in vacuum.
Example 6
A solid nanocomposite was formed from the resultant of Example 5 by heating at 60° C. under vacuum for 12 hours and continued vacuum at 23° C. for 48 hours. This material was melt compression molded at 200° C. for 4 minutes thereby producing 20 mil films. Films were tested on a Mocon 2/20 for oxygen transmission at 30° C. The results are shown in table 3. Uniaxial tensile properties were also measured on 1 mini-tensile specimens I inch long and 20 mil thick. Tests were conducted using an Instron Tester with a cross head speed of 20 inches per minute. Results of these tests are shown in table 4. Information obtained from electron micrographs of this sample are summarized in table 2. The average number of silicate layers in each particle of layered material range from about 10 to about 1000, with an average number of layers of about 160. Additionally, the interlayer separation was measured to be about 25 Å.
Also shown in Tables 3 and 4 are results obtained with a film made according to the method of Example 5 and 6 but without clay (Comparative Example 2).
TABLE 1______________________________________Wt. % Clay 0.2% 0.8% 1.1% 1.2% 4% 8%______________________________________Layer repeat distance N/A N/A N/A N/A 80Å 80Åwithout surfactantLayer repeat distance 20Å 20Å -- 20Å 20Å 20Åwith surfactantconcentration of 100%cation exchange capacity(C.E.C.)Layer repeat distance -- -- 30Å -- -- --with surfactantconcentration of 1140%C.E.C.______________________________________
TABLE 2______________________________________ Amount of layered material having more Average AveragePolymerization than 10 and less than number interlayerMethod 1,000 layers. (Vol.%) of layers separation______________________________________In-situ 99.996% 230 36ÅPre-formed 99.998% 161 25Å______________________________________
TABLE 3______________________________________Film Wt % Clay Oxygen Transmission ##STR1##______________________________________Example 4 15.3 4,138Comparative 0 12,340Example 1Example 6 26.3 2,610Comparative 0 6520Example 2______________________________________
TABLE 4______________________________________ Energy Stress @ Break Strain @ Break 100% Modulus BreakFilm (psi) (%) (psi) (in-lbs.)______________________________________Comparative 2,001 560 503 12.1Example 1Example 4 2,312 497 699 11.3Example (6) 1,421 267 835 2.53Comparative 298 1,322 53 1.60Example 2______________________________________ | The present invention relates to a latex comprising water and a layered material intercalated with a polymer. The invention also relates to a nanocomposite material comprising a layered material intercalated with a polymer. The latex can be produced by forming a dispersion of layered material in water, adding surfactant, polymerizable monomer or monomers, and a polymerization initiator to the mixture and then polymerizing the monomer to form a latex. The latex can also be formed from preformed polymers. Composite materials formed from latexes produced by either method have improved mechanical properties and reduced air permeability. | 2 |
[0001] This application is a continuation of International Application No. PCT/EP02/11353 filed Sep. 26, 2002, which claims the benefit of priority of European Application No. 01 402 460.8, filed Sep. 26, 2001.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to compounds useful for treating pathological states, which arise from or are exacerbated by cell proliferation, to pharmaceutical compositions comprising these compounds, and to methods of inhibiting cell proliferation in a mammal.
[0004] 2. Description of the Art
[0005] Neoplastic diseases, characterized by the proliferation of cells, which are not subject to normal cell proliferating controls, are a major cause of death in humans and other mammals. Cancer chemotherapy has provided new and more effective drugs to treat these diseases and has also demonstrated that drugs, which are inhibitors of cyclin-dependent kinases are effective in inhibiting the proliferation of neoplastic cells.
[0006] Regulators at cell cycle checkpoints determine the decision for a cell to proceed through the cell cycle. Progression of the cell cycle is driven by cyclin-dependent kinases (CDKs) which are activated by oscillating members of the cyclin family, resulting in substrate phosphorylation and ultimately cell division. In addition, endogenous inhibitors of CDKs (INK4 family and KIP/CIP family) negatively regulate the activity of CDKs. Normal cell growth is due to a balance between activators of CDKs (cyclins) and endogenous inhibitors of CDKS. In several types of cancer, aberrant expression or activity of several components of the cell cycle has been described.
[0007] Cdk4 functions in G1 phase of the cell cycle and is activated by D-type cyclins, which results in substrate phosphorylation and progression to S phase. The only known substrate for cdk4 is the retinoblastoma gene product (pRb), a major tumor suppressor gene product, which functions as a major checkpoint control in regulation of the G1/S phase transition. Hyperphosphorylation of pRb by CDKs causes the release of E2F (a family of transcription factors) bound to pRb which then activate genes necessary for cell cycle progression, e.g. thymidine kinase, thymidylate synthase, cyclin E and cyclin A. Cyclin DI is amplified or overexpressed in many types of cancer (breast, ovarian, bladder, esophogeal, lung, lymphoma), while the gene for p16, the endogenous inhibitor of cdk4, is deleted, mutated, or aberrantly methylated in many tumor types. A point mutation in cdk4 was reported in a melanoma tumor that rendered the enzyme unable to bind p16 resulting in a constitutively active enzyme. All of the conditions described above lead to activation of cdk4 and cell cycle progression and tumor cell growth.
[0008] Arguments to designate CDK2 as an anticancer agent can be found in the literature << Cyclin E activates Cdk2 which acts to phosphorylate pRb resulting in an irreversible commitment to cell division and transition into S-phase >> (P. L. Toogood, Medicinal Research Reviews (2001), 21(6); 487-498. and << CDK2 (and possibly CDK3) is required for G1 progression and entry into S phase. In complex with cyclin E, it sustains pRb hyperphosphrylation to support progression through G1 and into S phase. In addition many other cellular targets of CDK2-CyclinE have been identified . . . . In complex with cyclinA, CDK2 plays a role in inactivating E2F and is required for completion of S phase. >> T. D. Davies et al. (2001) Structure 9, 389-397.
[0009] An added level of regulation of CDK activity exists. Cyclin-dependent kinase activating kinase (CAK) is a positive regulator of CDKs. CAK phosphorylates the catalytic CDKs on a conserved threonine residue to render the target enzyme completely active.
[0010] Because the defects in cell cycle molecules lead to CDK activation and subsequently cell cycle progression, it is logical that inhibition of CDK enzyme activity should block cell cycle progression and tumor cell growth.
[0011] The first CDK inhibitor to enter clinical trials is the compound known as flavopiridol. This compound is currently in Phase II clinical trials and is the only molecule in its class in the clinic at the present time. The aim of this invention is to produce molecules more active than flavopiridol.
[0012] It is known following publication of WO00/41669 that benzimidazole carbamate derivatives are vascular damaging agents that can be used for treating cancer, the sulfonoester derivatives claimed in this patent application are not at all exemplified and their anticancerous way of action is not described. Our invention relates specifically to sulfonesters derivatives of those carbamates.
SUMMARY OF THE INVENTION
[0013] In one embodiment of the present invention are disclosed compounds of formula (I)
wherein A is an aryl or heteroaryl entity wherein R 1 is selected from the group consisting of
alkyl, eventually substituted by an alkoxy, heteroalkyl, aryl, acyl, acyl derivatives, halogen alkoxy eventually substituted by an alkyl, heteroalkyl, aryl, heteroaryl, alkoxyalkyl, hydroxyalkyl amide or a perfluoroalkoxy group or an alkylthio eventually substituted by an amide or a perfluoroalkylthio aryl or heteroaryl eventually substituted by one or more alkyl group, alkoxy group, nitro group, cyano group, acyl derivative, perfluoroalkoxy group, perfluoroalkyl group, heteroaryl group, aryloxy group halogen 4 NH 2 4 NH alkyl or cycloalkyl eventually substituted with an an acyl, an acyl derivative, an hydroxy, an amino, alkoxy, heterocyclyl or aryl group 4 N imidazolyl 3 SO 2 Me when A is phenyl
wherein R2 is selected from the group consisting of
CO-alkyl eventually substituted by amino, acid, acid derivative, alkoxy, aryl or OH groups CO-aralkyl eventually substituted by alkoxy, halogeno, amino, acid or acid derivatives CO-aryl eventually substituted CO-alkoxy eventually substituted by aryl CO-amino, CO—NHR 3 , CO—NR 3 R 4 wherein R 3 and R 4 are selected independently from hydrogen, alkyl, hydroxyalkyl, alkoxyalkyl, fluoroalkyl, alkynyl, heteroalkyl, alkylheteroalkyl, aryl, aralkyl or together form an alkylen chain including eventually one to 4 more heteroatoms aryl or aralkyl eventually substituted by heterocycloalkyl, alkyl, aryl, alkoxy, amino, fluoroalkyl, acyl derivatives, halogen
or a pharmaceutically acceptable salt.
[0032] Among the preferred compounds of formula (I) are those where A represents a phenyl, thiophene, isoxazole, oxazole, pyrazole, furan, or pyridine, and more preferably those where A is a phenyl group.
[0033] Among the preferred compounds of formula (I) are those wherein the aryl, aralkyl, heteroaryl or heteroarylalkyl are optionally substituted with one or more similar or different groups selected from halogen, alkoxy, alkyl, hydroxyalkyl, alkylthio, amino, mono or dialkylamino, heterocyclylamino, arylamino, heteroarylamino, heteroaryl, nitro, heterocycloalkyl, perfluoroalkyl, perfluroroalkoxy, perfluoroalkylthio, acyl derivatives.
[0034] Among the preferred compounds of formula (I) are those wherein R 2 is an aminocarbonyl group substituted by a substituent selected from monoalkylamino or a monoarylamino substituent In the preferred compounds of formula (I) are those containing for R 2 an amino substituent and preferably a monoalkylamino or a monoarylamino substituent and still more preferably those containing a monoalkylamino substituent with an acyl derivative.
[0035] Among the alkyl or alkylene substituents which are substituted are included those substituted with one or more amino, aminoalkyl, aminoalkylamino, hydroxy, alkoxy, hydroxyalkoxy, acyl, acyl derivatives, alkyl, heteroalkyl, arylalkyl, arylamino, aryloxy, or aryl groups.
[0036] Among the alkoxy or alkythio substituents are included the alkoxy or alkylthio groups substituted with one or more amino, acyl, acyl derivatives, alkyl, arylalkyl or aryl groups.
[0037] Among the acyl groups or acyl derivatives groups are included the carboxylic acids and the sulfonic acids, the derivatives of which being mainly ester or carbamoyl esters.
[0038] The alkyl chain of the present invention includes linear, branched or cyclic chain containing 1 to 10 carbon atoms. The alkoxy chain of the present invention includes linear, branched or cyclic chains containing 1 to 4 carbon atoms. The aryl groups include phenyl or naphthyl groups, heteroaryl groups containing one to four heteroatoms selected from S, N or O such as furyl, thiophen, isoxazole, oxazole, pyrazole, furane, pyridine. The heterocyclyl group contains one to four heteroatoms choosen from N, O, S and 2 to 6 carbon atoms.
[0039] Among the preferred compounds are those containing an alkyl chain 1 to 10 carbon atoms and those containing acycloalkyl chain 3 to 5 carbon atoms. When the alkyl chain is substituted by an alkoxy group this last group has preferably one carbon atom.
[0040] Among the compounds of formula (I) the following compounds are much more preferred:
Methyl-5-(4-[2-hydroxyethyl]aminophenylsulfonyloxy)benzimidazole-2-carbamate Methyl-5-(4-[4-hydroxbutyl]aminophenylsulfonyloxy)benzimidazole-2-carbamate Methyl-5-(4-[2-methoxyethyl]aminophenylsulfonyloxy)benzimidazole-2-carbamate Methyl-5-(4-[1-imidazolyl]-phenylsulfonyloxy)benzimidazole-2-carbamate Methyl-5-(4-[2-pyridylmethyl]aminophenylsulfonyloxy)benzimidazole-2-carbamate Methyl-5-(4-ethylaminophenylsulfonyloxy)benzimidazole-2-carbamate Methyl-5-(4-[N-glycinyl]-phenylsulfonyloxy)benzimidazole-2-carbamate Methyl-5-(4-[1-methyl,2-hydroxyethyl]aminophenylsulfonyloxy)benzimidazole-2-carbamate Methyl-5-(4-[2-methyl,2-hydroxyethyl]aminophenylsulfonyloxy)benzimidazole-2-carbamate Methyl-5-(4-isopropylaminophenylsulfonyloxy)benzimidazole-2-carbamate Methyl-5-(4-[1-ethyl 2-hydroxyethyl]aminophenyl sulfonyloxy)benzimidazole-2-carbamate Methyl-5-(4-butylaminophenylsulfonyloxy)benzimidazole-2-carbamate Methyl-5-(4-[3-methoxypropyl]aminophenylsulfonyloxy)benzimidazole-2-carbamate Methyl-5-(4-methylaminophenylsulfonyloxy)benzimidazole-2-carbamate Methyl-5-(4-[2-sulfonylethyl]aminophenylsulfonyloxy)benzimidazole-2-carbamate Methyl-5-(4-aminophenylsulfonyloxy)benzimidazole-2-carbamate Methyl-5-(4-[2-diethylaminoethyl]aminophenylsulfonyloxy)benzimidazole-2-carbamate Methyl-5-(4-[1-tetrathydrofurylmethyl]aminophenylsulfonyloxy)benzimidazole-2-carbamate Methyl-5-(4-cyclopentylaminophenylsulfonyloxy)benzimidazole-2-carbamate Methyl-5-(4-[2-phenylethyl]aminophenylsulfonyloxy)benzimidazole-2-carbamate N-[5-(4-[imidazolyl]-phenylsulfonyloxy)-1H-benzimidazole-2-yl]-methylurea N-[5-(4-cyclopentylaminophenylsulfonyloxy)-1H-benzimidazole-2-yl]-methylurea N-[5-(4-cyclopentylaminophenylsulfonyloxy)-1H-benzimidazole-2-yl]-dimethylurea 4-Imidazol-1-yl-benzenesulfonic acid 2-benzoylamino-1H-benzoimidazol-5-yl ester 4-Imidazol-1-yl-benzenesulfonic acid 2-phenylacetylamino-1H-benzoimidazol-5-yl ester 4-Imidazol-1-yl-benzenesulfonic acid 2-(2-tert-butoxycarbonylamino-acetylamino)-1H-benzoimidazol-5-yl ester N-[5-(4-Imidazol-1-yl-benzenesulfonyloxy)-1H-benzoimidazol-2-yl]-succinamic acid methyl ester 4-[5-(4-Imidazol-1-yl-benzenesulfonyloxy)-1H-benzoimidazol-2-ylcarbamoyl]-butyric acid methyl ester 4-[5-(4-Imidazol-1-yl-benzenesulfonyloxy)-1H-benzoimidazol-2-ylcarbamoyl]-butyric acid methyl ester 4-Imidazol-1-yl-benzenesulfonic acid 2-(cyclohexanecarbonyl-amino)-1H-benzoimidazol-5-yl ester 4-Imidazol-1-yl-benzenesulfonic acid 2-[(pyridine-2-carbonyl)-amino]-1H-benzoimidazol-5-yl ester 4-Imidazol-1-yl-benzenesulfonic acid 2-[(pyridine-3-carbonyl)-amino]-1H-benzoimidazol-5-yl ester 4-Imidazol-1-yl-benzenesulfonic acid 2-[(pyridine-4-carbonyl)-amino]-1H-benzoimidazol-5-yl ester 4-Imidazol-1-yl-benzenesulfonic acid 2-pentanoylamino-1H-benzoimidazol-5-yl ester 4-Imidazol-1-yl-benzenesulfonic acid 2-hexanoylamino-1H-benzoimidazol-5-yl ester 4-Imidazol-1-yl-benzenesulfonic acid 2-(2-cyclopropyl-acetylamino)-1H-benzoimidazol-5-yl ester 4-Imidazol-1-yl-benzenesulfonic acid 2-(2-cyclohexyl-acetylamino)-1H-benzoimidazol-5-yl ester 4-Imidazol-1-yl-benzenesulfonic acid 2-(2-methoxy-acetylamino)-1H-benzoimidazol-5-yl ester 4-Imidazol-1-yl-benzenesulfonic acid 2-(2-dimethylamino-acetylamino)-1H-benzoimidazol-5-yl ester 4-Cyclopentylamino-benzenesulfonic acid 2-benzoylamino-1H-benzoimidazol-5-yl ester 4-Cyclopentylamino-benzenesulfonic acid 2-phenylacetylamino-1H-benzoimidazol-5-yl ester 4-Cyclopentylamino-benzenesulfonic acid 2-(2-tert-butoxycarbonylamino-acetylamino)-1H-benzoimidazol-5-yl ester N-[5-(4-Cyclopentylamino-benzenesulfonyloxy)-1H-benzoimidazol-2-yl]-succinamic acid methyl ester 4-[5-(4-Cyclopentylamino-benzenesulfonyloxy)-1H-benzoimidazol-2-ylcarbamoyl]-butyric acid methyl ester 4-Cyclopentylamino-benzenesulfonic acid 2-(cyclopropanecarbonyl-amino)-1H-benzoimidazol-5-yl ester 4-Cyclopentylamino-benzenesulfonic acid 2-(cyclohexanecarbonyl-amino)-1H-benzoimidazol-5-yl ester 4-Cyclopentylamino-benzenesulfonic acid 2-[(pyridine-2-carbonyl)-amino]-1H-benzoimidazol-5-yl ester 4-Cyclopentylamino-benzenesulfonic acid 2-[(pyridine-4-carbonyl)-amino]-1H-benzoimidazol-5-yl ester 4-Cyclopentylamino-benzenesulfonic acid 2-[(pyridine-4-carbonyl)-amino]-1H-benzoimidazol-5-yl ester 4-Cyclopentylamino-benzenesulfonic acid 2-pentanoylamino-1H-benzoimidazol-5-yl ester 4-Cyclopentylamino-benzenesulfonic acid 2-hexanoylamino-1H-benzoimidazol-5-yl ester 4-Cyclopentylamino-benzenesulfonic acid 2-(2-cyclopropyl-acetylamino)-1H-benzoimidazol-5-yl ester 4-Cyclopentylamino-benzenesulfonic acid 2-(2-cyclohexyl-acetylamino)-1H-benzoimidazol-5-yl ester 4-Cyclopentylamino-benzenesulfonic acid 2-(2-methoxy-acetylamino)-1H-benzoimidazol-5-yl ester 4-Cyclopentylamino-benzenesulfonic acid 2-(2-dimethylamino-acetylamino)-1H-benzoimidazol-5-yl ester 4-Imidazol-1-yl-benzenesulfonic acid 2-(3-cyclopropyl-ureido)-1H-benzoimidazol-5-yl ester 4-Cyclopentylamino-benzenesulfonic acid 2-(3-cyclopropyl-ureido)-1H-benzoimidazol-5-yl ester 4-Imidazol-1-yl-benzenesulfonic acid 2-(3-isopropyl-ureido)-1H-benzoimidazol-5-yl ester 4-Cyclopentylamino-benzenesulfonic acid 2-(3-isopropyl-ureido)-1H-benzoimidazol-5-yl ester 4-Imidazol-1-yl-benzenesulfonic acid 2-(3-butyl-ureido)-1H-benzoimidazol-5-yl ester 4-Cyclopentylamino-benzenesulfonic acid 2-(3-butyl-ureido)-1H-benzoimidazol-5-yl ester 4-Imidazol-1-yl-benzenesulfonic acid 2-[3-(2-fluoro-phenyl)-ureido]-1H-benzoimidazol-5-yl ester 4-Cyclopentylamino-benzenesulfonic acid 2-[3-(2-fluoro-phenyl)-ureido]-1H-benzoimidazol-5-yl ester 4-Imidazol-1-yl-benzenesulfonic acid 2-[3-(2-methoxy-phenyl)-ureido]-1H-benzoimidazol-5-yl ester 4-Cyclopentylamino-benzenesulfonic acid 2-[3-(2-methoxy-phenyl)-ureido]-1H-benzoimidazol-5-yl ester 4-Imidazol-1-yl-benzenesulfonic acid 2-[3-(3-methoxy-phenyl)-ureido]-1H-benzoimidazol-5-yl ester 4-Cyclopentylamino-benzenesulfonic acid 2-[3-(3-methoxy-phenyl)-ureido]-1H-benzoimidazol-5-yl ester 4-Imidazol-1-yl-benzenesulfonic acid 2-[3-(4-methoxy-phenyl)-ureido]-1H-benzoimidazol-5-yl ester 4-Cyclopentylamino-benzenesulfonic acid 2-[3-(4-methoxy-phenyl)-ureido]-1H-benzoimidazol-5-yl ester 4-Imidazol-1-yl-benzenesulfonic acid 2-[3-(2-chloro-phenyl)-ureido]-1H-benzoimidazol-5-yl ester 4-Cyclopentylamino-benzenesulfonic acid 2-[3-(2-chloro-phenyl)-ureido]-1H-benzoimidazol-5-yl ester 4-Imidazol-1-yl-benzenesulfonic acid 2-[3-(4-chloro-phenyl)-ureido]-1H-benzoimidazol-5-yl ester 4-Cyclopentylamino-benzenesulfonic acid 2-[3-(4-chloro-phenyl)-ureido]-1H-benzoimidazol-5-yl ester 4-Imidazol-1-yl-benzenesulfonic acid 2-[3-(2-methoxy-benzyl)-ureido]-1H-benzoimidazol-5-yl ester 4-Cyclopentylamino-benzenesulfonic acid 2-[3-(2-methoxy-benzyl)-ureido]-1H-benzoimidazol-5-yl ester 4-Cyclopentylamino-benzenesulfonic acid 2-[3-(3-fluoro-benzyl)-ureido]-1H-benzoimidazol-5-yl ester 4-Imidazol-1-yl-benzenesulfonic acid 2-[3-(3-chloro-phenyl)-ureido]-1H-benzoimidazol-5-yl ester 4-Cyclopentylamino-benzenesulfonic acid 2-[3-(3-chloro-phenyl)-ureido]-1H-benzoimidazol-5-yl ester 4-Imidazol-1-yl-benzenesulfonic acid 2-(3-isobutyl-ureido)-1H-benzoimidazol-5-yl ester 4-Cyclopentylamino-benzenesulfonic acid 2-(3-isobutyl-ureido)-1H-benzoimidazol-5-yl ester 4-Imidazol-1-yl-benzenesulfonic acid 2-[3-(2-dimethylamino-ethyl)-ureido]-1H-benzoimidazol-5-yl ester 4-Cyclopentylamino-benzenesulfonic acid 2-[3-(2-dimethylamino-ethyl)-ureido]-1H-benzoimidazol-5-yl ester 4-Imidazol-1-yl-benzenesulfonic acid 2-(3-ethyl-ureido)-1H-benzoimidazol-5-yl ester 4-Cyclopentylamino-benzenesulfonic acid 2-(3-ethyl-ureido)-1H-benzoimidazol-5-yl ester {3-[5-(4-Cyclopentylamino-benzenesulfonyloxy)-1H-benzoimidazol-2-yl]-ureido}-acetic acid 4-Imidazol-1-yl-benzenesulfonic acid 2-[3-(2-sulfo-ethyl)-ureido]-1H-benzoimidazol-5-yl ester 4-Imidazol-1-yl-benzenesulfonic acid 2-[3-(2-methoxy-ethyl)-ureido]-1H-benzoimidazol-5-yl ester 4-Cyclopentylamino-benzenesulfonic acid 2-[3-(2-methoxy-ethyl)-ureido]-1H-benzoimidazol-5-yl ester 4-Imidazol-1-yl-benzenesulfonic acid 2-[3-(4-dimethylamino-phenyl)-ureido]-1H-benzoimidazol-5-yl ester 4-Cyclopentylamino-benzenesulfonic acid 2-[3-(4-dimethylamino-phenyl)-ureido]-1H-benzoimidazol-5-yl ester 4-Imidazol-1-yl-benzenesulfonic acid 2-(3-pyridin-2-ylmethyl-ureido)-1H-benzoimidazol-5-yl ester 4-Cyclopentylamino-benzenesulfonic acid 2-(3-pyridin-2-ylmethyl-ureido)-1H-benzoimidazol-5-yl ester 4-Imidazol-1-yl-benzenesulfonic acid 2-(3-cyclobutyl-ureido)-1H-benzoimidazol-5-yl ester 4-Cyclopentylamino-benzenesulfonic acid 2-(3-cyclobutyl-ureido)-1H-benzoimidazol-5-yl ester 4-Imidazol-1-yl-benzenesulfonic acid 2-(3-pyridin-4-ylmethyl-ureido)-1H-benzoimidazol-5-yl ester 4-Cyclopentylamino-benzenesulfonic acid 2-(3-pyridin-4-ylmethyl-ureido)-1H-benzoimidazol-5-yl ester 4-Imidazol-1-yl-benzenesulfonic acid 2-(3-tert-butyl-ureido)-1H-benzoimidazol-5-yl ester 4-Cyclopentylamino-benzenesulfonic acid 2-(3-tert-butyl-ureido)-1H-benzoimidazol-5-yl ester 4-Imidazol-1-yl-benzenesulfonic acid 2-(3-phenyl-ureido)-1H-benzoimidazol-5-yl ester 4-Cyclopentylamino-benzenesulfonic acid 2-(3-phenyl-ureido)-1H-benzoimidazol-5-yl ester 4-Imidazol-1-yl-benzenesulfonic acid 2-(3-cyclohexyl-ureido)-1H-benzoimidazol-5-yl ester 4-Cyclopentylamino-benzenesulfonic acid 2-(3-cyclohexyl-ureido)-1H-benzoimidazol-5-yl ester; 4-Imidazol-1-yl-benzenesulfonic acid 2-(3-cyclopentyl-ureido)-1H-benzoimidazol-5-yl ester 4-Imidazol-1-yl-benzenesulfonic acid 2-[3-(3-fluoro-phenyl)-ureido]-1H-benzoimidazol-5-yl ester 4-Cyclopentylamino-benzenesulfonic acid 2-[3-(3-fluoro-phenyl)-ureido]-1H-benzoimidazol-5-yl ester 4-Cyclopentylamino-benzenesulfonic acid 2-[3-(2-hydroxy-ethyl)-ureido]-1H-benzoimidazol-5-yl ester 4-Imidazol-1-yl-benzenesulfonic acid 2-[3-(2-hydroxy-ethyl)-ureido]-1H-benzoimidazol-5-yl ester 4-Imidazol-1-yl-benzenesulfonic acid 2-[3-(4-fluoro-phenyl)-ureido]-1H-benzoimidazol-5-yl ester 4-Cyclopentylamino-benzenesulfonic acid 2-[3-(4-fluoro-phenyl)-ureido]-1H-benzoimidazol-5-yl ester 4-Imidazol-1-yl-benzenesulfonic acid 2-[3-(2-chloro-benzyl)-ureido]-1H-benzoimidazol-5-yl ester 4-Cyclopentylamino-benzenesulfonic acid 2-[3-(2-chloro-benzyl)-ureido]-1H-benzoimidazol-5-yl ester 4-Imidazol-1-yl-benzenesulfonic acid 2-[3-(2-fluoro-benzyl)-ureido]-1H-benzoimidazol-5-yl ester 4-Cyclopentylamino-benzenesulfonic acid 2-[3-(2-fluoro-benzyl)-ureido]-1H-benzoimidazol-5-yl ester 4-Imidazol-1-yl-benzenesulfonic acid 2-[(azetidine-1-carbonyl)-amino]-1H-benzoimidazol-5-yl ester 4-Cyclopentylamino-benzenesulfonic acid 2-[(azetidine-1-carbonyl)-amino]-1H-benzoimidazol-5-yl ester 4-Imidazol-1-yl-benzenesulfonic acid 2-(3-pyridin-3-ylmethyl-ureido)-1H-benzoimidazol-5-yl ester 4-Cyclopentylamino-benzenesulfonic acid 2-(3-pyridin-3-ylmethyl-ureido)-1H-benzoimidazol-5-yl ester 4-Imidazol-1-yl-benzenesulfonic acid 2-{3-[3-(4-methyl-piperazin-1-yl)-propyl]-ureido}-1H-benzoimidazol-5-yl ester 4-Cyclopentylamino-benzenesulfonic acid 2-{3-[3-(4-methyl-piperazin-1-yl)-propyl]-ureido}-1H-benzoimidazol-5-yl ester 4-Imidazol-1-yl-benzenesulfonic acid 2-(3-benzyl-ureido)-1H-benzoimidazol-5-yl ester 4-Cyclopentylamino-benzenesulfonic acid 2-(3-benzyl-ureido)-1H-benzoimidazol-5-yl ester 4-{3-[5-(4-Cyclopentylamino-benzenesulfonyloxy)-1H-benzoimidazol-2-yl]-ureido}-butyric acid methyl ester; 4-{3-[5-(4-Cyclopentylamino-benzenesulfonyloxy)-1H-benzoimidazol-2-yl]-ureido}-butyric acid ethyl ester 4-{3-[5-(4-Cyclopentylamino-benzenesulfonyloxy)-1H-benzoimidazol-2-yl]-ureido}-acetic acid methyl ester 4-Cyclopentylamino-benzenesulfonic acid 2-[3-(3-imidazol-1-yl-propyl)-ureido]-1H-benzoimidazol-5-yl ester 1-[5-(4-Cyclopentylamino-benzenesulfonyloxy)-1H-benzoimidazol-2S-ylcarbamoyl]-pyrrolidine-2-carboxylic acid 1-[5-(4-Cyclopentylamino-benzenesulfonyloxy)-1H-benzoimidazol-2S-ylcarbamoyl]-pyrrolidine-2-carboxylic acid methyl ester 4-Cyclopentylamino-benzenesulfonic acid 2-(3-carbamoylmethyl-ureido)-1H-benzoimidazol-5-yl ester 1-[5-(4-Cyclopentylamino-benzenesulfonyloxy)-1H-benzoimidazol-2-ylcarbamoyl]-piperidine-4-carboxylic acid ethyl ester 4-Cyclopentylamino-benzenesulfonic acid 2-(3-piperidin-4-ylmethyl-ureido)-1H-benzoimidazol-5-yl ester 4-Cyclopentylamino-benzenesulfonic acid 2-[3-(2-morpholin-4-yl-ethyl)-ureido]-1H-benzoimidazol-5-yl ester 4-Cyclopentylamino-benzenesulfonic acid 2-[3-(2-amino-2-methyl-propyl)-ureido]-1H-benzoimidazol-5-yl ester; 4-Cyclopentylamino-benzenesulfonic acid 2-[3-(4-hydroxy-cyclohexyl)-ureido]-1H-benzoimidazol-5-yl ester 4-Cyclopentylamino-benzenesulfonic acid 2-[3-(3-hydroxy-propyl)-ureido]-1H-benzoimidazol-5-yl ester 4-Cyclopentylamino-benzenesulfonic acid 2-[3-(1,1-dimethyl-propyl)-ureido]-1H-benzoimidazol-5-yl ester 4-Cyclopentylamino-benzenesulfonic acid 2-{3-[2-(2-hydroxy-ethylamino)-ethyl]-ureido}-1H-benzoimidazol-5-yl ester 4-Cyclopentylamino-benzenesulfonic acid 2-[3-(4-hydroxy-butyl)-ureido]-1H-benzoimidazol-5-yl ester 4-Cyclopentylamino-benzenesulfonic acid 2-{3-[3-(2-oxo-pyrrolidin-1-yl)-propyl]-ureido}-1H-benzoimidazol-5-yl ester 4-Cyclopentylamino-benzenesulfonic acid 2-[3-(2-carbamoyl-ethyl)-ureido]-1H-benzoimidazol-5-yl ester 4-Cyclopentylamino-benzenesulfonic acid 2-[(2S-carbamoyl-pyrrolidine-1-carbonyl)-amino]-1H-benzoimidazol-5-yl ester 4-Cyclopentylamino-benzenesulfonic acid 2-{3-[2-(2-hydroxy-ethoxy)-ethyl]-ureido}-1H-benzoimidazol-5-yl ester 4-Cyclopentylamino-benzenesulfonic acid 2-[3-(3-pyrrolidin-1-yl-propyl)-ureido]-1H-benzoimidazol-5-yl ester 4-Cyclopentylamino-benzenesulfonic acid 2-[3-(1-ethyl-pyrrolidin-2-ylmethyl)-ureido]-1H-benzoimidazol-5-yl ester 4-Cyclopentylamino-benzenesulfonic acid 2-[3-(2-pyrrolidin-1-yl-ethyl)-ureido]-1H-benzoimidazol-5-yl ester 4-Cyclopentylamino-benzenesulfonic acid 2-[3-(2-piperidin-1-yl-ethyl)-ureido]-1H-benzoimidazol-5-yl ester 4-Cyclopentylamino-benzenesulfonic acid 2-[3-(2-hydroxy-1-methyl-ethyl)-ureido]-1H-benzoimidazol-5-yl ester 4-Cyclopentylamino-benzenesulfonic acid 2-[3-(2-isopropylamino-ethyl)-ureido]-1H-benzoimidazol-5-yl ester 4-Cyclopentylamino-benzenesulfonic acid 2-[3-(2-diethylamino-ethyl)-ureido]-1H-benzoimidazol-5-yl ester 2-{3-[5-(4-Cyclopentylamino-benzenesulfonyloxy)-1H-benzoimidazol-2-yl]-ureido}-3S-hydroxy-propionic acid methyl ester 4-{3-[5-(4-Imidazol-1-yl-benzenesulfonyloxy)-1H-benzoimidazol-2-yl]-ureido}-butyric acid methyl ester 4-{3-[5-(4-Imidazol-1-yl-benzenesulfonyloxy)-1H-benzoimidazol-2-yl]-ureido}-butyric acid ethyl ester {3-[5-(4-Imidazol-1-yl-benzenesulfonyloxy)-1H-benzoimidazol-2-yl]-ureido}-acetic acid methyl ester 4-Imidazol-1-yl-benzenesulfonic acid 2-[3-(3-imidazol-1-yl-propyl)-ureido]-1H-benzoimidazol-5-yl ester 1-[5-(4-Imidazol-1-yl-benzenesulfonyloxy)-1H-benzoimidazol-2-ylcarbamoyl]-pyrrolidine-2-carboxylic acid 1-[5-(4-Imidazol-1-yl-benzenesulfonyloxy)-1H-benzoimidazol-2-ylcarbamoyl]-pyrrolidine-2-carboxylic acid methyl ester 4-Imidazol-1-yl-benzenesulfonic acid 2-(3-carbamoylmethyl-ureido)-1H-benzoimidazol-5-yl ester 1-[5-(4-Imidazol-1-yl-benzenesulfonyloxy)-1H-benzoimidazol-2-ylcarbamoyl]-piperidine-4-carboxylic acid ethyl ester 4-Imidazol-1-yl-benzenesulfonic acid 2-(3-piperidin-4-ylmethyl-ureido)-1H-benzoimidazol-5-yl ester 4-Imidazol-1-yl-benzenesulfonic acid 2-[3-(2-morpholin-4-yl-ethyl)-ureido]-1H-benzoimidazol-5-yl ester 4-Imidazol-1-yl-benzenesulfonic acid 2-[3-(2-amino-2-methyl-propyl)-ureido]-1H-benzoimidazol-5-yl ester 4-Imidazol-1-yl-benzenesulfonic acid 2-[3-(4-hydroxy-cyclohexyl)-ureido]-1H-benzoimidazol-5-yl ester 4-Imidazol-1-yl-benzenesulfonic acid 2-[3-(3-hydroxy-propyl)-ureido]-1H-benzoimidazol-5-yl ester 4-Imidazol-1-yl-benzenesulfonic acid 2-[3-(1,1-dimethyl-propyl)-ureido]-1H-benzoimidazol-5-yl ester 4-Imidazol-1-yl-benzenesulfonic acid 2-{3-[2-(2-hydroxy-ethylamino)-ethyl]-ureido}-1H-benzoimidazol-5-yl ester 4-Imidazol-1-yl-benzenesulfonic acid 2-[3-(4-hydroxy-butyl)-ureido]-1H-benzoimidazol-5-yl ester 4-Imidazol-1-yl-benzenesulfonic acid 2-{3-[3-(2-oxo-pyrrolidin-1-yl)-propyl]-ureido}-1H-benzoimidazol-5-yl ester 4-Imidazol-1-yl-benzenesulfonic acid 2-[3-(2-carbamoyl-ethyl)-ureido]-1H-benzoimidazol-5-yl ester 4-Imidazol-1-yl-benzenesulfonic acid 2-[3-(1,1-dimethyl-propyl)-ureido]-1H-benzoimidazol-5-yl ester 4-Imidazol-1-yl-benzenesulfonic acid 2-[(2-carbamoyl-pyrrolidine-1-carbonyl)-amino]-1H-benzoimidazol-5-yl ester 4-Imidazol-1-yl-benzenesulfonic acid 2-{3-[2-(2-hydroxy-ethoxy)-ethyl]-ureido}-1H-benzoimidazol-5-yl ester 4-Imidazol-1-yl-benzenesulfonic acid 2-[3-(3-pyrrolidin-1-yl-propyl)-ureido]-1H-benzoimidazol-5-yl ester 4-Imidazol-1-yl-benzenesulfonic acid 2-[3-(1-ethyl-pyrrolidin-2-ylmethyl)-ureido]-1H-benzoimidazol-5-yl ester 4-Imidazol-1-yl-benzenesulfonic acid 2-[3-(2-pyrrolidin-1-yl-ethyl)-ureido]-1H-benzoimidazol-5-yl ester 4-Imidazol-1-yl-benzenesulfonic acid 2-[3-(2-piperidin-1-yl-ethyl)-ureido]-1H-benzoimidazol-5-yl ester 4-Imidazol-1-yl-benzenesulfonic acid 2-[3-(2-hydroxy-1-methyl-ethyl)-ureido]-1H-benzoimidazol-5-yl ester 4-Imidazol-1-yl-benzenesulfonic acid 2-[3-(2-isopropylamino-ethyl)-ureido]-1H-benzoimidazol-5-yl ester 4-Imidazol-1-yl-benzenesulfonic acid 2-[3-(2-diethylamino-ethyl)-ureido]-1H-benzoimidazol-5-yl ester 2-{3-[5-(4-Imidazol-1-yl-benzenesulfonyloxy)-1H-benzoimidazol-2-yl]-ureido}-3-hydroxy-propionic acid methyl ester 4-[(Tetrahydro-furan-2-ylmethyl)-amino]-benzenesulfonic acid 2-(3-carbamoylmethyl-ureido)-1H-benzoimidazol-5-yl ester 4-[(Tetrahydro-furan-2-ylmethyl)-amino]-benzenesulfonic acid 2-[3-(2-hydroxy-ethyl)-ureido]-1H-benzoimidazol-5-yl ester 4-[(Tetrahydro-furan-2-ylmethyl)-amino]-benzenesulfonic acid 2-[3-(3-hydroxy-propyl)-ureido]-1H-benzoimidazol-5-yl ester 4-[(Tetrahydro-furan-2-ylmethyl)-amino]-benzenesulfonic acid 2-[3-(4-hydroxy-butyl)-ureido]-1H-benzoimidazol-5-yl ester 4-[(Tetrahydro-furan-2-ylmethyl)-amino]-benzenesulfonic acid 2-[3-(2-methoxy-1-methyl-ethyl)-ureido]-1H-benzoimidazol-5-yl ester 4-[(Tetrahydro-furan-2-ylmethyl)-amino]-benzenesulfonic acid 2-[3-(1-ethyl-pyrrolidin-2-ylmethyl)-ureido]-1H-benzoimidazol-5-yl ester 4-[(Tetrahydro-furan-2-ylmethyl)-amino]-benzenesulfonic acid 2-[3-(2-pyrrolidin-1-yl-ethyl)-ureido]-1H-benzoimidazol-5-yl ester 4-[(Tetrahydro-furan-2-ylmethyl)-amino]-benzenesulfonic acid 2-[3-(3-pyrrolidin-1-yl-propyl)-ureido]-1H-benzoimidazol-5-yl ester 4-[(Tetrahydro-furan-2-ylmethyl)-amino]-benzenesulfonic acid 2-[3-(2-morpholin-4-yl-ethyl)-ureido]-1H-benzoimidazol-5-yl ester 4-[(Tetrahydro-furan-2-ylmethyl)-amino]-benzenesulfonic acid 2-(3-ethyl-ureido) 1H-benzoimidazol-5-yl ester 4-[(Tetrahydro-furan-2-ylmethyl)-amino]-benzenesulfonic acid 2-(3-methyl-ureido)-1H-benzoimidazol-5-yl ester 4-[(Tetrahydro-furan-2-ylmethyl)-amino]-benzenesulfonic acid 2-(3-pyridin-2-ylmethyl-ureido)-1H-benzoimidazol-5-yl ester 4-[(Tetrahydro-furan-2-ylmethyl)-amino]-benzenesulfonic acid 2-(3-pyridin-3-ylmethyl-ureido)-1H-benzoimidazol-5-yl ester 4-[(Tetrahydro-furan-2-ylmethyl)-amino]-benzenesulfonic acid 2-{3-[3-(4-methyl-piperazin-1-yl)-propyl]-ureido}-1H-benzoimidazol-5-yl ester 4-[(Tetrahydro-furan-2-ylmethyl)-amino]-benzenesulfonic acid 2-[3-(2-sulfo-ethyl)-ureido]-1H-benzoimidazol-5-yl ester 4-[(Tetrahydro-furan-2-ylmethyl)-amino]-benzenesulfonic acid 2-(3-cyclobutyl-ureido)-1H-benzoimidazol-5-yl ester 4-[(Tetrahydro-furan-2-ylmethyl)-amino]-benzenesulfonic acid 2-{3-[3-(2-oxo-pyrrolidin-1-yl)-propyl]-ureido}-1H-benzoimidazol-5-yl ester 4-[(Tetrahydro-furan-2-ylmethyl)-amino]-benzenesulfonic acid 2-{3-[2-(2-hydroxy-ethylamino)-ethyl]-ureido}-1H-benzoimidazol-5-yl ester 4-[(Tetrahydro-furan-2-ylmethyl)-amino]-benzenesulfonic acid 2-[3-(2-piperidin-1-yl-ethyl)-ureido]-1H-benzoimidazol-5-yl ester 4-Benzylamino-benzenesulfonic acid 2-(cyclopropanecarbonyl-amino)-1H-benzoimidazol-5-yl ester 4-Methylamino-benzenesulfonic acid 2-(cyclopropanecarbonyl-amino)-1H-benzoimidazol-5-yl ester 4-(2-Hydroxy-ethylamino)-benzenesulfonic acid 2-(cyclopropanecarbonyl-amino)-1H-benzoimidazol-5-yl ester 4-(3-Hydroxy-propylamino)-benzenesulfonic acid 2-(cyclopropanecarbonyl-amino)-1H-benzoimidazol-5-yl ester 4-(4-Hydroxy-butylamino)-benzenesulfonic acid 2-(cyclopropanecarbonyl-amino)-1H-benzoimidazol-5-yl ester 4-(2-Methoxy-1-methyl-ethylamino)-benzenesulfonic acid 2-(cyclopropanecarbonyl-amino)-1H-benzoimidazol-5-yl ester 4-(2-Pyrrolidin-1-yl-ethylamino)-benzenesulfonic acid 2-(cyclopropanecarbonyl-amino)-1H-benzoimidazol-5-yl ester 4-(1-Hydroxymethyl-propylamino)-benzenesulfonic acid 2-(cyclopropanecarbonyl-amino)-1H-benzoimidazol-5-yl ester 4-(2-Hydroxy-1-methyl-ethylamino)-benzenesulfonic acid 2-(cyclopropanecarbonyl-amino)-1H-benzoimidazol-5-yl ester 4-(2-Piperidin-1-yl-ethylamino)-benzenesulfonic acid 2-(cyclopropanecarbonyl-amino)-1H-benzoimidazol-5-yl ester 4-(3-Pyrrolidin-1-yl-propylamino)-benzenesulfonic acid 2-(cyclopropanecarbonyl-amino)-1H-benzoimidazol-5-yl ester 4-(3-Hydroxy-2,2-dimethyl-propylamino)-benzenesulfonic acid 2-(cyclopropane-carbonyl-amino)-1H-benzoimidazol-5-yl ester 4-[(Pyridin-3-ylmethyl)-amino]-benzenesulfonic acid 2-(cyclopropanecarbonyl-amino)-1H-benzoimidazol-5-yl ester 4-[3-(4-Methyl-piperazin-1-yl)-propylamino]-benzenesulfonic acid 2-(cyclopropane-carbonyl-amino)-1H-benzoimidazol-5-yl ester 4-(2-Methoxy-benzylamino)benzenesulfonic acid 2-(cyclopropanecarbonyl-amino)-1H-benzoimidazol-5-yl ester 4-(4-Hydroxy-cyclohexylamino)-benzenesulfonic acid 2-(cyclopropanecarbonyl-amino)-1H-benzoimidazol-5-yl ester 4-(2-Diethylamino-ethylamino)-benzenesulfonic acid 2-(cyclopropanecarbonyl-amino)-1H-benzoimidazol-5-yl ester 4-(1S-Hydroxymethyl-propylamino)-benzenesulfonic acid 2-(cyclopropanecarbonyl-amino)-1H-benzoimidazol-5-yl ester 4-(2-Ethylamino-ethylamino)-benzenesulfonic acid 2-(cyclopropanecarbonyl-amino)-1H-benzoimidazol-5-yl ester 4-(2-Diisopropylamino-ethylamino)-benzenesulfonic acid 2-(cyclopropanecarbonyl-amino)-1H-benzoimidazol-5-yl ester 4-(2-Morpholin-4-yl-ethylamino)-benzenesulfonic acid 2-(cyclopropanecarbonyl-amino)-1H-benzoimidazol-5-yl ester 4-(1-Aza-bicyclo[2.2.2]oct-3-ylamino)-benzenesulfonic acid 2-(cyclopropane-carbonyl-amino)-1H-benzoimidazol-5-yl ester 4-(2-Phenylamino-ethylamino)-benzenesulfonic acid 2-(cyclopropanecarbonyl-amino)-1H-benzoimidazol-5-yl ester 4-(1-Benzyl-pyrrolidin-3-ylamino)-benzenesulfonic acid 2-(cyclopropanecarbonyl-amino)-1H-benzoimidazol-5-yl ester 4-(2R-Carbamoyl-pyrrolidin-1-yl)-benzenesulfonic acid 2-(cyclopropanecarbonyl-amino)-1H-benzoimidazol-5-yl ester 4-(3-Dimethylamino-propylamino)-benzenesulfonic acid 2-(cyclopropanecarbonyl-amino)-1H-benzoimidazol-5-yl ester 4-(2-piperazin-1-yl-ethylamino)-benzenesulfonic acid 2-(cyclopropanecarbonyl-amino)-1H-benzoimidazol-5-yl ester 4-(2-Carbamoyl-cyclohexylamino)-benzenesulfonic acid 2-(cyclopropanecarbonyl-amino)-1H-benzoimidazol-5-yl ester 4-(2-Acetylamino-ethylamino)-benzenesulfonic acid 2-(cyclopropanecarbonyl-amino)-1H-benzoimidazol-5-yl ester 4-[2-(2-Amino-ethylamino)-ethylamino]-benzenesulfonic acid 2-(cyclopropane-carbonyl-amino)-1H-benzoimidazol-5-yl ester 4-[3-(2-Oxo-pyrrolidin-1-yl)-propylamino]-benzenesulfonic acid 2-(cyclopropane-carbonyl-amino)-1H-benzoimidazol-5-yl ester 4-[2-(1H-Imidazol-4-yl)-ethylamino]-benzenesulfonic acid 2-(cyclopropanecarbonyl-amino)-1H-benzoimidazol-5-yl ester 4-[(Pyridin-2-ylmethyl)-amino]-benzenesulfonic acid 2-(cyclopropanecarbonyl-amino)-1H-benzoimidazol-5-yl ester 4-Cyclobutylamino-benzenesulfonic acid 2-(cyclopropanecarbonyl-amino)-1H-benzoimidazol-5-yl ester 4-[2-(2-Hydroxy-ethoxy)-ethylamino]-benzenesulfonic acid 2-(cyclopropane-carbonyl-amino)-1H-benzoimidazol-5-yl ester 4-(2,3-Dihydroxy-propylamino)-benzenesulfonic acid 2-(cyclopropanecarbonyl-amino)-1H-benzoimidazol-5-yl ester 4-(2-Imidazol-1-yl-ethylamino)-benzenesulfonic acid 2-(cyclopropanecarbonyl-amino)-1H-benzoimidazol-5-yl ester 4-[2-(2-Hydroxy-ethylamino)-ethylamino]-benzenesulfonic acid 2-(cyclopropane-carbonyl-amino)-1H-benzoimidazol-5-yl ester 4-(2-Methoxy-ethylamino)-benzenesulfonic acid 2-(cyclopropanecarbonyl-amino)-1H-benzoimidazol-5-yl ester 4-(2-Dimethylamino-1-methyl-ethylamino)-benzenesulfonic acid 2-(cyclopropane-carbonyl-amino)-1H-benzoimidazol-5-yl ester 4-(Pyrrolidin-3-ylamino)-benzenesulfonic acid 2-(cyclopropanecarbonyl-amino)-1H-benzoimidazol-5-yl ester 4-[2-(1H-Indol-3-yl)-ethylamino]-benzenesulfonic acid 2-(cyclopropanecarbonyl-amino)-1H-benzoimidazol-5-yl ester 4-(2-Dimethylamino-ethylamino)-benzenesulfonic acid 2-(cyclopropanecarbonyl-amino)-1H-benzoimidazol-5-yl ester 4-(2-Phenoxy-ethylamino)-benzenesulfonic acid 2-(cyclopropanecarbonyl-amino)-1H-benzoimidazol-5-yl ester 4-(Bicyclo[2.2.1]hept-2-ylamino)-benzenesulfonic acid 2-(cyclopropanecarbonyl-amino)-1H-benzoimidazol-5-yl ester 4-(2-Methylamino-ethylamino)-benzenesulfonic acid 2-(cyclopropanecarbonyl-amino)-1H-benzoimidazol-5-yl ester 4-(2-Propylamino-ethylamino)-benzenesulfonic acid 2-(cyclopropanecarbonyl-amino)-1H-benzoimidazol-5-yl ester 4-(1-Methyl-2-phenoxy-ethylamino)-benzenesulfonic acid 2-(cyclopropanecarbonyl-amino)-1H-benzoimidazol-5-yl ester 4-[(Piperidin-4-ylmethyl)-amino]-benzenesulfonic acid 2-(cyclopropanecarbonyl-amino)-1H-benzoimidazol-5-yl ester 4-(4-Methoxy-benzylamino)-benzenesulfonic acid 2-(cyclopropanecarbonyl-amino)-1H-benzoimidazol-5-yl ester 4-(1H-Benzoimidazol-5-ylamino)-benzenesulfonic acid 2-(cyclopropanecarbonyl-amino)-1H-benzoimidazol-5-yl ester 4-(3-Methoxy-propylamino)-benzenesulfonic acid 2-(cyclopropanecarbonyl-amino)-1H-benzoimidazol-5-yl ester 4-(2,2-Dimethoxy-ethylamino)-benzenesulfonic acid 2-(cyclopropanecarbonyl-amino)-1H-benzoimidazol-5-yl ester 4-(4-Dimethylamino-phenylamino)-benzenesulfonic acid 2-(cyclopropanecarbonyl-amino)-1H-benzoimidazol-5-yl ester 4-(3-Methoxy-benzylamino)-benzenesulfonic acid 2-(cyclopropanecarbonyl-amino)-1H-benzoimidazol-5-yl ester 4-(4-Pyrrolidin-1-yl-butylamino)-benzenesulfonic acid 2-(cyclopropanecarbonyl-amino)-1H-benzoimidazol-5-yl ester 4-(2,3-Dimethoxy-benzylamino)-benzenesulfonic acid 2-(cyclopropanecarbonyl-amino)-1H-benzoimidazol-5-yl ester 4-Prop-2-ynylamino-benzenesulfonic acid 2-(cyclopropanecarbonyl-amino)-1H-benzoimidazol-5-yl ester 4-[4-(2-Hydroxy-ethyl)-piperazin-1-yl]-benzenesulfonic acid 2-(cyclopropane-carbonyl-amino)-1H-benzoimidazol-5-yl ester 4-[(Pyridin-4-ylmethyl)-amino]-benzenesulfonic acid 2-(cyclopropanecarbonyl-amino)-1H-benzoimidazol-5-yl ester 4-[2-(Ethyl-m-tolyl-amino)-ethylamino]-benzenesulfonic acid 2-(cyclopropane-carbonyl-amino)-1H-benzoimidazol-5-yl ester 4-(2-Hydroxy-cyclohexylamino)-benzenesulfonic acid 2-(cyclopropanecarbonyl-amino)-1H-benzoimidazol-5-yl ester 4-(3-Dimethylamino-2,2-dimethyl-propylamino)-benzenesulfonic acid 2-(cyclopropanecarbonyl-amino)-1H-benzoimidazol-5-yl ester 4-[3-(2-Hydroxy-ethylamino)-propylamino]-benzenesulfonic acid 2-(cyclopropane-carbonyl-amino)-1H-benzoimidazol-5-yl ester 4-[(Tetrahydro-furan-2-ylmethyl)-amino]-benzenesulfonic acid 2-(cyclopropane-carbonyl-amino)-1H-benzoimidazol-5-yl ester 4-[(Tetrahydro-furan-2R-ylmethyl)-amino]-benzenesulfonic acid 2-(cyclopropane-carbonyl-amino)-1H-benzoimidazol-5-yl ester 4-[(Tetrahydro-furan-2S-ylmethyl)-amino]-benzenesulfonic acid 2-(cyclopropane-carbonyl-amino)-1H-benzoimidazol-5-yl ester 4-(2-Butylamino-ethylamino)-benzenesulfonic acid 2-(cyclopropanecarbonyl-amino)-1H-benzoimidazol-5-yl ester 4-(3-Methylamino-propylamino)-benzenesulfonic acid 2-(cyclopropanecarbonyl-amino)-1H-benzoimidazol-5-yl ester 4-(1S,2-Dicarbamoyl-ethylamino)-benzenesulfonic acid 2-(cyclopropanecarbonyl-amino)-1H-benzoimidazol-5-yl ester 2-{4-[2-(Cyclopropanecarbonyl-amino)-1H-benzoimidazol-5-yloxysulfonyl]-phenylamino}-3R-hydroxy-propionic acid methyl ester 4-(2-Carbamoyl-ethylamino)-benzenesulfonic acid 2-(cyclopropanecarbonyl-amino)-1H-benzoimidazol-5-yl ester 4-(3-Methoxy-propylamino)-benzenesulfonic acid 2-(cyclopropanecarbonyl-amino)-1H-benzoimidazol-5-yl ester 4-(3,4,5-Trimethoxy-benzylamino)-benzenesulfonic acid 2-(cyclopropanecarbonyl-amino)-1H-benzoimidazol-5-yl ester 4-(Carbamoylmethyl-amino)-benzenesulfonic acid 2-(cyclopropanecarbonyl-amino)-1H-benzoimidazol-5-yl ester 1-{4-[2-(Cyclopropanecarbonyl-amino)-1H-benzoimidazol-5-yloxysulfonyl]-phenyl}-piperidine-4-carboxylic acid ethyl ester 4-(2-Amino-2-methyl-propylamino)-benzenesulfonic acid 2-(cyclopropanecarbonyl-amino)-1H-benzoimidazol-5-yl ester 3-{4-[2-(Cyclopropanecarbonyl-amino)-1H-benzoimidazol-5-yloxysulfonyl]-phenylamino}-propionic acid methyl ester 4-(3-Morpholin-4-yl-propylamino)-benzenesulfonic acid 2-(cyclopropanecarbonyl-amino)-1H-benzoimidazol-5-yl ester 4-(5-Hydroxy-pentylamino)-benzenesulfonic acid 2-(cyclopropanecarbonyl-amino)-1H-benzoimidazol-5-yl ester 4-[(5S-Amino-2,2,4S-trimethyl-cyclopentylmethyl)-amino]-benzenesulfonic acid 2-(cyclopropanecarbonyl-amino)-1H-benzoimidazol-5-yl ester 4-(2-Hydroxymethyl-phenylamino)-benzenesulfonic acid 2-(cyclopropanecarbonyl-amino)-1H-benzoimidazol-5-yl ester 4-(4-Ethoxy-phenylamino)-benzenesulfonic acid 2-(cyclopropanecarbonyl-amino)-1H-benzoimidazol-5-yl ester 4-Ethylamino-benzenesulfonic acid 2-(cyclopropanecarbonyl-amino)-1H-benzoimidazol-5-yl ester 4-(2-Sulfo-ethylamino)-benzenesulfonic acid 2-(cyclopropanecarbonyl-amino)-1H-benzoimidazol-5-yl ester 4-{4-[2-(Cyclopropanecarbonyl-amino)-1H-benzoimidazol-5-yloxysulfonyl]-phenylamino}-piperidine-1-carboxylic acid ethyl ester 4-({4-[2-(Cyclopropanecarbonyl-amino)-1H-benzoimidazol-5-yloxysulfonyl]-phenylamino}-methyl)-benzoic acid 4-[(1-Carbamimidoyl-piperidin-4-ylmethyl)-amino]-benzenesulfonic acid 2-(cyclopropanecarbonyl-amino)-1H-benzoimidazol-5-yl ester 4-{4-[2-(Cyclopropanecarbonyl-amino)-1H-benzoimidazol-5-yloxysulfonyl]-phenyl}-piperazine-1-carboxylic acid tert-butyl ester 3-{4-[2-(Cyclopropanecarbonyl-amino)-1H-benzoimidazol-5-yloxysulfonyl]-phenylamino}-3-phenyl-propionic acid 4-Piperidin-1-yl-benzenesulfonic acid 2-(cyclopropanecarbonyl-amino)-1H-benzoimidazol-5-yl ester 4-(1-Methyl-4-oxo-imidazolidin-2-ylideneamino)-benzenesulfonic acid 2-(cyclopropanecarbonyl-amino)-1H-benzoimidazol-5-yl ester 4-(4-Methyl-piperazin-1-yl)-benzenesulfonic acid 2-(cyclopropanecarbonyl-amino)-1H-benzoimidazol-5-yl ester 4-(3-Hydroxy-pyrrolidin-1-yl)-benzenesulfonic acid 2-(cyclopropanecarbonyl-amino)-1H-benzoimidazol-5-yl ester 4-(Cyclopropylmethyl-amino)-benzenesulfonic acid 2-(cyclopropanecarbonyl-amino)-1H-benzoimidazol-5-yl ester 4-[(2-Dimethylamino-ethyl)-methyl-amino]-benzenesulfonic acid 2-(cyclopropane-carbonyl-amino)-1H-benzoimidazol-5-yl ester 4-Isobutylamino-benzenesulfonic acid 2-(cyclopropanecarbonyl-amino)-1H-benzoimidazol-5-yl ester 4-[Ethyl-(2-hydroxy-ethyl)-amino]-benzenesulfonic acid 2-(cyclopropanecarbonyl-amino)-1H-benzoimidazol-5-yl ester 4-(2-Hydroxy-1-hydroxymethyl-ethylamino)-benzenesulfonic acid 2-(cyclopropane-carbonyl-amino)-1H-benzoimidazol-5-yl ester 4-Propylamino-benzenesulfonic acid 2-(cyclopropanecarbonyl-amino)-1H-benzoimidazol-5-yl ester 4-Cyclopropylamino-benzenesulfonic acid 2-(cyclopropanecarbonyl-amino)-1H-benzoimidazol-5-yl ester 4-Morpholin-4-yl-benzenesulfonic acid 2-(cyclopropanecarbonyl-amino)-1H-benzoimidazol-5-yl ester 4-[2-(1-Methyl-pyrrolidin-2-yl)-ethylamino]-benzenesulfonic acid 2-(cyclopropane-carbonyl-amino)-1H-benzoimidazol-5-yl ester 4-[(1,3-Dimethyl-1H-pyrazol-4-ylmethyl)-amino]-benzenesulfonic acid 2-(cyclopropanecarbonyl-amino)-1H-benzoimidazol-5-yl ester 4-(4-Acetylamino-benzylamino)-benzenesulfonic acid 2-(cyclopropanecarbonyl-amino)-1H-benzoimidazol-5-yl ester 4-(3-Cyclohexylamino-propylamino)-benzenesulfonic acid 2-(cyclopropanecarbonyl-amino)-1H-benzoimidazol-5-yl ester 4-(3-Ethoxy-propylamino)-benzenesulfonic acid 2-(cyclopropanecarbonyl-amino)-1H-benzoimidazol-5-yl ester 4-Pyrrolidin-1-yl-benzenesulfonic acid 2-(cyclopropanecarbonyl-amino)-1H-benzoimidazol-5-yl ester 4-(4-Methyl-benzylamino)-benzenesulfonic acid 2-(cyclopropanecarbonyl-amino)-1H-benzoimidazol-5-yl ester 4-[1,4′]Bipiperidinyl-1′-yl-benzenesulfonic acid 2-(cyclopropanecarbonyl-amino)-1H-benzoimidazol-5-yl ester 4-(2-Pyridin-3-yl-pyrrolidin-1-yl)-benzenesulfonic acid 2-(cyclopropanecarbonyl-amino)-1H-benzoimidazol-5-yl ester 4-(4-Hydroxy-piperidin-1-yl)-benzenesulfonic acid 2-(cyclopropanecarbonyl-amino)-1H-benzoimidazol-5-yl ester 4-[(2-Hydroxy-ethyl)-methyl-amino]-benzenesulfonic acid 2-(cyclopropanecarbonyl-amino)-1H-benzoimidazol-5-yl ester 4-[(1-Ethyl-pyrrolidin-2-ylmethyl)-amino]-benzenesulfonic acid 2-(cyclopropane-carbonyl-amino)-1H-benzoimidazol-5-yl ester 4-(3-Hydroxy-pyridin-2-ylamino)-benzenesulfonic acid 2-(cyclopropanecarbonyl-amino)-1H-benzoimidazol-5-yl ester 4-[(1-Carbamoyl-piperidin-4-ylmethyl)-amino]-benzenesulfonic acid 2-(cyclopropanecarbonyl-amino)-1H-benzoimidazol-5-yl ester 4-(2-Pyrrol-1-yl-ethylamino)-benzenesulfonic acid 2-(cyclopropanecarbonyl-amino)-1H-benzoimidazol-5-yl ester 4-(4-Cyclopentyl-piperazin-1-yl)-benzenesulfonic acid 2-(cyclopropanecarbonyl-amino)-1H-benzoimidazol-5-yl ester 4-(2-Propoxy-ethylamino)-benzenesulfonic acid 2-(cyclopropanecarbonyl-amino)-1H-benzoimidazol-5-yl ester 4-(3-Cyclohexylamino-propylamino)-benzenesulfonic acid 2-(cyclopropanecarbonyl-amino)-1H-benzoimidazol-5-yl ester 4-(1H-Indol-5-ylamino)-benzenesulfonic acid 2-(cyclopropanecarbonyl-amino)-1H-benzoimidazol-5-yl ester 4-(4-Amino-benzylamino)-benzenesulfonic acid 2-(cyclopropanecarbonyl-amino)-1H-benzoimidazol-5-yl ester 4-(2S-Methoxymethyl-pyrrolidin-1-yl)-benzenesulfonic acid 2-(cyclopropane-carbonyl-amino)-1H-benzoimidazol-5-yl ester 4-[4-(2-Hydroxy-ethyl)-piperidin-1-yl]-benzenesulfonic acid 2-(cyclopropane-carbonyl-amino)-1H-benzoimidazol-5-yl ester 4-[2-(2-Hydroxy-ethyl)-piperidin-1-yl]-benzenesulfonic acid 2-(cyclopropane-carbonyl-amino)-1H-benzoimidazol-5-yl ester 4-(2-Isopropylamino-ethylamino)-benzenesulfonic acid 2-(cyclopropanecarbonyl-amino)-1H-benzoimidazol-5-yl ester 3-{4-[2-(Cyclopropanecarbonyl-amino)-1H-benzoimidazol-5-yloxysulfonyl]-phenylamino}-propionic acid 4-[Methyl-(2-methylamino-ethyl)-amino]-benzenesulfonic acid 2-(cyclopropane-carbonyl-amino)-1H-benzoimidazol-5-yl ester 4-(3-Acetylamino-pyrrolidin-1-yl)-benzenesulfonic acid 2-(cyclopropanecarbonyl-amino)-1H-benzoimidazol-5-yl ester 4-(Carbamoylmethyl-amino)-benzenesulfonic acid 2-(cyclopropanecarbonyl-amino)-1H-benzoimidazol-5-yl ester 4-(4-Hydroxy-piperidin-1-yl)-benzenesulfonic acid 2-(cyclopropanecarbonyl-amino)-1H-benzoimidazol-5-yl ester 4-(4-Dimethylamino-benzylamino)-benzenesulfonic acid 2-(cyclopropanecarbonyl-amino)-1H-benzoimidazol-5-yl ester 4-(3-Imidazol-1-yl-propylamino)-benzenesulfonic acid 2-(cyclopropanecarbonyl-amino)-1H-benzoimidazol-5-yl ester 4-(Quinoxalin-5-ylamino)-benzenesulfonic acid 2-(cyclopropanecarbonyl-amino)-1H-benzoimidazol-5-yl ester 4-[4-(2-Hydroxy-ethyl)-piperazin-1-yl]-benzenesulfonic acid 2-(cyclopropane-carbonyl-amino)-1H-benzoimidazol-5-yl ester 4-(2-Hydroxy-1,1-dimethyl-ethylamino)-benzenesulfonic acid 2-(cyclopropane-carbonyl-amino)-1H-benzoimidazol-5-yl ester 1-{4-[2-(Cyclopropanecarbonyl-amino)-1H-benzoimidazol-5-yloxysulfonyl]-phenyl}-piperidine-4-carboxylic acid 6-{4-[2-(Cyclopropanecarbonyl-amino)-1H-benzoimidazol-5-yloxysulfonyl]-phenylamino}-hexanoic acid methyl ester 4-[4-(4-Methoxy-phenyl)-piperazin-1-yl]-benzenesulfonic acid 2-(cyclopropane-carbonyl-amino)-1H-benzoimidazol-5-yl ester 4-[4-(2-Methoxy-ethyl)-piperazin-1-yl]-benzenesulfonic acid 2-(cyclopropane-carbonyl-amino)-1H-benzoimidazol-5-yl ester 4-[(2-Hydroxy-ethyl)-phenyl-amino]-benzenesulfonic acid 2-(cyclopropanecarbonyl-amino)-1H-benzoimidazol-5-yl ester 4-[(Furan-2-ylmethyl)-amino]-benzenesulfonic acid 2-(cyclopropanecarbonyl-amino)-1H-benzoimidazol-5-yl ester 1-{4-[2-(Cyclopropanecarbonyl-amino)-1H-benzoimidazol-5-yloxysulfonyl]-phenyl}-aziridine-2-carboxylic acid methyl ester 4-(4-Carbamoyl-piperidin-1-yl)-benzenesulfonic acid 2-(cyclopropanecarbonyl-amino)-1H-benzoimidazol-5-yl ester 4-(3-Methyl-piperazin-1-yl)-benzenesulfonic acid 2-(cyclopropanecarbonyl-amino)-1H-benzoimidazol-5-yl ester 4-(2,6-Dimethyl-morpholin-4-yl)-benzenesulfonic acid 2-(cyclopropanecarbonyl-amino)-1H-benzoimidazol-5-yl ester 4-(4-Phenyl-piperazin-1-yl)-benzenesulfonic acid 2-(cyclopropanecarbonyl-amino)-1H-benzoimidazol-5-yl ester 4-(4-Pyridin-2-yl-piperazin-1-yl)-benzenesulfonic acid 2-(cyclopropanecarbonyl-amino)-1H-benzoimidazol-5-yl ester 4-(4-Diethylamino-1-methyl-butylamino)-benzenesulfonic acid 2-(cyclopropane-carbonyl-amino)-1H-benzoimidazol-5-yl ester 4-{4-[2-(Cyclopropanecarbonyl-amino)-1H-benzoimidazol-5-yloxysulfonyl]-phenyl}-piperazine-1-carboxylic acid ethyl ester 4-(5-Hydroxy-naphthalen-1-ylamino)-benzenesulfonic acid 2-(cyclopropanecarbonyl-amino)-1H-benzoimidazol-5-yl ester 4-[2-(4-Hydroxy-3-methoxy-phenyl)-ethylamino]-benzenesulfonic acid 2-(cyclopropanecarbonyl-amino)-1H-benzoimidazol-5-yl ester 4-(9H-Purin-6-ylamino)-benzenesulfonic acid 2-(cyclopropanecarbonyl-amino)-1H-benzoimidazol-5-yl ester 1-{4-[2-(Cyclopropanecarbonyl-amino)-1H-benzoimidazol-5-yloxysulfonyl]-phenyl}-piperidine-3-carboxylic acid 4-(3,3-Dimethyl-piperidin-1-yl)-benzenesulfonic acid 2-(cyclopropanecarbonyl-amino)-1H-benzoimidazol-5-yl ester 4-(4-Methyl-piperidin-1-yl)-benzenesulfonic acid 2-(cyclopropanecarbonyl-amino)-1H-benzoimidazol-5-yl ester 4-(2-Pyridin-2-yl-ethylamino)-benzenesulfonic acid 2-(cyclopropanecarbonyl-amino)-1H-benzoimidazol-5-yl ester 4-(3-Hydroxymethyl-phenylamino)-benzenesulfonic acid 2-(cyclopropanecarbonyl-amino)-1H-benzoimidazol-5-yl ester 4-(2-Oxo-2,3-dihydro-1H-pyrimidin-4-ylideneamino)-benzenesulfonic acid 2-(cyclopropanecarbonyl-amino)-1H-benzoimidazol-5-yl ester 4-(3-Piperidin-1-yl-propylamino)-benzenesulfonic acid 2-(cyclopropanecarbonyl-amino)-1H-benzoimidazol-5-yl ester 4-[2-(1H-Indol-3-yl)-ethylamino]-benzenesulfonic acid 2-(cyclopropanecarbonyl-amino)-1H-benzoimidazol-5-yl ester 4-(5-Carbamoyl-1H-imidazol-4-ylamino)-benzenesulfonic acid 2-(cyclopropane-carbonyl-amino)-1H-benzoimidazol-5-yl ester 4-(1-Hydroxymethyl-butylamino)-benzenesulfonic acid 2-(cyclopropanecarbonyl-amino)-1H-benzoimidazol-5-yl ester 4-(1-Benzyl-piperidin-4-ylamino)-benzenesulfonic acid 2-(cyclopropanecarbonyl-amino)-1H-benzoimidazol-5-yl ester 4-{4-[2-(2-Hydroxy-ethoxy)-ethyl]-piperazin-1-yl}-benzenesulfonic acid 2-(cyclopropanecarbonyl-amino)-1H-benzoimidazol-5-yl ester 4-(4-Methyl-[1,4]diazepan-1-yl)-benzenesulfonic acid 2-(cyclopropanecarbonyl-amino)-1H-benzoimidazol-5-yl ester 4-(3-Azepan-1-yl-propylamino)-benzenesulfonic acid 2-(cyclopropanecarbonyl-amino)-1H-benzoimidazol-5-yl ester 4-(2,6-cis-Dimethyl-morpholin-4-yl)-benzenesulfonic acid 2-(cyclopropanecarbonyl-amino)-1H-benzoimidazol-5-yl ester 4-(2S-Hydroxymethyl-pyrrolidin-1-yl)-benzenesulfonic acid 2-(cyclopropane-carbonyl-amino)-1H-benzoimidazol-5-yl ester 4-[4-(3-Pyrrolidin-1-yl-propyl)-[1,4]diazepan-1-yl]-benzenesulfonic acid 2-(cyclopropanecarbonyl-amino)-1H-benzoimidazol-5-yl ester 4-trifluoromethoxy-benzenesulfonic acid 2-methoxycarbonylamino-1H-benzoimidazol-5-yl ester 3,5-Dimethyl-isoxazole-4-sulfonic acid 2-methoxycarbonylamino-1H-benzoimidazol-5-yl ester Thiophene-2-sulfonic acid 2-methoxycarbonylamino-1H-benzoimidazol-5-yl ester 5-Isoxazol-3-yl-thiophene-2-sulfonic acid 2-methoxycarbonylamino-1H-benzoimidazol-5-yl ester 2-Fluoro-benzenesulfonic acid 2-methoxycarbonylamino-1H-benzoimidazol-5-yl ester 5-(1-Methyl-5-trifluoromethyl-1H-pyrazol-3-yl)-thiophene-2-sulfonic acid 2-methoxycarbonylamino-1H-benzoimidazol-5-yl ester 3-Trifluoromethoxy-benzenesulfonic acid 2-methoxycarbonylamino-1H-benzoimidazol-5-yl ester 2-Trifluoromethoxy-benzenesulfonic acid 2-methoxycarbonylamino-1H-benzo-imidazol-5-yl ester 2,6-Difluoro-benzenesulfonic acid 2-methoxycarbonylamino-1H-benzoimidazol-5-yl ester 3-Methoxy-benzenesulfonic acid 2-methoxycarbonylamino-1H-benzoimidazol-5-yl ester 3-(2-Methoxycarbonylamino-1H-benzoimidazol-5-yloxysulfonyl)-thiophene-2-carboxylic acid methyl ester 3,4-Dimethoxy-benzenesulfonic acid 2-methoxycarbonylamino-1H-benzoimidazol-5-yl ester 3-Nitro-benzenesulfonic acid 2-methoxycarbonylamino-1H-benzoimidazol-5-yl ester 3-Trifluoromethyl-benzenesulfonic acid 2-methoxycarbonylamino-1H-benzo-imidazol-5-yl ester 2-Cyano-benzenesulfonic acid 2-methoxycarbonylamino-1H-benzoimidazol-5-yl ester 2-Trifluoromethyl-benzenesulfonic acid 2-methoxycarbonylamino-1H-benzo-imidazol-5-yl ester 2,4-Difluoro-benzenesulfonic acid 2-methoxycarbonylamino-1H-benzoimidazol-5-yl ester 5-Fluoro-2-methyl-benzenesulfonic acid 2-methoxycarbonylamino-1H-benzo-imidazol-5-yl ester 3-Fluoro-benzenesulfonic acid 2-methoxycarbonylamino-1H-benzoimidazol-5-yl ester 4-Cyano-benzenesulfonic acid 2-methoxycarbonylamino-1H-benzoimidazol-5-yl ester 2-Methoxy-5-(2-methoxycarbonylamino-3H-benzoimidazol-5-yloxysulfonyl)-thiophene-3-carboxylic acid methyl ester 1,3,5-Trimethyl-1H-pyrazole-4-sulfonic acid 2-methoxycarbonylamino-3H-benzoimidazol-5-yl ester 6-Morpholin-4-yl-pyridine-3-sulfonic acid 2-methoxycarbonylamino-3H-benzoimidazol-5-yl ester 2,4,6-Trifluoro-benzenesulfonic acid 2-methoxycarbonylamino-1H-benzoimidazol-5-yl ester 4-benzyloxy-benzenesulfonic acid 2-methoxycarbonylamino-1H-benzoimidazol-5-yl ester 4-Ethoxy-benzenesulfonic acid 2-methoxycarbonylamino-3H-benzoimidazol-5-yl ester 4-(2-Morpholin-4-yl-ethoxy)-benzenesulfonic acid 2-methoxycarbonylamino-3H-benzoimidazol-5-yl ester 4-(2-Methoxy-ethoxy)-benzenesulfonic acid 2-methoxycarbonylamino-3H-benzoimidazol-5-yl ester 4-(2-piperidin-1-yl-ethoxy)-benzenesulfonic acid 2-methoxycarbonylamino-3H-benzoimidazol-5-yl ester [4-(2-Methoxycarbonylamino-3H-benzoimidazol-5-yloxysulfonyl)-phenoxy]-acetic acid 4-(2-oxo-2-pyrrolidin-1-yl-ethoxy)-benzenesulfonic acid 2-methoxycarbonylamino-1H-benzoimidazol-5-yl-ester 4-[2-(4-Methyl-piperazin-1-yl)-2-oxo-ethoxy]-benzenesulfonic acid 2-methoxy-carbonylamino-1H-benzoimidazol-5-yl ester 4-[(3-diethylamino-propylcarbamoyl)-methoxy]-benzenesulfonic acid 2-methoxy-carbonylamino-1H-benzoimidazol-5-yl ester 4-{[(furan-2-ylmethyl)-carbamoyl]-methoxy}-benzenesulfonic acid 2-methoxy-carbonylamino-1H-benzoimidazol-5-yl ester 4-(cyclopropylmethyl-amino)-benzenesulfonic acid 2-methoxycarbonylamino-1H-benzoimidazol-5-yl ester 4-(2-methoxy-ethylamino)-benzenesulfonic acid 2-methoxycarbonylamino-1H-benzoimidazol-5-yl ester 4-(2-hydroxy-1-methyl-ethylamino)-benzenesulfonic acid 2-methoxycarbonylamino-1H-benzoimidazol-5-yl ester 4-(benzylamino)-benzenesulfonic acid 2-methoxycarbonylamino-1H-benzoimidazol-5-yl ester 4-(2-Morpholin-4-yl-ethylamino)-benzenesulfonic acid 2-methoxycarbonylamino-1H-benzoimidazol-5-yl ester 4-(2-Piperidin-4-yl-ethylamino)-benzenesulfonic acid 2-[3-(2-piperidin-1-yl-ethyl)-ureido]-3H-benzoimidazol-5-yl ester 4-[(1-Ethyl-pyrrolidin-2-ylmethyl)-amino]-benzenesulfonic acid 2-[3-(2-piperidin-1-yl-ethyl)-ureido]-3H-benzoimidazol-5-yl ester 4-cyclopentylamino-benzenesulfonic acid 2-(3,4-dimethoxy-phenylamino)-1H-benzoimidazol-5-yl ester 4-Cyclopentylamino-benzenesulfonic acid 2-phenylamino-1H-benzoimidazol-5-yl ester 4-Cyclopentylamino-benzenesulfonic acid 2-(4-morpholin-4-yl-phenylamino)-1H-benzoimidazol-5-yl ester 4-Cyclopentylamino-benzenesulfonic acid 2-(3,5-dimethyl-phenylamino)-1H-benzoimidazol-5-yl ester 4-Cyclopentylamino-benzenesulfonic acid 2-(4-methoxy-phenylamino)-1H-benzoimidazol-5-yl ester 4-Cyclopentylamino-benzenesulfonic acid 2-(4-dimethylamino-phenylamino)-1H-benzoimidazol-5-yl ester 4-Cyclopentylamino-benzenesulfonic acid 2-(3-methoxy-5-trifluoromethyl-phenylamino)-1H-benzoimidazol-5-yl ester 3-[5-(4-Cyclopentylamino-benzenesulfonyloxy)-1H-benzoimidazol-2-ylamino]-benzoic acid ethyl ester 4-Cyclopentylamino-benzenesulfonic acid 2-[(4-(4-methyl-piperazin-1-yl)-phenylamino)-1H-benzoimidazol-5-yl ester 4-cyclopentylamino-benzenesulfonic acid 2-(3-phenyl-propionylamino)-1H-benzoimidazol-5-yl ester 4-cyclopentylamino-benzenesulfonic acid 2-[2-2-methoxy-ethoxy)-acetylamino]-1H-benzoimidazol-5-yl ester 4-fluoro-benzenesulfonic acid 2-(3(chloro-4-methoxy-benzylamino)-3H-benzoimidazol-5-yl ester 4-Fluoro-benzenesulfonic acid 2-[(3-phenyl-[1,2,4]oxadiazol-5-ylmethyl)-amino]-3H-benzoimidazol-5-yl ester 4-Fluoro-benzenesulfonic acid 2-(3-chloro-benzylamino)-3H-benzoimidazol-5-yl ester 4-Fluoro-benzenesulfonic acid 2-(3-methoxy-benzylamino)-3H-benzoimidazol-5-yl ester 4-Fluoro-benzenesulfonic acid 2-benzylamino-3H-benzoimidazol-5-yl ester 4-cyclopentylamino-benzenesulfonic acid 2-benzylamino-3H-benzoimidazol-5-yl ester 4-Cyclopentylamino-benzenesulfonic acid 2-[(3-phenyl-[1,2,4]oxadiazol-5-ylmethyl)-amino]-3H-benzoimidazol-5-yl ester 4-Cyclopentylamino-benzenesulfonic acid 2-(3-methoxy-benzylamino)-3H-benzoimidazol-5-yl ester 4-Cyclopentylamino-benzenesulfonic acid 2-(3-chloro-4-methoxy-benzylamino)-3H-benzoimidazol-5-yl ester 4-(Cyclopropylmethyl-amino)-benzenesulfonic acid 2-[3-(2-morpholin-4-yl-ethyl)-ureido]-1H-benzoimidazol-5-yl ester 4-(Cyclopropylmethyl-amino)-benzenesulfonic acid 2-[3-(2-morpholin-4-yl-ethyl)-ureido]-1H-benzoimidazol-5-yl ester 4-(Cyclopropylmethyl-amino)-benzenesulfonic acid 2-(3-pyridin-2-ylmethyl)-ureido]-1H-benzoimidazol-5-yl ester 4-(Cyclopropylmethyl-amino)-benzenesulfonic acid 2-[3-(2-methoxy-ethyl)-ureido]-1H-benzoimidazol-5-yl ester 4-(Cyclopropylmethyl-amino)-benzenesulfonic acid 2-[3-(2-ethyl)-ureido]-1H-benzoimidazol-5-yl ester 4-(2-Methoxy-ethylamino)-benzenesulfonic acid 2-[3-(2-morpholin-4-yl-ethyl)-ureido]-1H-benzoimidazol-5-yl ester 4-(2-Methoxy-ethylamino)-benzenesulfonic acid 2-(3-pyridin-2-ylmethyl)-ureido]-1H-benzoimidazol-5-yl ester 4-(2-Methoxy-ethylamino)-benzenesulfonic acid 2-[3-(2-methoxy-ethyl)-ureido]-1H-benzoimidazol-5-yl ester 4-(2-Methoxy-ethylamino)-benzenesulfonic acid 2-[3-(2-ethyl)-ureido]-1H-benzoimidazol-5-yl ester 4-(2-Hydroxy-1-methyl-ethylamino)-benzenesulfonic acid 2-[3-(2-morpholin-4-yl-ethyl)-ureido]-1H-benzoimidazol-5-yl ester 4-(2-Hydroxy-1-methyl-ethylamino)-benzenesulfonic acid 2-(3-pyridin-2-ylmethyl)-ureido]-1H-benzoimidazol-5-yl ester 4-(2-Hydroxy-1-methyl-ethylamino)-benzenesulfonic acid 2-[3-(2-methoxy-ethyl)-ureido]-1H-benzoimidazol-5-yl ester 4-(2-Hydroxy-1-methyl-ethylamino)-benzenesulfonic acid 2-[3-(2-ethyl)-ureido]-1H-benzoimidazol-5-yl ester 4-Benzyloxy-benzenesulfonic acid 2-[3-(2-morpholin-4-yl-ethyl)-ureido]-1H-benzoimidazol-5-yl ester 4-Benzyloxy-benzenesulfonic acid 2-(3-pyridin-2-ylmethyl)-ureido]-1H-benzoimidazol-5-yl ester 4-Benzyloxy-benzenesulfonic acid 2-[3-(2-methoxy-ethyl)-ureido]-1H-benzoimidazol-5-yl ester 4-benzyloxy-benzenesulfonic acid 2-[3-(2-ethyl)-ureido]-1H-benzoimidazol-5-yl ester 4-(2-Morpholin-4-yl-ethylamino)-benzenesulfonic acid 2-(3-pyridin-2-ylmethyl)-ureido]-1H-benzoimidazol-5-yl ester 4-(2-Morpholin-4-yl-ethylamino)-benzenesulfonic acid 2-[3-(2-methoxy-ethyl)-ureido]-1H-benzoimidazol-5-yl ester 4-[(Piperidin-4-ylmethyl)-amino)-benzenesulfonic acid 2-[3-(2-morpholin-4-yl-ethyl)-ureido]-1H-benzoimidazol-5-yl ester 4-[(Piperidin-4-ylmethyl)-amino]-benzenesulfonic acid 2-(3-pyridin-2-ylmethyl)-ureido]-1H-benzoimidazol-5-yl ester 4-[(Piperidin-4-ylmethyl)-amino]-benzenesulfonic acid 2-[3-(2-methoxy-ethyl)-ureido]-1H-benzoimidazol-5-yl ester 4-Benzylamino-benzenesulfonic acid 2-[3-(2-morpholin-4-yl-ethyl)-ureido]-1H-benzoimidazol-5-yl ester 4-Benzylamino-benzenesulfonic acid 2-(3-pyridin-2-ylmethyl)-ureido]-1H-benzoimidazol-5-yl ester 4-Benzylamino-benzenesulfonic acid 2-[3-(2-methoxy-ethyl)-ureido]-1H-benzoimidazol-5-yl ester 4-Benzylamino-benzenesulfonic acid 2-[3-(2-ethyl)-ureido]-1H-benzoimidazol-5-yl ester 4-[(1-ethyl-pyrrolidin-2ylmethyl)-amino]-benzenesulfonic acid 2-(3-pyridin-2-ylmethyl)-ureido]-1H-benzoimidazol-5-yl ester 4-(4-hydroxy-piperidin-1-yl)-benzenesulfonic acid 2-[(4-hydroxy-piperidine-1-carbonyl)-amino]-1H-benzoimidazol-5-yl ester 4-(4-Methyl-piperazin-1-yl)-benzenesulfonic acid 2-[(4-methyl-piperazin-1-carbonyl)-amino]-3H-benzoimidazol-5-yl ester 4-[(tetrahydro-pyran-4-ylmethyl)-amino]-benezenesulfonic acid 2-[3-(tetrahydro-pyran-4-ylmethyl)-ureido]-3H-benzoimidazol-5-yl ester 4-(2-Fluoro-ethylamino)-benzenesulfonic acid 2-[3-(2-fluoro-ethyl)-ureido]-3H-benzoimidazol-5-yl ester 4-(2-piperidin-1-yl-ethylamino)-benzenesulfonic acid 2-[3-(2-piperidin-1-yl-ethyl)-ureido]-3H-benzoimidazol-5-yl ester 4-phenethylamino-benzenesulfonic acid 2-(3-phenethyl-ureido)-3H-benzoimidazol-5-yl ester 4-[3-(2-oxo-pyrrolidin-1-yl)-propylamino]-benzenesulfonic acid 2-{3-[3-(2-oxo-pyrrolidin-1-yl)-propyl]-ureido}-3H-benzoimidazol-5-yl ester 4-(4-fluoro-benzylamino)-benzenesulfonic acid 2-[3-(4-fluoro-benzyl)-ureido]-3H-benzoimidazol-5-yl ester 4-(2-hydroxy-2-methyl-propylamino)-benzenesulfonic acid 2-[3-(2-hydroxy-3-methyl-propyl)-ureido]-3H-benzoimidazol-5-yl ester 4-(3-hydroxy-propylamino)-benzenesulfonic acid 2-[3-(3-hydroxy-propyl)-ureido]-3H-benzoimidazol-5-yl ester 4-(2,2,6,6-tetramethyl-piperidin-4-ylamino)-benzenesulfonic acid 2-[3-(2,2,6,6-tetramethyl-piperidin-4-yl)-ureido]-3H-benzoimidazol-5-yl ester 4-(2-dimethylamino-ethylamino)-benzenesulfonic acid 2-[3-(2-dimethylamino-ethyl)-ureido]-3H-benzoimidazol-5-yl ester 4-morpholin-4-yl-benzenesulfonic acid 2-[(morpholine-4-carbonyl)-amino]-3H-benzoimidazol-5-yl ester 4-(2-Hydroxy-3-methoxy-propylamino)-benzenesulfonic acid 2-[3-(2-hydroxy-3-methoxy-propyl)-ureido]-3H-benzoimidazol-5-yl ester 4-[(Pyridin-2-ylmethyl)-amino]-benzenesulfonic acid 2-(3-pyridin-2-yl-ethyl-ureido)-3H-benzoimidazol-5-yl ester 4-(2-hydroxy-propylamino)-benzenesulfonic acid 2-[3-(2-hydroxy-propyl)-ureido]-3H-benzoimidazol-5-yl ester 4-(4-methoxy-benzylamino)-benzenesulfonic acid 2-[3-(4-methoxy-benzyl)-ureido]-3H-benzoimidazol-5-yl ester 4-(2-pyrrolidin-1-yl-ethylamino)-benzenesulfonic acid 2-[3-(2-pyrrolidin-1-yl-ethyl)-ureido]-3H-benzoimidazol-5-yl ester 4-(1-phenyl-ethylamino)-benzenesulfonic acid 2-[3-(1-phenyl-ethyl)-ureido]-3H-benzoimidazol-5-yl ester 4-(2-diethylamino-ethylamino)-benzenesulfonic acid 2-[3-(2-diethylamino-ethyl)-ureido]-3H-benzoimidazol-5-yl ester 4-(1-hydroxymethyl-cyclopentylamino)-benzenesulfonic acid 2-[3-(1-hydroxy-methyl-cyclopentyl)-ureido]-3H-benzoimidazol-5-yl ester 3-(4-{2-[3-(3-Methoxycarbonyl-ethyl)-ureido]-1H-benzoimidazol-5-yloxysulfonyl}-phenylamino)-propionic acid methyl ester 4-(4-Hydroxy-piperidin-1-yl)-benzenesulfonic acid 2-[3-(2-morpholin-4-yl-ethyl)-ureido]-1H-benzoimidazol-5-yl ester 4-(4-methyl-piperazin-1-yl)-benzenesulfonic acid 2-[3-(2-morpholin-4-yl-ethyl)-ureido]-3H-benzimidazol-5-yl ester 4-(4-methyl-piperazin-1-yl)-benzenesulfonic acid 2-(3-pyridin-2-ylmethyl-ureido)-3H-benzimidazol-5-yl ester 4-(4-methyl-piperazin-1-yl)-benzenesulfonic acid 2-[3-(2-methoxy-ethyl)-ureido]-3H-benzimidazol-5-yl ester 4-(4-hydroxy-piperidin-1-yl)-benzenesulfonic acid 2-[3-(2-morpholin-4-yl-ethyl)-ureido]-3H-benzimidazol-5-yl ester 4-(4-hydroxy-piperidin-1-yl)-benzenesulfonic acid 2-(3-pyridin-2-ylmethyl-ureido)-3H-benzimidazol-5-yl ester 4-(4-hydroxy-piperidin-1-yl)-benzenesulfonic acid 2-[3-(2-methoxy-ethyl)-ureido]-3H-benzimidazol-5-yl ester 4-(4-hydroxy-piperidin-1-yl)-benzenesulfonic acid 2-(3-ethyl-ureido)-3H-benzimidazol-5-yl ester 4-[(Pyridin-2-ylmethyl)-amino]-benzenesulfonic acid 2-[3-(2-morpholin-4-yl-ethyl)-ureido]-3H-benzimidazol-5-yl ester 4-[(Pyridin-2-ylmethyl)-amino]-benzenesulfonic acid 2-(3-pyridin-2-ylmethyl-ureido)-3H-benzimidazol-5-yl ester 4-[(Pyridin-2-ylmethyl)-amino]-benzenesulfonic acid 2-[3-(2-methoxy-ethyl)-ureido]-3H-benzimidazol-5-yl ester 4-[(Pyridin-2-ylmethyl)-amino]-benzenesulfonic acid 2-[3-(2-methoxy-ethyl)-ureido]-3H-benzimidazol-5-yl ester 4-(3-Hydroxy-propylamino)-benzenesulfonic acid 2-[3-(2-morpholin-4-yl-ethyl)-ureido]-3H-benzimidazol-5-yl ester 4-(3-Hydroxy-propylamino)-benzenesulfonic acid 2-(3-pyridin-2-ylmethyl-ureido)-3H-benzimidazol-5-yl ester 4-(3-Hydroxy-propylamino)-benzenesulfonic acid 2-[3-(2-methoxy-ethyl)-ureido]-3H-benzimidazol-5-yl ester 4-(3-Hydroxy-propylamino)-benzenesulfonic acid 2-(3-ethyl-ureido)-3H-benzimidazol-5-yl ester 4-(2,2,6,6-tetramethyl-piperidin-4-ylamino)-benzenesulfonic acid 2-[3-(2-morpholin-4-yl-ethyl)-ureido]-3H-benzimidazol-5-yl ester 4-(2,2,6,6-tetramethyl-piperidin-4-ylamino)-benzenesulfonic acid 2-(3-pyridin-2-ylmethyl-ureido)-3H-benzimidazol-5-yl ester 4-(2-dimethylamino-ethylamino)-benzenesulfonic acid 2-[3-(2-morpholin-4-yl-ethyl)-ureido]-3H-benzimidazol-5-yl ester 4-(2-dimethylamino-ethylamino)-benzenesulfonic acid 2-(3-pyridin-2-ylmethyl-ureido)-3H-benzimidazol-5-yl ester 4-morpholin-4-yl-benzenesulfonic acid 2-[3-(2-morpholin-4-yl-ethyl)-ureido]-3H-benzimidazol-5-yl ester 4-morpholin-4-yl-benzenesulfonic acid 2-(3-pyridin-2-ylmethyl-ureido)-3H-benzimidazol-5-yl ester 4-[3-(2-oxo-pyrrolidin-1-yl)-propylamino)-benzenesulfonic acid 2-[3-(2-morpholin-4-yl-ethyl)-ureido]-3H-benzimidazol-5-yl ester 4-[3-(2-oxo-pyrrolidin-1-yl)-propylamino]-benzenesulfonic acid 2-(3-pyridin-2-ylmethyl-ureido)-3H-benzimidazol-5-yl ester 4-(3-Hydroxy-propylamino)-benzenesulfonic acid 2-(3-ethyl-ureido)-3H-benzimidazol-5-yl ester 4-(2-Hydroxy-2-methyl-propylamino)-benzenesulfonic acid 2-[3-(2-morpholin-4-yl-ethyl)-ureido]-3H-benzimidazol-5-yl ester 4-(2-Hydroxy-2-methyl-propylamino)-benzenesulfonic acid 2-(3-pyridin-2-ylmethyl-ureido)-3H-benzimidazol-5-yl ester 4-(2-Hydroxy-2-methyl-propylamino)-benzenesulfonic acid 2-[3-(2-methoxy-ethyl)-ureido]-3H-benzimidazol-5-yl ester 4-(2-Hydroxy-2-methyl-propylamino)-benzenesulfonic acid-2-[3-(3-hydroxy-propyl)-ureido]-3H-benzimidazol-5-yl ester 4-[(Tetrahydro-pyran-4-ylmethyl)-amino]-benzenesulfonic acid 2-[3-(2-morpholin-4-yl-ethyl)-ureido]-3H-benzimidazol-5-yl ester 4-[(Tetrahydro-pyran-4-ylmethyl)-amino]-benzenesulfonic acid 2-(3-pyridin-2-ylmethyl-ureido)-3H-benzimidazol-5-yl ester 4-[(Tetrahydro-pyran-4-ylmethyl)-amino]-benzenesulfonic acid 2-[3-(2-methoxy-ethyl)-ureido]-3H-benzimidazol-5-yl ester 4-[(Tetrahydro-pyran-4-ylmethyl)-amino]-benzenesulfonic acid 2-[3-(3-hydroxy-propyl)-ureido]-3H-benzimidazol-5-yl ester 4-(2-fluoro-ethylamino)-benzenesulfonic acid 2-[3-(2-morpholin-4-yl-ethyl)-ureido]-3H-benzimidazol-5-yl ester 4-(2-fluoro-ethylamino)-benzenesulfonic acid 2-(3-pyridin-2-ylmethyl-ureido)-3H-benzimidazol-5-yl ester 4-(2-Piperidin-1-yl-ethylamino)-benzenesulfonic acid 2-[3-(2-morpholin-4-yl-ethyl)-ureido]-3H-benzimidazol-5-yl ester 4-(2-Piperidin-1-yl-ethylamino)-benzenesulfonic acid 2-(3-pyridin-2-ylmethyl-ureido)-3H-benzimidazol-5-yl ester 4-phenethylamino-benzenesulfonic acid 2-[3-(2-morpholin-4-yl-ethyl)-ureido]-3H-benzimidazol-5-yl ester 4-phenethylamino-benzenesulfonic acid 2-[3-(2-methoxy-ethyl)-ureido]-3H-benzimidazol-5-yl ester 4-phenethylamino-benzenesulfonic acid 2-(3-ethyl-ureido)-3H-benzimidazol-5-yl ester 4-phenethylamino-benzenesulfonic acid 2-[3-(3-hydroxy-propyl)-ureido]-3H-benzimidazol-5-yl ester 4-(2-hydroxy-propylamino)-benzenesulfonic acid 2-[3-(2-morpholin-4-yl-ethyl)-ureido]-3H-benzimidazol-5-yl ester 4-(2-hydroxy-propylamino)-benzenesulfonic acid 2-(3-ethyl-ureido)-3H-benzimidazol-5-yl ester 4-(4-methoxy-benzylamino)-benzenesulfonic acid 2-[3-(2-morpholin-4-yl-ethyl)-ureido]-3H-benzimidazol-5-yl ester 4-(4-methoxy-benzylamino)-benzenesulfonic acid 2-(3-ethyl-ureido)-3H-benzimidazol-5-yl ester 4-(4-methoxy-benzylamino)-benzenesulfonic acid 2-(3-pyridin-2-ylmethyl-ureido)-3H-benzimidazol-5-yl ester 4-(4-methoxy-benzylamino)-benzenesulfonic acid 2-[3-(3-hydroxy-propyl)-ureido]-3H-benzimidazol-5-yl ester 4-(4-methoxy-benzylamino)-benzenesulfonic acid 2-[3-(2-methoxy-ethyl)-ureido]-3H-benzimidazol-5-yl ester 4-(2-pyrrolidin-1-yl-ethylamino)-benzenesulfonic acid 2-(3-ethyl-ureido)-3H-benzimidazol-5-yl ester 4-(2-pyrrolidin-1-yl-ethylamino)-benzenesulfonic acid 2-(3-pyridin-2-ylmethyl-ureido)-3H-benzimidazol-5-yl ester 4-(2-pyrrolidin-1-yl-ethylamino)-benzenesulfonic acid 2-[3-(2-methoxy-ethyl)-ureido]-3H-benzimidazol-5-yl ester 4-(1-phenyl-ethylamino)-benzenesulfonic acid 2-(3-ethyl-ureido)-3H-benzimidazol-5-yl ester 4-(2-diethylamino-ethylamino)-benzenesulfonic acid 2-(3-pyridin-2-ylmethyl-ureido)-3H-benzimidazol-5-yl ester Thiophene-2-sulfonic acid 2-[3-(2-ethyl)-ureido]-1H-benzoimidazol-5-yl ester Thiophene-2-sulfonic acid 2-[3-(2-methoxy-ethyl)-ureido]-1H-benzoimidazol-5-yl ester Thiophene-2-sulfonic acid 2-[3-(2-morpholin-4-yl-ethyl)-ureido]-1H-benzoimidazol-5-yl ester Thiophene-2-sulfonic acid 2-(3-pyridin-2-ylmethyl)-ureido]-1H-benzoimidazol-5-yl ester 4-{2-[3-(2-methoxy-ethyl)-ureido]-1H-benzoimidazol-5-yloxysulfonyl}-phenyl ester Benzoic acid 4-{2-[3-(2-morpholin-4-yl-ethyl)-ureido}-1H-benzoimidazol-5-yloxy-sulfonyl}-phenyl ester Benzoic acid 4-[2-([3-pyridin-2-ylmethyl)-ureido)-1H-benzoimidazol-5-yloxy-sulfonyl]-phenyl ester 2,6-difluoro-benzenesulfonic acid 2-(3-pyridin-2-ylmethyl-ureido)-3H-benzoimidazol-5-yl ester 2,6-difluoro-benzenesulfonic acid 3-(2-methoxy-ethyl)-3H-benzoimidazol-5-yl ester
DETAILED DESCRIPTION OF THE INVENTION
[0580] In still yet another embodiment is disclosed use of compounds of formula (I) for treating cancer diseases.
[0581] In still yet another embodiment is disclosed a method of inhibiting CDK4 enzymes in a mammal in recognized need of such treatment comprising administering to the mammal a therapeutically effective amount of compounds of formula (I).
[0582] In still yet another embodiment is disclosed a pharmaceutical composition which comprises a therapeutically effective amount of a compound of formula (I) in combination with a pharmaceutically acceptable carrier.
[0583] The term “pharmaceutically acceptable salt”, as used herein, refers to salts, which are suitable for use in contact with the tissues of humans and lower animals. Pharmaceutically acceptable salts are described in detail in J. Pharmaceutical Sciences, 1977, 66:1 et seq. hereby incorporated by reference. Representative acid addition salts include acetate, citrate, aspartate, benzenesulfonate, hydrochloride, lactate, maleate, methanesulfonate, oxalate, and phosphate.
Chemical Synthesis
[0584] Compounds of the present invention can be easily prepared starting from 2-amino-5-(−4-fluorophenylsulfonyloxy)nitrobenzene, the process of preparation of which is described in U.S. Pat. No. 3,996,368.
[0585] In a first step this starting material is reacted with the amine bearing the R1 radical in a suitable solvent for carrying out the reaction. Among the list of solvents suitable for dissolving 2-amino-5-(4-fluorophenylsulfonyloxy)nitrobenzene and the amine can be cited the glycols such as ethyl glycol, and the aprotic solvents such as dioxane, dimethylformamide, N-methylpyrrolidone. The preferred temperature for this reaction is comprised between room temperature and the reflux temperature. To recover the intermediate product it is preferred to precipitate the intermediate with hydrochloric acid.
[0586] In a second step the compound of step 1 is hydrogenated with hydrogen preferably in presence of Raney nickel (nitro group reduction method A) or palladium on carbon (nitro group reduction method B) in a suitable solvent choosen among the same list as for step 1 in mixture with an alcohol such as methanol. After reaction the catalyst is taken off by filtration.
[0587] In a third step the benzimidazole ring is closed by action of 1,3-bis(methoxycarbonyl)-2-methyl-2-thiopseudourea on the intermediate obtained in step 2 without intermediate separation. The reaction mixture is heated to reflux with stirring. The final product (methyl-benzimidazole-2-carbamate) is isolated after evaporation of the solvent under reduced pressure and solubilization in ethyl acetate then crystallisation. A final purification is carried out in methanol with a crystallisation in the same solvent.
[0588] Methyl-benzimidazole-2-carbamate can be converted to benzimidazole-2-ureas by treatment with an amine in a suitable solvent such as dimethylformamide, tetrahydrofuran or N-methylpyrrolidone in the presence of a base such as 1,8-diazabicyclo[5.4.0]undec-7-ene in a pressure vessel. The preferred temperature for this reaction is comprised between room temperature and 120° C.
[0589] tert-Butyl-benzimidazole-2-carbamate can be prepared by performing the third step described above using 1,3-bis(tert-butoxycarbonyl)-2-methyl-2-thiopseudourea instead of 1,3-bis(methoxycarbonyl)-2-methyl-2-thiopseudourea. These derivatives can be converted to the corresponding 2-aminobenzimidazole derivative using tert-butylcarbamate deprotection methods known by the persons skilled in the art. The 2-aminobenzimidazoles can be converted to the corresponding amides by reaction with carboxylic acid derivatives using methods known by the persons skilled in the art.
Formulations
[0590] The present invention also provides pharmaceutical compositions, which comprise compounds of the present invention formulated together with one or more non-toxic pharmaceutically acceptable carriers. The pharmaceutical compositions may be specially formulated for oral administration in solid or liquid form or for parenteral injection.
[0591] The term “parenteral”, as used herein, refers to modes of administration, which include intravenous, intramuscular, intraperitoneal, subcutaneous and infusion.
[0592] Solid dosage forms for oral administration include capsules, tablets, pills, powders and granules. In such solid dosage forms, the active compound is mixed with at least one inert, pharmaceutically acceptable excipient or carrier.
[0593] Solid compositions of a similar type may also be employed as fillers in soft and hard-filled gelatin capsules.
[0594] The compounds of the present invention may be administered alone or mixed with other anticancer agents. Among the possible combinations, there may be mentioned
alkylating agents and in particular cyclophosphamide, melphalan, ifosfamide, chlorambucil, busulfan, thiotepa, prednimustine, carmustine, lomustine, semustine, streptozotocin, decarbazine, temozolomide, procarbazine and hexamethylmelamine platinum derivatives such as in particular cisplatin, carboplatin or oxaliplatin, antibiotic agents such as in particular bleomycin, mitomycin, dactinomycin, antimicrotubule agents such as in particular vinblastine, vincristine, vindesine, vinorelbine, taxoids (paclitaxel and docetaxel), anthracyclines such as in particular doxorubicin, daunorubicin, idarubicin, epirubicin, mitoxantrone, losoxantrone, group I and II topoisomerases such as etoposide, teniposide, amsacrine, irinotecan, topotecan and tomudex, fluoropyrimidines such as 5-fluorouracil, UFT, floxuridine, cytidine analogues such as 5-azacytidine, cytarabine, gemcitabine, 6-mercaptomurine, 6-thioguanine, adenosine analogues such as pentostatin, cytarabine or fludarabine phosphate, methotrexate and folinic acid, various enzymes and compounds such as L-asparaginase, hydroxyurea, trans-retinoic acid, suramine, dexrazoxane, amifostine, herceptin as well as oestrogenic and androgenic hormones.
[0606] It is also possible to combine a radiation treatment with the compounds of the present invention. This treatment may be administered simultaneously, separately or sequentially. The treatment will be adapted to the patient to be treated by the practitioner.
[0607] The invention will be more fully described by the following examples, which must not be considered as a limitation of the invention.
EXAMPLES
[heading-0608] Method for Analytical Determination
Liquid Chromatography Coupled to Mass Spectrometry (LC/MS) Analysis
[0609] LC/MS analyses were conducted on a Micromass instrument model LCT linked to an HP 1100 model instrument. Compound abundance was detected using an HP G1315A (model) photodiode array detector in the 200-600 nm wavelength range and a Sedex 65 (model) evaporative light scattering detector. Mass spectra were acquired in the 160 to 2000 amu range. Data were analysed using the Micromass MassLynx software. Separation were carried out on a Hypersil Highpurity C18, 5 μm particle size column (50×4.6 mm) eluted by a linear gradient of 10 to 90% acetonitrile containing 0.05% (v/v) trifluoroacetic acid (TFA) in water containing 0.05% (v/v) TFA in 6.50 min at a flow rate of 1 ml/min.
[heading-0610] Method for Purification
LC/MS Triggered Purification
[0611] Compounds were purified by LC/MS using a Waters FractionLynx system composed of a Waters model 600 gradient pump, a Waters model 515 regeneration pump, a Waters Reagent Manager make-up pump, a Waters model 2700 sample manager autoinjector, two Rheodyne model LabPro switches, a Waters model 996 photodiode array detector, a Waters model ZMD mass spectrometer and a Gilson model 204 fraction collector. The Waters FractionLynx software controlled the instrument. Separation were conducted alternatively on two Waters Symmetry columns (C 18 , 5 μM, 19×50 mm, catalogue number 186000210), one column was under regeneration by a 95/5 (v/v) water/acetonitrile mixture containing 0.07% TFA (v/v) while the other one is separating. Columns were eluted by a linear gradient of acetonitrile containing 0.07% (v/v) TFA in water containing 0.07% (v/v) TFA, from 5 to 95% (v/v) in 8 min and 2 min at 95% acetonitrile containing 0.07% (v/v) TFA, at a flow rate of 10 ml/min. At the output of the separating column the flow was split to the 1/1000 ratio using a LC Packing AccuRate splitter; 1/1000 of the flow was mixed with methanol (0.5 ml/min. flow rate) and sent to the detectors, this flow was split again ¾ of the flow was sent to the photodiode array detector and ¼ to the mass spectrometer; the rest of the output of the column (999/1000) was sent to the fraction collector were flow was directed normally to waste unless expected mass signal was detected by the FractionLynx software. The FractionLynx software was supplied with molecular formulas of expected compounds and triggered the collection of compounds when mass signal corresponding to [M+H] + and [M+Na] + are detected. In certain cases (depending on analytical LC/MS result, when [M+2H] ++ was detected as an intense ion) the FractionLynx software was additionally supplied with calculated half molecular weight (MW/2), in these conditions collection was also triggered when mass signal corresponding to [M+2H] ++ and [M+Na+H] ++ are detected. Compounds were collected in tarred glass tubes. After collection, solvent was evaporated in a Jouan model RC 10.10 centrifuge evaporator or a Genevac model HT8 centrifuge evaporator and the amount of compound was determined by weighing of the tubes after solvent evaporation.
Method of Preparation of Compounds of the Invention
[0612] 2-amino-5-(4-fluorophenylsulfonyloxy)nitrobenzene (melting point 161° C.), the starting material, can be prepared according to U.S. Pat. No. 3,996,368.
Example 1
Preparation of Methyl-5-(4-[2-hydroxyethyl]aminophenylsulfonyloxy) benzimidazole-2-carbamate
[0613]
[0614] step 1: 15.6 g of 2-amino-5-(4-fluorophenylsulfonyloxy)nitrobenzene were combined with 25 ml ethanolamine in 100 ml ethyl glycol in a round bottom flask. The reaction mixture was heated to reflux for 90 min and then cooled on ice. Reaction mixture was then diluted with 250 ml of 2N aqueous HCl, the compound precipitated and was filtered off with suction. The preciptate was the washed with water and dried, yielding 15.5 g of 2-amino-5-(4-[2-hydroxyethyl]aminophenylsulfonyloxy)nitro benzene (melting point 180° C.).
[0615] step 2: 15.5 g of 2-amino-5-(4-[2-hydroxyethyl]aminophenylsulfonyloxy)nitro-benzene in 75 ml of methanol and 75 ml of dimethylformamide are hydrogenated under atmospheric pressure with a catalytic amount of Raney Nickel (method A). After hydrogen uptake is complete, the catalyst was filtered off with suction, washed with methanol and the filtrate is concentred under reduced pressure
[0616] step 3: concentrated filtrate of step 2 was taken up in 150 ml methanol and 30 ml of glacial acetic acid, 10.3 g of 1,3-bis(methoxycarbonyl)-2-methyl-2-thiopseudourea was added and reaction mixture was heated to reflux with stirring for 3 hours. Solvents were then evaporated under reduced pressure, concentrate was then dissolved in hot ethylacetate, crystallized by cooling and washed with ethylacetate. Compound was then solubilized in 250 ml refluxing methanol, crystallized by cooling and washed with methanol and dried yielding 7.4 g of the title compound. (Melting point 170° C., LC/MS analysis: retention time=2.8 min., mass spectrum: 407.24, [M+H] + )
Example 2
Preparation of Methyl-5-(4-[4-hydroxbutyl]aminophenylsulfonyloxy) benzimidazole-2-carbamate
[0617]
[0618] step 1: 19.7 g of 2-amino-5-(4-fluorophenylsulfonyloxy)nitrobenzene were combined with 20 g butanolamine in 200 ml N-methylpyrrolidinone in a round bottom flask. The reaction mixture was heated to reflux for 120 min and then solvent was evaporated under reduced pressure. Concentrate was then solubilized with ethylacetate and extracted with 2N aqueous HCl and water and then dried over sodium sulfate and dried under reduced pressure. The concentrate was recrystallized in isopropanol, filtered under suction, washed with isopropanol and dried, yielding 13.1 g of 2-amino-5-(4-[4-hydroxbuyl]aminophenylsulfonyloxy)nitrobenzene (melting point 105° C.).
[0619] step 2: 13.1 g of 2-amino-5-(4-[4-hydroxbutyl]aminophenylsulfonyloxy)nitro-benzene in 75 ml of methanol and 75 ml of dimethylformamide are hydrogenated under atmospheric pressure with a catalytic amount of Raney Nickel (Method A). After hydrogen uptake is complete, the catalyst was filtered off with suction, washed with methanol and the filtrate is concentred under reduced pressure.
[0620] step 3: concentrated filtrate of step 2 was taken up in 100 ml methanol and 20 ml of glacial acetic acid, 8.2 g of 1,3-bis(methoxycarbonyl)-2-methyl-2-thiopseudourea was added and reaction mixture was heated to reflux with stirring for 3 hours. Solvents were then evaporated under reduced pressure, concentrate washed with 2N aqueous ammonia, water and dried. Concentrate was then dissolved in hot ethyl acetate, crystallized by cooling and washed with ethyl acetate. Compound was then solubilized in refluxing methanol, crystallized by cooling and washed with methanol and dried yielding 6.3 g of the title compound. (Melting point 180° C., LC/MS analysis: retention time=2.9 min., mass spectrum: 435.29, [M+H] + )
Example 3
Preparation of Methyl-5-(4-[2-methoxyethyl]aminophenylsulfonyloxy) benzimidazole-2-carbamate
[0621]
[0622] step 1: 15.6 g of 2-amino-5-(4-fluorophenylsulfonyloxy)nitrobenzene were combined with 35 ml methoxyethylamine in 100 ml dioxane in a round bottom flask. The reaction mixture was heated to reflux for 8 hours and then cooled to 40° C. and extracted two times with 250 ml water. Concentrate was solubilized with ethyl acetate and extracted with 2N aqueous HCl and water, the organic phase was then dried under reduced pressure, yielding 19.2 g of 2-amino-5-(4-[2-methoxyethyl]aminophenylsulfonyloxy)nitrobenzene (melting point 105° C.).
[0623] step 2: 18.2 g of 2-amino-5-(4-[2-methoxyethyl]aminophenylsulfonyloxy)nitro-benzene in 75 ml of methanol and 75 ml of dimethylformamide are hydrogenated under atmospheric pressure with a catalytic amount of Raney Nickel (Method A). After hydrogen uptake is complete, the catalyst was filtered off with suction, washed with methanol and the filtrate is concentred under reduced pressure.
[0624] step 3: concentrated filtrate of step 2 was taken up in 150 ml methanol and 25 ml of glacial acetic acid, 12.3 g of 1,3-bis(methoxycarbonyl)-2-methyl-2-thiopseudourea was added and reaction mixture was heated to reflux with stirring for 3 hours. Solvents were then evaporated under reduced pressure, and concentrate was crystallized with methanol saturated with ammonia, washed with water, methanol and dried, yielding 12 g of the title compound. (Melting point 155° C., LC/MS analysis: retention time=3.1 min., mass spectrum: 421.25, [M+H] + ).
Example 4
Preparation of Methyl-5-(4-[1-imidazolyl]-phenylsulfonyloxy) benzimidazole-2-carbamate
[0625]
[0626] step 1: 15.6 g of 2-amino-5-(4-fluorophenylsulfonyloxy)nitrobenzene were combined with 20.7 g imidazole in 100 ml dimethylformamide in a round bottom flask. The reaction mixture was heated to reflux for 3 hours and then cooled to room temperature. Reaction mixture was then precipitated by addition of water filtered and precipitate was washed with water and dried. Residue was resolubilized in hot ethyl glycol, crystallized by cooling and the crystals were washed with methanol and dried, yielding 10.4 g of 2-amino-5-(4-[1-imidazolyl]-phenylsulfonyloxy)nitro-benzene (melting point 209° C.).
[0627] step 2: 10.4 g of 2-amino-5-(4-[1-imidazolyl]-phenylsulfonyloxy)nitrobenzene in 75 ml of methanol and 75 ml of dimethylformamide are hydrogenated under atmospheric pressure with a catalytic amount of Raney Nickel. After hydrogen uptake is complete, the catalyst was filtered off with suction, washed with methanol and the filtrate is concentred under reduced pressure (Method A). Alternatively 5 g of 2-amino-5-(4-[1-imidazolyl]-phenylsulfonyloxy)nitrobenzene in 475 ml of methanol and 25 ml of dimethylformamide are hydrogenated under 5 bars pressure with 10% (w/w) of palladium on carbon at 30° C. during 6 hours (Method B) yielding 4.18 g (91%) of expected product.
[0628] step 3: concentrated filtrate of step 2 was taken up in 150 ml methanol and 25 ml of glacial acetic acid, 10.3 g of 1,3-bis(methoxycarbonyl)-2-methyl-2-thiopseudourea was added and reaction mixture was heated to reflux with stirring for 3 hours. After cooling to room temperature reaction mixture was precipitated by addition of ethyl acetate, filtered by suction and washed by ethyl acetate. Filtrate was then resolubilized with 50 ml dimethylformamide and 250 ml of methanol was added. Mixture crystallised upon cooling and crystals were washed with methanol and dried under reduced pressure, yielding 9.4 g of the title compound. (Melting point 258° C., LC/MS analysis: retention time=2.5 min., mass spectrum: 414.23, [M+H] + ; 382.19 fragmentation of carbamate: loss of methanol, NMR, IR).
Example 5
Preparation of Methyl-5-(4-[2-pyridylmethyl]aminophenylsulfonyloxy) benzimidazole-2-carbamate
[0629]
[0630] In a similar manner to examples 1 to 4, title compound was obtained by reacting 2-aminomethylpyridine with 2-amino-5-(4-fluorophenylsulfonyloxy)nitrobenzene at step 1 of the procedure described above and using nitro group reduction method A. (LC/MS analysis: retention time=2.6 min., mass spectrum: 454.28, [M+H] + ; 907.53, [2M+H] + ; 422.24, fragmentation of carbamate: loss of methanol).
Example 6
Preparation of Methyl-5-(4-ethylaminophenylsulfonyloxy) benzimidazole-2-carbamate
[0631]
[0632] In a similar manner to examples 1 to 4, title compound was obtained by reacting ethylamine with 2-amino-5-(4-fluorophenylsulfonyloxy)nitrobenzene at step 1 of the procedure described above and using nitro group reduction method A. (LC/MS analysis: retention time=3.2 min., mass spectrum: 390.98, [M+H] + ).
Example 7
Preparation of Methyl-5-(4-[N-Glycinyl]-phenylsulfonyloxy) benzimidazole-2-carbamate
[0633]
[0634] In a similar manner to examples 1 to 4, title compound was obtained by reacting glycine with 2-amino-5-(4-fluorophenylsulfonyloxy)nitrobenzene at step 1 of the procedure described above and using nitro group reduction method A. (LC/MS analysis: retention time=2.8 min., mass spectrum: 421.21, [M+H] + ).
Example 8
Preparation of Methyl-5-(4-[1-methyl,2-hydroxyethyl]aminophenyl-sulfonyloxy) benzimidazole-2-carbamate
[0635]
[0636] In a similar manner to examples 1 to 4, title compound was obtained by reacting 2-aminopropanol with 2-amino-5-(4-fluorophenylsulfonyloxy)nitrobenzene at step 1 of the procedure described above and using nitro group reduction method A. (LC/MS analysis: retention time=2.9 min., mass spectrum: 421.27, [M+H] + ).
Example 9
Preparation of Methyl-5-(4-[2-methyl,2-hydroxyethyl]aminophenyl-sulfonyloxy) benzimidazole-2-carbamate
[0637]
[0638] In a similar manner to examples 1 to 4, title compound was obtained by reacting 1-methyl-2-aminoethanol with 2-amino-5-(4-fluorophenylsulfonyloxy)nitrobenzene at step 1 of the procedure described above and using nitro group reduction method A. (LC/MS analysis: retention time=2.9 min., mass spectrum: 421.27, [M+H] + ).
Example 10
Preparation of Methyl-5-(4-isopropylaminophenylsulfonyloxy) benzimidazole-2-carbamate
[0639]
[0640] In a similar manner to examples 1 to 4, title compound was obtained by reacting isopropylamine with 2-amino-5-(4-fluorophenylsulfonyloxy)nitrobenzene at step 1 of the procedure described above and using nitro group reduction method A. (LC/MS analysis: retention time=3.4 min., mass spectrum: 405.27, [M+H] + ).
Example 11
Preparation of Methyl-5-(4-[1-ethyl, 2-hydroxyethyl]aminophenyl sulfonyloxy)benzimidazole-2-carbamate
[0641]
[0642] In a similar manner to examples 1 to 4, title compound was obtained by reacting 2-aminobutanol with 2-amino-5-(4-fluorophenylsulfonyloxy)nitrobenzene at step 1 of the procedure described above and using nitro group reduction method A. (LC/MS analysis: retention time=3.0 min., mass spectrum: 435.30, [M+H] + ).
Example 12
Preparation of Methyl-5-(4-butylaminophenylsulfonyloxy) benzimidazole-2-carbamate
[0643]
[0644] In a similar manner to examples 1 to 4, title compound was obtained by reacting butylamine with 2-amino-5-(4-fluorophenylsulfonyloxy)nitrobenzene at step 1 of the procedure described above and using nitro group reduction method A. (LC/MS analysis: retention time=3.6 min., mass spectrum: 419.25, [M+H] + ).
Example 13
Preparation of Methyl-5-(4-[3-methoxypropyl]aminophenyl-sulfonyloxy) benzimidazole-2-carbamate
[0645]
[0646] In a similar manner to examples 1 to 4, title compound was obtained by reacting 3-methoxypropanolamine with 2-amino-5-(4-fluorophenylsulfonyloxy)nitrobenzene at step 1 of the procedure described above and using nitro group reduction method A. (LC/MS analysis: retention time=3.2 min., mass spectrum: 435.27, [M+H] + ).
Example 14
Preparation of Methyl-5-(4-methylaminophenylsulfonyloxy) benzimidazole-2-carbamate
[0647]
[0648] In a similar manner to examples 1 to 4, title compound was obtained by reacting methylamine with 2-amino-5-(4-fluorophenylsulfonyloxy)nitrobenzene at step 1 of the procedure described above and using nitro group reduction method A. (LC/MS analysis: retention time=3.0 min., mass spectrum: 377.22, [M+H] + ).
Example 15
Preparation of Methyl-5-(4-[2-sulfonylethyl]aminophenylsulfonyloxy) benzimidazole-2-carbamate
[0649]
[0650] In a similar manner to examples 1 to 4, title compound was obtained by reacting 2-aminoethanesulfonic acid with 2-amino-5-(4-fluorophenylsulfonyloxy)nitrobenzene at step 1 of the procedure described above and using nitro group reduction method A. (LC/MS analysis: retention time=2.6 min., mass spectrum: 471.19, [M+H] + ; 941.41, [2M+H] + ).
Example 16
Preparation of Methyl-5-(4-aminophenylsulfonyloxy)benzimidazole-2-carbamate
[0651]
[0652] In a similar manner to examples 1 to 4, title compound was obtained by reacting ammonia with 2-amino-5-(4-fluorophenylsulfonyloxy)nitrobenzene at step 1 of the procedure described above and using nitro group reduction method A. (LC/MS analysis: retention time=2.9 min., mass spectrum: 363.19, [M+H] + ).
Example 17
Preparation of Methyl-5-(4-[2-diethylaminoethyl]aminophenyl-sulfonyloxy) benzimidazole-2-carbamate
[0653]
[0654] In a similar manner to examples 1 to 4, title compound was obtained by reacting 2-diethylaminoethylamine with 2-amino-5-(4-fluorophenylsulfonyloxy)nitrobenzene at step 1 of the procedure described above and using nitro group reduction method A. (LC/MS analysis: retention time=2.6 min., mass spectrum: 462.34, [M+H] + ; 923.65, [2M+H] + ; 430.30, fragmentation of carbamate: loss of methanol).
Example 18
Preparation of Methyl-5-(4-[1-tetrathydrofurylmethyl]aminophenyl-sulfonyloxy) benzimidazole-2-carbamate
[0655]
[0656] In a similar manner to examples 1 to 4, title compound was obtained by reacting tetrahydrofurfurylamine with 2-amino-5-(4-fluorophenylsulfonyloxy)nitrobenzene at step 1 of the procedure described above and using nitro group reduction method A. (LC/MS analysis: retention time=3.2 min., mass spectrum: 447.24, [M+H] + ).
Example 19
Preparation of Methyl-5-(4-cyclopentylaminophenylsulfonyloxy) benzimidazole-2-carbamate
[0657]
[0658] In a similar manner to examples 1 to 4, title compound was obtained by reacting cyclopentylamine with 2-amino-5-(4-fluorophenylsulfonyloxy)nitrobenzene at step 1 of the procedure described above and using nitro group reduction method A. (LC/MS analysis: retention time=3.6 min., mass spectrum: 431.29, [M+H] + ).
Example 20
Preparation of Methyl-5-(4-[2-phenylethyl]aminophenylsulfonyloxy) benzimidazole-2-carbamate
[0659]
[0660] In a similar manner to examples 1 to 4, title compound was obtained by reacting phenethylamine with 2-amino-5-(4-fluorophenylsulfonyloxy)nitrobenzene at step 1 of the procedure described above and using nitro group reduction method A. (LC/MS analysis: retention time=3.6 min., mass spectrum: 467.26, [M+H] + ).
Example 21
Preparation of 5-(4-[1-imidazolyl]-phenylsulfonyloxy)-1H-benzimidazole-2-ylamine: an intermediate for amide product synthesis
[0661]
[0662] For step 1 and 2, intermediate of title compound is obtained in similar manner to step 1 end 2 of example 4.
[0663] step 3: 8 g of step 2 compound were taken up in 128 ml methanol and 21.6 ml acetic acid in a 250 ml round bottom flask. Mixture was heated to reflux and 9.13 g of 1,3-bis(tert-butoxycarbonyl)-2-methyl-2-thiopseudourea was added. Reaction mixture was heated to reflux with stirring for 4 hours. Solid was obtained by cooling to 0° C. for one hour and washed with ethyl acetate, triturated and dried on a glass frit yielding 7.55 g compound.
[0664] step 4: Compound of step 3 was taken up in 80 ml dichloromethane and 40 ml trifluoroacetic acid. Reaction mixture was stirred for 4 hours at room temperature. Solvents were evaporated under reduced pressure. Concentrated filtrate was taken in 75 ml water and 50 ml of sodium carbonate aqueous solution (10% w/w). Precipitate obtained was washed with dichloromethane and dried on a glass frit yielding 5.3 g title compound.
Example 22
Preparation of 5-(4-cyclopentylaminophenylsulfonyloxy)-1H-benzimidazole-2-ylamine: an intermediate for amide product synthesis
[0665]
[0666] For step 1 and 2, intermediate of title compound is obtained in similar manner to step 1 end 2 of example 19.
[0667] For step 3 and 4, title compound is obtained in similar manner to example 21.
Example 23
Preparation of N-[5-(4-Imidazol-1-yl-benzenesulfonyloxy)-1H-benzoimidazol-2-yl]-succinamic acid methyl ester
[0668]
[0669] step 1: 8.9 mg of succinamic acid methyl ester, 25 mg of 2-(1H-benzotriazole-1-yl)-1,1,3,3-tetramethyluronium hexafluorophosphate (HBTU) and 12 μl diisopropyl-ethylamine were taken up in 0.4 ml dimethylformamide. Reaction mixture was stirred at room temperature for one hour and 5-(4-[1-imidazolyl]-phenylsulfonyloxy)-1H-benzimidazole-2-ylamine was added in 0.2 ml dimethylformamide. Reaction mixture was then stirred at room temperature for 24 hours. Solvent was evaporated in a Jouan model RC 10.10 centrifuge evaporator and title compound was solubilised in 0.5 ml dimethylsulfoxide for LCMS trigged purification yielding 3.9 mg of N-[5-(4-[1-imidazolyl]-phenylsulfonyloxy)-1H-benzimidazole-2-yl]-succinamic-acid-methyl ester. (LC/MS analysis: retention time=2.70 min., mass spectrum: 470.34, [M+H] + ).
Example 24
Preparation of 4-Cyclopentylamino-benzenesulfonic acid 2-(2-tert-butoxycarbonylamino-acetylamino)-1H-benzoimidazol-5-yl ester
[0670]
step 1: 11.3 mg of N-(tert-butoxycarbonyl)glycine, 25 mg HBTU and 12 μl diisopropylethylamine were taken up in 0.4 ml dimethylformamide. Reaction mixture was stirred at room temperature for one hour and 5-(4-cyclopentylaminophenylsulfonyloxy)-1H-benzimidazole-2-ylamine was added in 0.2 ml dimethylformamide. Reaction mixture was then stirred at room temperature for 24 hours. Solvent was evaporated in a Jouan model RC 10.10 centrifuge evaporator and title compound was solubilised in 0.5 ml dimethylsulfoxide for LCMS trigged purification yielding 2.4 mg of N-[5-(4-cyclopentylaminophenylsulfonyloxy)-1H-benzimidazole-2-yl]-tert-butoxycarbonylglycineamid. (LC/MS analysis: retention time=3.87 min., mass spectrum: 530.38, [M+H] + ).
Example 25
Preparation of N-[5-(4-Cyclopentylamino-benzenesulfonyloxy)-1H-benzoimidazol-2-yl]-succinamic acid methyl ester
[0672]
[0673] In a similar manner to example 24, title compound was obtained by reacting succinamic acid methyl ester with N-5-(4-cyclopentylaminophenylsulfonyloxy)-1H-benzimidazole-2-ylamine (LC/MS analysis: retention time=3.72 min., mass spectrum: 487.34, [M+H] + ).
Example 26
Preparation of 4-[5-(4-Cyclopentylamino-benzenesulfonyloxy)-1H-benzoimidazol-2-ylcarbamoyl]-butyric acid methyl ester
[0674]
[0675] In a similar manner to example 24, title compound was obtained by reacting butyric acid methylester with N-5-(4-cyclopentylaminophenylsulfonyloxy)-1H-benzimidazole-2-ylamine. (LC/MS analysis: retention time=3.75 min., mass spectrum: 501.36, [M+H] + ).
Example 27
Preparation of 4-Cyclopentylamino-benzenesulfonic acid 2-(cyclopropanecarbonyl-amino)-1H-benzoimidazol-5-yl ester
[0676]
[0677] In a similar manner to example 24, title compound was obtained by reacting cyclopropane carboxylic acid with 5-(4-cyclopentylaminophenylsulfonyloxy)-1H-benzimidazole-2-ylamine. (LC/MS analysis: retention time=3.76 min., mass spectrum: 441.36, [M+H] + ).
Example 28
Preparation of 4-Cyclopentylamino-benzenesulfonic acid 2-(2-methoxy-acetylamino)-1H-benzoimidazol-5-yl ester
[0678]
[0679] In a similar manner to example 24, title compound was obtained by reacting methoxyaceticacid with 5-(4-cyclopentylaminophenylsulfonyloxy)-1H-benzimidazole-2-ylamine. (LC/MS analysis: retention time=3.66 min., mass spectrum: 445.34, [M+H] + ).
Example 29
Preparation of 4-Cyclopentylamino-benzenesulfonic acid 2-(2-dimethylamino-acetylamino)-1H-benzoimidazol-5-yl ester
[0680]
[0681] In a similar manner to example 24, title compound was obtained by reacting N,N-dimethylglycine with 5-(4-cyclopentylaminophenylsulfonyloxy)-1H-benzimidazole-2-ylamine. (LC/MS analysis: retention time=3.36 min., mass spectrum: 458.36, [M+H] + ).
Example 30
N-[5-(4-[imidazolyl]-phenylsulfonyloxy)-1H-benzimidazole-2-yl]-methylurea
[0682]
10 mg of methyl-5-(4-[imidazolyl]-phenylsulfoxy)benzimidazole-2-carbamate (example 4) were combined with 50 μl methylamine (2.0 M in tetrahydrofuran) and 5 μl 1,8-Diazabicyclo[5.4.0]undec-7-ene in 2 ml N-methylpyrrolidone/tetrahydrofuran (1/1) in a 24 well Inox plate for high pressure reaction. The reaction mixture was put under a 10 Bars argon pressure and then heated to 80° C. for 4 hours, and then cooled at room temperature. Compounds were put in an assay tube and tetrahydrofuran was evaporated under reduced pressure and compound in N-methylpyrrolidone were directly purified by preparative LCMS under conditions described above. After purification, solution was dry-concentrated in a JOUAN RC1010 evaporator. (LC/MS analysis: retention time=2.23 min., mass spectrum: 413.23, [M+H] + ).
Example 31
N-[5-(4-cyclopentylaminophenylsulfonyloxy)-1H-benzimidazole-2-yl]-methylurea
[0684]
[0685] In a similar manner to example 30, title compound was obtained by reacting methyl-5-(4-cyclopentylaminophenylsulfonyloxy)benzimidazole-2-carbamate (example 19) with methylamine (2.0 M in tetrahydrofuran). (LC/MS analysis: retention time=3.30 min., mass spectrum: 430.27, [M+H] + ).
Example 32
N-[5-(4-cyclopentylaminophenylsulfonyloxy)-1H-benzimidazole-2-yl]-dimethylurea
[0686]
[0687] Title compound was obtained by reacting 10 mg of methyl-5-(4-cyclopentylaminophenylsulfonyloxy)benzimidazole-2-carbamate (example 19) with 50 μl dimethylamine (2.0 M in tetrahydrofuran) and 5 μl 1,8-diazabicyclo[5.4.0]undec-7-ene in 2 ml dimethylformamide in a 24 well Inox plate for high pressure reaction. The reaction mixture was put under a 10 Bars argon pressure and then heated to 80° C. for 4 hours, and then cooled at room temperature. Compounds were put in an assay tube and dimethylformamide was evaporated in a JOUAN RC1010 evaporator. Compound was diluted in 0.5 ml dimethylsulfoxide for LC/MS trigged purification yielding 9 mg of the title compound (LC/MS analysis: retention time=3.35 min., mass spectrum: 444.29, [M+H] + ).
Example 33
4-Cyclopentylamino-benzenesulfonic acid 2-(3-cyclopropyl-ureido)-1H-benzoimidazol-5-yl ester
[0688]
10 mg of methyl-5-(4-cyclopentylaminophenylsulfonyloxy)benzimidazole-2-carbamate (example 19) were combined with 25 μl cyclopropylamine and 10 μl 1,8-diazabicyclo[5.4.0]undec-7-ene in 2 ml N-methylpyrrolidone/tetrahydrofuran (0.8/1.2) in a 24 well Inox plate for high pressure reaction. The reaction mixture was put under a 10 Bars argon pressure and then heated to 60° C. for 40 hours, and then cooled to room temperature. Compounds were put in an assay tube, tetrahydrofuran was evaporated under reduced pressure and compound in N-methylpyrrolidone was directly purified by LC/MS trigged purification yielding 8.7 mg title compound. (LC/MS analysis: retention time=3.66 min., mass spectrum: 456.36, [M+H] + ).
Example 34
4-Cyclopentylamino-benzenesulfonic acid 2-(3-isopropyl-ureido)-1H-benzoimidazol-5-yl ester
[0690]
[0691] In a similar manner to example 33, title compound was obtained by reacting methyl-5-(4-cyclopentylaminophenylsulfonyloxy)benzimidazole-2-carbamate (example 19) with isopropylamine. (LC/MS analysis: retention time=3.78 min., mass spectrum: 458.36, [M+H] + ).
Example 35
4-Cyclopentylamino-benzenesulfonic acid 2-(3-butyl-ureido)-1H-benzoimidazol-5-yl ester
[0692]
[0693] In a similar manner to example 33, title compound was obtained by reacting methyl-5-(4-cyclopentylaminophenylsulfonyloxy)benzimidazole-2-carbamate (example 19) with butylamine. (LC/MS analysis: retention time=3.90 min., mass spectrum: 472.39, [M+H] + ).
Example 36
4-Imidazol-1-yl-benzenesulfonic acid 2-[3-(2-fluoro-phenyl)-ureido]-1H-benzoimidazol-5-yl ester
[0694]
[0695] In a similar manner to example 30, title compound was obtained by reacting methyl-5-(4-[imidazolyl]-phenylsulfoxy)benzimidazole-2-carbamate (example 4) with 2-fluoro-aniline. (LC/MS analysis: retention time=3.03 min., mass spectrum: 493.28, [M+H] + ).
Example 37
4-Cyclopentylamino-benzenesulfonic acid 2-[3-(2-fluoro-phenyl)-ureido]-1H-benzoimidazol-5-yl ester
[0696]
[0697] In a similar manner to example 33, title compound was obtained by reacting methyl-5-(4-cyclopentylaminophenylsulfonyloxy)benzimidazole-2-carbamate (example 19) with 2-fluoro-aniline. (LC/MS analysis: retention time=3.99 min., mass spectrum: 510.32, [M+H] + ).
Example 38
4-Cyclopentylamino-benzenesulfonic acid 2-[3-(3-methoxy-phenyl)-ureido]-1H-benzoimidazol-5-yl ester
[0698]
[0699] In a similar manner to example 33, title compound was obtained by reacting methyl-5-(4-cyclopentylaminophenylsulfonyloxy)benzimidazole-2-carbamate (example 19) with m-anisidine (LC/MS analysis: retention time=4.02 min., mass spectrum: 522.33, [M+H] + ).
Example 39
4-Cyclopentylamino-benzenesulfonic acid 2-[3-(4-methoxy-phenyl)-ureido]-1H-benzoimidazol-5-yl ester
[0700]
[0701] In a similar manner to example 33, title compound was obtained by reacting methyl-5-(4-cyclopentylaminophenylsulfonyloxy)benzimidazole-2-carbamate (example 19) with p-anisidine (LC/MS analysis: retention time=3.97 min., mass spectrum: 522.34, [M+H] + ).
Example 40
4-Cyclopentylamino-benzenesulfonic acid 2-[3-(4-chloro-phenyl)-ureido]-1H-benzoimidazol-5-yl ester
[0702]
[0703] In a similar manner to example 33, title compound was obtained by reacting methyl-5-(4-cyclopentylaminophenylsulfonyloxy)benzimidazole-2-carbamate (example 19) with 4-chloroaniline. (LC/MS analysis: retention time=4.20 min., mass spectrum: 526.28, [M+H] + ).
Example 41
4-Cyclopentylamino-benzenesulfonic acid 2-[3-(3-fluoro-benzyl)-ureido]-1H-benzoimidazol-5-yl ester
[0704]
[0705] In a similar manner to example 33, title compound was obtained by reacting methyl-5-(4-cyclopentylaminophenylsulfonyloxy)benzimidazole-2-carbamate (example 19) with 3-fluorobenzylamine. (LC/MS analysis: retention time=3.96 min., mass spectrum: 524.33, [M+H] + ).
Example 42
4-Cyclopentylamino-benzenesulfonic acid 2-[3-(3-chloro-phenyl)-ureido]-1H-benzoimidazol-5-yl ester
[0706]
[0707] In a similar manner to example 33, title compound was obtained by reacting methyl-5-(4-cyclopentylaminophenylsulfonyloxy)benzimidazole-2-carbamate (example 19) with 3-chloroaniline. (LC/MS analysis: retention time=4.21 min., mass spectrum: 526.28, [M+H] + ).
Example 43
4-Cyclopentylamino-benzenesulfonic acid 2-(3-isobutyl-ureido)-1H-benzoimidazol-5-yl ester
[0708]
[0709] In a similar manner to example 33, title compound was obtained by reacting methyl-5-(4-cyclopentylaminophenylsulfonyloxy)benzimidazole-2-carbamate (example 19) with isobutylamine. (LC/MS analysis: retention time=3.88 min., mass spectrum: 472.38, [M+H] + ).
Example 44
4-Cyclopentylamino-benzenesulfonic acid 2-[3-(2-dimethylamino-ethyl)-ureido]-1H-benzoimidazol-5-yl ester
[0710]
[0711] In a similar manner to example 33, title compound was obtained by reacting methyl-5-(4-cyclopentylaminophenylsulfonyloxy)benzimidazole-2-carbamate (example 19) with N,N-dimethylethylenediamine. (LC/MS analysis: retention time=3.22 min., mass spectrum: 487.38, [M+H] + ).
Example 45
4-Cyclopentylamino-benzenesulfonic acid 2-(3-ethyl-ureido)-1H-benzoimidazol-5-yl ester;
[0712]
[0713] In a similar manner to example 33, title compound was obtained by reacting methyl-5-(4-cyclopentylaminophenylsulfonyloxy)benzimidazole-2-carbamate (example 19) with ethylamine (33% in water). (LC/MS analysis: retention time=3.64 min., mass spectrum: 444.35, [M+H] + ).
Example 46
{ 3 -[5-(4-Cyclopentylamino-benzenesulfonyloxy)-1H-benzoimidazol-2-yl]-ureido}-acetic acid
[0714]
[0715] In a similar manner to example 33, title compound was obtained by reacting methyl-5-(4-cyclopentylaminophenylsulfonyloxy)benzimidazole-2-carbamate (example 19) with glycine. (LC/MS analysis: retention time=3.48 min., mass spectrum: 474.31, [M+H] + ).
Example 47
4-Imidazol-1-yl-benzenesulfonic acid 2-[3-(2-sulfo-ethyl)-ureido]-1H-benzoimidazol-5-yl ester
[0716]
[0717] In a similar manner to example 30, title compound was obtained by reacting methyl-5-(4-[imidazolyl]-phenylsulfoxy)benzimidazole-2-carbamate (example 4) with 2-aminoethanesulfonic acid. (LC/MS analysis: retention time=2.40 min., mass spectrum: 507.21, [M+H] + ).
Example 48
4-Cyclopentylamino-benzenesulfonic acid 2-[3-(2-methoxy-ethyl)-ureido]-1H-benzoimidazol-5-yl ester
[0718]
[0719] In a similar manner to example 33, title compound was obtained by reacting methyl-5-(4-cyclopentylaminophenylsulfonyloxy)benzimidazole-2-carbamate (example 19) with 2-methoxyethylamine. (LC/MS analysis: retention time=3.60 min., mass spectrum: 474.34, [M+H] + ).
Example 49
4-Cyclopentylamino-benzenesulfonic acid 2-[3-(4-dimethylamino-phenyl)-ureido]-1H-benzoimidazol-5-yl ester
[0720]
[0721] In a similar manner to example 33, title compound was obtained by reacting methyl-5-(4-cyclopentylaminophenylsulfonyloxy)benzimidazole-2-carbamate (example 19) with N,N-dimethyl-1,4-phenylenediamine. (LC/MS analysis: retention time=3.42 min., mass spectrum: 535.34, [M+H] + ).
Example 50
4-Cyclopentylamino-benzenesulfonic acid 2-(3-pyridin-2-ylmethyl-ureido)-1H-benzoimidazol-5-yl ester
[0722]
[0723] In a similar manner to example 33, title compound was obtained by reacting methyl-5-(4-cyclopentylaminophenylsulfonyloxy)benzimidazole-2-carbamate (example 19) with 2-aminomethylpyridine. (LC/MS analysis: retention time=3.30 min., mass spectrum: 507.33, [M+H] + ).
Example 51
4-Cyclopentylamino-benzenesulfonic acid 2-(3-cyclobutyl-ureido)-1H-benzoimidazol-5-yl ester
[0724]
[0725] In a similar manner to example 33, title compound was obtained by reacting methyl-5-(4-cyclopentylaminophenylsulfonyloxy)benzimidazole-2-carbamate (example 19) with cyclobutylamine. (LC/MS analysis: retention time=3.84 min., mass spectrum: 470.36, [M+H] + ).
Example 52
4-Cyclopentylamino-benzenesulfonic acid 2-(3-pyridin-4-ylmethyl-ureido)-1H-benzoimidazol-5-yl ester
[0726]
[0727] In a similar manner to example 33, title compound was obtained by reacting methyl-5-(4-cyclopentylaminophenylsulfonyloxy)benzimidazole-2-carbamate (example 19) with 4-(aminomethyl)pyridine. (LC/MS analysis: retention time=3.24 min., mass spectrum: 507.33, [M+H] + ).
Example 53
4-Cyclopentylamino-benzenesulfonic acid 2-(3-tert-butyl-ureido)-1H-benzoimidazol-5-yl ester
[0728]
[0729] In a similar manner to example 33, title compound was obtained by reacting methyl-5-(4-cyclopentylaminophenylsulfonyloxy)benzimidazole-2-carbamate (example 19) with tert-butylamine. (LC/MS analysis: retention time=3.93 min., mass spectrum: 472.36, [M+H] + ).
Example 54
4-[(Tetrahydro-furan-2-ylmethyl)-amino]-benzenesulfonic acid 2-(3-methyl-ureido)-1H-benzoimidazol-5-yl ester
[0730]
10 mg of methyl-5-(4-[1-tetrathydrofurylmethyl]aminophenyl-sulfonyloxy) benzimidazole-2-carbamate (example 18) were combined with 50 μl methylamine (2.0 M in tetrahydrofuran) and 5 μl 1,8-diazabicyclo[5.4.0]undec-7-ene in 2 ml N-methylpyrrolidone/tetrahydrofuran (1/1) in a 24 well Inox plate for high pressure reaction. The reaction mixture was put under a 10 Bars argon pressure and then heated to 80° C. for 4 hours, and then cooled at room temperature. Compounds were put in an assay tube and tetrahydrofuran was evaporated under reduce pressure and compound in N-methylpyrrolidone were directly purified by preparative LCMS in conditions described above. After purification, solution were dry-concentrated in a JOUAN RC1010 evaporator. (LC/MS analysis: retention time=2.91 min., mass spectrum: 446.07, [M+H] + ).
Example 55
4-Fluoro-benzenesulfonic acid 2-(cyclopropanecarbonyl-amino)-1H-benzoimidazol-5-yl ester
[0732]
[0733] step 1: 10 g of 4-amino-3-nitrophenol in 180 ml of ethanol were hydrogenated under 40 bars pressure at 23° C. temperature with catalytic amound of palladium on carbon. Reaction was performed in an Inox flask for high pressure. After hydrogen uptake was complete, the catalyst was filtered off with suction, washed with methanol and the filtrate was concentred under reduced pressure yielding 8 g of crude 3,4-diaminophenol.
[0734] Step 2: 5.75 g of 3,4-diaminophenol were combined with 15.5 g of 1,3-bis(tert-butoxycarbonyl)-2-methyl-2-thiopseudourea in 150 ml methanol and 22 ml acetic acid in a round bottom flask. The reaction mixture was heated to reflux with stirring for 3 hours. Solvents were then evaporated under reduce pressure yielding 7.13 g crude (5-hydroxy-1H-benzoimidazol-2-yl)-carbamic acid tert-butyl ester. Step 3: 5.98 g of (5-hydroxy-1H-benzoimidazol-2-yl)-carbamic acid tert-butyl ester were combinated with 4.67 g of 4-fluorobenzenesulfonyl chloride and 6.75 ml of trietylamine in 100 ml acetone. The reaction mixture was stirred at room temperature for 1 hour. Solvents were evaporated under reduced pressure yielding 6.45 g crude 4-fluoro-benzenesulfonic acid 2-tert-butoxycarbonylamino-1H-benzoimidazol-5-yl ester.
[0735] Step 4: 6.45 g of 4-fluoro-benzenesulfonic acid 2-tert-butoxycarbonylamino-1H-benzoimidazol-5-yl ester were combined with 15 ml trifluoroacetic acid in 60 ml dichloromethane. The reaction mixture was stirred overnight at room temperature. Solvents were evaporated under reduced pressure. The residue was washed with ethyl ether and dried on glass frit yielding 6.58 g of 4-fluoro-benzenesulfonic acid 2-amino-1H-benzoimidazol-5-yl ester trifluoroacetic acid salt.
[0736] Step 5: 5.53 g of 4-fluoro-benzenesulfonic acid 2-amino-1H-benzoimidazol-5-yl ester trifluoroacetic acid salt were combinated with 1.8 ml of cyclopropanecarbonylchloride and 5 ml triethylamine in 75 ml dichloromethane. Reaction mixture was stirred at room temperature for 1 hour. Solvents were evaporated under reduced pressure. The residue was then taken up in dichloromethane, washed with water and dried with magnesium sulfate. Dichloromethane was evaporated under reduced pressure and precipitate obtained was dried on glass frit yielding 4.88 g of 4-fluoro-benzenesulfonic acid 2-amino-3-cyclopropanecarbonyl-3H-benzoimidazol-5-yl ester.
[0737] Step 6: 3.27 g of 4-fluoro-benzenesulfonic acid 2-amino-3-cyclopropanecarbonyl-3H-benzoimidazol-5-yl ester; were combinated with 106 mg of 4-(dimethylamino)pyridine in 80 ml acetonitrile. the reaction mixture was heated at 85° C. temperature for 72 hours with stirring. Yellow solution obtained was diluted in dichloromethane, washed with water and dried under magnesium sulfate. Solvents were evaporated under reduced pressure yielding 3.19 g of the title compound.
Example 56
Preparation of 4-[(1-Ethyl-pyrrolidin-2-ylmethyl)-amino]-benzenesulfonic acid 2-(cyclopropanecarbonyl-amino)-1H-benzoimidazol-5-yl ester.
[0738]
[0739] Title compound was obtained by reacting 12 mg of 4-fluoro-benzenesulfonic acid 2-(cyclopropanecarbonyl-amino)-1H-benzoimidazol-5-yl ester (example 55) with 21 mg of 2-(aminomethyl)-1-ethylpyrrolidine and 50 mg cesium carbonate in 600 μl dimethylsulfoxide. Reaction was performed in a 24 well Inox plate for high pressure. The reaction mixture was put under 10 bars argon pressure and then heated to 110° C. for 50 hours. Cesium carbonate was filtered off and compound in DMSO was directly purified by LCMS triggered purification yielding 10.7 mg title compound. (LC/MS analysis: retention time=2.58 min, mass spectrum: 483.99, [M+H] + .
Example 57
[0740] By using a method similar to that for the preparation of example 30, combining methyl-5-(4-[1-imidazolyl]-phenylsulfonyloxy)benzimidazole-2-carbamate precursor (example 4) with suitable amine were obtained the following compounds that were characterized by analytical LC/MS ([M+H] + and retention time given in the following table.
n o Precursor Retention example example Amine compound [M + H] + time (min) 57-a 4 4-Imidazol-1-yl- benzenesulfonic acid 2-(3- phenyl-ureido)-1H- benzoimidazol-5-yl ester 475.23 2.75 57-b 4 4-Imidazol-1-yl- benzenesulfonic acid 2-(3- cyclohexyl-ureido)-1H- benzoimidazol-5-yl ester 481.28 2.76 57-c 4 4-Imidazol-1-yl- benzenesulfonic acid 2-(3- cyclopentyl-ureido)-1H- benzoimidazol-5-yl ester 467.24 2.62 57-d 4 4-Imidazol-1-yl- benzenesulfonic acid 2-[3- (3-fluoro-phenyl)-ureido]- 1H-benzoimidazol-5-yl ester 493.22 2.87 57-e 4 4-Imidazol-1-yl- benzenesulfonic acid 2-[3- (2-hydroxy-ethyl)- ureido]-1H- benzoimidazol-5-yl ester 443.23 2.32 57-f 4 4-Imidazol-1-yl- benzenesulfonic acid 2-[3- (4-fluoro-phenyl)-ureido]- 1H-benzoimidazol-5-yl ester 493.22 2.80 57-g 4 4-Imidazol-1-yl- benzenesulfonic acid 2-[3- (2-chloro-benzyl)-ureido]- 1H-benzoimidazol-5-yl ester 523.25 3.08 57-h 4 4-Imidazol-1-yl- benzenesulfonic acid 2-[3- (2-fluoro-benzyl)-ureido]- 1H-benzoimidazol-5-yl ester 507.28 3.00 57-i 4 4-Imidazol-1-yl- benzenesulfonic acid 2- [(azetidine-1-carbonyl)- amino]-1H- benzoimidazol-5-yl ester 439.31 2.55 57-j 4 4-Imidazol-1-yl- benzenesulfonic acid 2-(3- pyridin-3-ylmethyl-ureido)- 1H-benzoimidazol-5-yl ester 490.31 2.39 57-k 4 4-Imidazol-1-yl- benzenesulfonic acid 2-{3- [3-(4-methyl-piperazin- 1-yl)-propyl]-ureido}-1H- benzoimidazol-5-yl ester 539.36 2.34 57-l 4 4-Imidazol-1-yl- benzenesulfonic acid 2-(3- benzyl-ureido)-1H- benzoimidazol-5-yl ester 489.25 2.71
Example 58
[0741] By using a method similar to that for the preparation of example 33, combining methyl-5-(4-cyclopentylaminophenylsulfonyloxy)benzimidazole-2-carbamate (example 19) with suitable amine were obtained the following compounds that were characterized by analytical LC/MS ([M+H] + and retention time given in the following table).
n o Precursor Retention example example Amine compound [M + H] + time (min) 58-a 19 4-Cyclopentylamino- benzenesulfonic acid 2-(3- phenyl-ureido)-1H- benzoimidazol-5-yl ester 492.28 3.77 58-b 19 4-Cyclopentylamino- benzenesulfonic acid 2-(3- cyclohexyl-ureido)-1H- benzoimidazol-5-yl ester; 498.31 3.79 58-c 19 4-Cyclopentylamino- benzenesulfonic acid 2-(3- cyclopentyl-ureido)-1H- benzoimidazol-5-yl ester 484.29 3.68 58-d 19 4-Cyclopentylamino- benzenesulfonic acid 2-[3- (3-fluoro-phenyl)-ureido]- 1H-benzoimidazol-5-yl ester 510.25 3.87 58-e 19 4-Cyclopentylamino- benzenesulfonic acid 2-[3- (2-hydroxy-ethyl)- ureido]-1H- benzoimidazol-5-yl ester 460.28 3.17 58-f 19 4-Cyclopentylamino- benzenesulfonic acid 2-[3- (4-fluoro-phenyl)-ureido]- 1H-benzoimidazol-5-yl ester 510.24 3.80 58-g 19 4-Cyclopentylamino- benzenesulfonic acid 2-[3- (2-chloro-benzyl)-ureido]- 1H-benzoimidazol-5-yl ester 540.28 4.05 58-h 19 4-Cyclopentylamino- benzenesulfonic acid 2-[3- (2-fluoro-benzyl)-ureido]- 1H-benzoimidazol-5-yl ester 524.33 3.97 58-i 19 4-Cyclopentylamino- benzenesulfonic acid 2- [(azetidine-1-carbonyl)- amino]-1H-benzoimidazol- 5-yl ester 456.37 3.60 58-j 19 4-Cyclopentylamino- benzenesulfonic acid 2-(3- pyridin-3-ylmethyl-ureido)- 1H-benzoimidazol-5-yl ester 507.35 3.24 58-k 19 4-Cyclopentylamino- benzenesulfonic acid 2- {3-[3-(4-methyl-piperazin- 1-yl)-propyl]-ureido}-1H- benzoimidazol-5-yl ester 556.39 3.09 58-l 19 4-Cyclopentylamino- benzenesulfonic acid 2-(3- benzyl-ureido)-1H- benzoimidazol-5-yl ester 506.31 3.70 58-m 19 4-{3-[5-(4-Cyclopentylamino- benzenesulfonyloxy)-1H- benzoimidazol-2-yl]- ureido}-butyric acid methyl ester 516.31 3.74 58-n 19 4-{3-[5-(4-Cyclopentylamino- benzenesulfonyloxy)-1H- benzoimidazol-2-yl]- ureido}-butyric acid ethyl ester 530.30 3.84 58-o 19 4-{3-[5-(4-Cyclopentylamino- benzenesulfonyloxy)-1H- benzoimidazol-2-yl]- ureido}-acetic acid methyl ester 488.26 3.65 58-p 19 4-Cyclopentylamino- benzenesulfonic acid 2-[3- (3-imidazol-1-yl-propyl)- ureido]-1H-benzoimidazol- 5-yl ester 524.30 3.29 58-q 19 1-[5-(4-Cyclopentylamino- benzenesulfonyloxy)-1H- benzoimidazol-2S- ylcarbamoyl]-pyrrolidine- 2-carboxylic acid 514.27 3.56 58-r 19 1-[5-(4-Cyclopentylamino- benzenesulfonyloxy)-1H- benzoimidazol-2S-yl- carbamoyl]-pyrrolidine- 2-carboxylic acid methyl ester 528.27 3.79 58-s 19 4-Cyclopentylamino- benzenesulfonic acid 2-(3- carbamoylmethyl-ureido)- 1H-benzoimidazol-5-yl ester 473.28 3.38 58-t 19 1-[5-(4-Cyclopentylamino- benzenesulfonyloxy)-1H- benzoimidazol-2-yl- carbamoyl]-piperidine-4- carboxylic acid ethyl ester 556.29 3.93 58-u 19 4-Cyclopentylamino- benzenesulfonic acid 2-(3- piperidin-4-ylmethyl- ureido)-1H-benzoimidazol- 5-yl ester 513.33 3.25 58-v 19 4-Cyclopentylamino- benzenesulfonic acid 2-[3- (2-morpholin-4-yl-ethyl)- ureido]-1H-benzoimidazol- 5-yl ester 529.31 3.27 58-w 19 4-Cyclopentylamino- benzenesulfonic acid 2-[3- (2-amino-2-methyl-propyl)- ureido]-1H-benzoimidazol- 5-yl ester 487.32 3.25 58-x 19 4-Cyclopentylamino- benzenesulfonic acid 2-[3- (4trans-hydroxy-cyclohexyl)- ureido]-1H-benzoimidazol- 5-yl ester 514.30 3.54 58-y 19 4-Cyclopentylamino- benzenesulfonic acid 2-[3- (3-hydroxy-propyl)-ureido]- 1H-benzoimidazol-5-yl ester 474.28 3.46 58-z 19 4-Cyclopentylamino- benzenesulfonic acid 2-[3- (1,1-dimethyl-propyl)-ureido]- 1H-benzoimidazol-5-yl ester 486.33 4.08 58-aa 19 4-Cyclopentylamino- benzenesulfonic acid 2-{3-[2- (2-hydroxy-ethylamino)- ethyl]-ureido}-1H- benzoimidazol-5-yl ester 503.30 3.19 58-ab 19 4-Cyclopentylamino- benzenesulfonic acid 2-[3- (4-hydroxy-butyl)-ureido]-1H- benzoimidazol-5-yl ester 488.29 3.49 58-ac 19 4-Cyclopentylamino- benzenesulfonic acid 2- {3-[3-(2-oxo-pyrrolidin-1- yl)-propyl]-ureido}-1H- benzoimidazol-5-yl ester 541.29 3.54 58-ad 19 4-Cyclopentylamino- benzenesulfonic acid 2-[3- (2-carbamoyl-ethyl)-ureido]- 1H-benzoimidazol-5-yl ester 487.30 3.40 58-ac 19 4-Cyclopentylamino- benzenesulfonic acid 2- [(2S-carbamoyl-pyrrolidine- 1-carbonyl)-amino]-1H- benzoimidazol-5-yl ester 513.30 3.42 58-af 19 4-Cyclopentylamino- benzenesulfonic acid 2- {3-[2-(2-hydroxy-ethoxy)- ethyl]-ureido}-1H- benzoimidazol-5-yl ester 504.30 3.46 58-ag 19 4-Cyclopentylamino- benzenesulfonic acid 2-[3- (3-pyrrolidin-1-yl-propyl)- ureido]-1H- benzoimidazol-5-yl ester 527.35 3.33 58-ah 19 4-Cyclopentylamino- benzenesulfonic acid 2-[3- (1-ethyl-pyrrolidin-2- ylmethyl)-ureido]-1H- benzoimidazol-5-yl ester 527.35 3.30 58-ai 19 4-Cyclopentylamino- benzenesulfonic acid 2-[3- (2-pyrrolidin-1-yl-ethyl)- ureido]-1H- benzoimidazol-5-yl ester 513.34 3.29 58-aj 19 4-Cyclopentylamino- benzenesulfonic acid 2-[3- (2-piperidin-1-yl-ethyl)- ureido]-1H- benzoimidazol-5-yl ester 527.35 3.33 58-ak 19 4-Cyclopentylamino- benzenesulfonic acid 2-[3- (2-hydroxy-1-methyl- ethyl)-ureido]-1H- benzoimidazol-5-yl ester 474.30 3.51 58-al 19 4-Cyclopentylamino- benzenesulfonic acid 2-[3- (2-isopropylamino-ethyl)- ureido]-1H- benzoimidazol-5-yl ester 501.34 3.31 58-am 19 4-Cyclopentylamino- benzenesulfonic acid 2-[3- (2-diethylamino-ethyl)- ureido]-1H- benzoimidazol-5-yl ester 515.34 3.31 58-an 19 2-{3-[5-(4-Cyclopentylamino- benzenesulfonyloxy)-1H- benzoimidazol-2-yl]- ureido}-3S-hydroxy- propionic acid methyl ester 518.27 3.55
Example 59
[0742] By using a method similar to that for the preparation of example 54, combining methyl-5-(4-[1-tetrathydrofurylmethyl]aminophenyl-sulfonyloxy)benzimidazole-2-carbamate (example 18) with suitable amine were obtained the following compounds that were characterized by analytical LC/MS ([M+H] + and retention time given in the following table).
n o Precursor Retention example example Amine compound [M + H] + time (min) 59-a 18 4-[(Tetrahydro-furan-2- ylmethyl)-amino]- benzenesulfonic acid 2-(3- carbamoylmethyl-ureido)- 1H-benzoimidazol-5-yl ester 489.15 2.78 59-b 18 4-[(Tetrahydro-furan-2- ylmethyl)-amino]- benzenesulfonic acid 2-[3- (2-hydroxy-ethyl)-ureido]-1H- benzoimidazol-5-yl ester 476.15 2.91 59-c 18 4-[(Tetrahydro-furan-2- ylmethyl)-amino]- benzenesulfonic acid 2-[3- (3-hydroxy-propyl)-ureido]-1H- benzoimidazol-5-yl ester 490.18 2.89 59-d 18 4-[(Tetrahydro-furan-2- ylmethyl)-amino]- benzenesulfonic acid 2-[3- (4-hydroxy-butyl)-ureido]-1H- benzoimidazol-5-yl ester 504.19 3.44 59-e 18 4-[(Tetrahydro-furan-2- ylmethyl)-amino]-benzenesulfonic acid 2-[3-(2-methoxy-1- methyl-ethyl)-ureido]-1H- benzoimidazol-5-yl ester 504.19 3.11 59-f 18 4-[(Tetrahydro-furan-2- ylmethyl)-amino]-benzenesulfonic acid 2-[3-(1-ethyl-pyrrolidin- 2-ylmethyl)-ureido]-1H- benzoimidazol-5-yl ester 543.24 2.89 59-g 18 4-[(Tetrahydro-furan-2- ylmethyl)-amino]-benzenesulfonic acid 2-[3-(2-pyrrolidin-1-yl- ethyl)-ureido]-1H- benzoimidazol-5-yl ester 529.22 2.66 59-h 18 4-[(Tetrahydro-furan-2- ylmethyl)-amino]-benzenesulfonic acid 2-[3-(3-pyrrolidin-1-yl- propyl)-ureido]-1H- benzoimidazol-5-yl ester 543.25 2.73 59-i 18 4-[(Tetrahydro-furan-2- ylmethyl)-amino]-benzenesulfonic acid 2-[3-(2-morpholin-4-yl- ethyl)-ureido]-1H- benzoimidazol-5-yl ester 545.23 2.61 59-j 18 4-[(Tetrahydro-furan-2- ylmethyl)-amino]-benzenesulfonic acid 2-(3-ethyl-ureido)-1H- benzoimidazol-5-yl ester 460.17 3.08 59-k 18 4-[(Tetrahydro-furan-2- ylmethyl)-amino]-benzenesulfonic acid 2-(3-pyridin-2-ylmethyl- ureido)-1H-benzoimidazol-5-yl ester 523.07 2.70 59-l 18 4-[(Tetrahydro-furan-2- ylmethyl)-amino]- benzenesulfonic acid 2-(3- pyridin-3-ylmethyl-ureido)-1H- benzoimidazol-5-yl ester 523.19 2.64 59-m 18 4-[(Tetrahydro-furan-2- ylmethyl)-amino]- benzenesulfonic acid 2- {3-[3-(4-methyl-piperazin- 1-yl)-propyl]-ureido}-1H- benzoimidazol-5-yl ester 572.27 2.60 59-n 18 4-[(Tetrahydro-furan-2- ylmethyl)-amino]- benzenesulfonic acid 2-[3- (2-sulfo-ethyl)-ureido]- 1H-benzoimidazol-5-yl ester 540.13 2.81 59-o 18 4-[(Tetrahydro-furan-2- ylmethyl)-amino]- benzenesulfonic acid 2-(3- cyclobutyl-ureido)-1H- benzoimidazol-5-yl ester 486.19 3.28 59-p 18 4-[(Tetrahydro-furan-2- ylmethyl)-amino]- benzenesulfonic acid 2- {3-[3-(2-oxo-pyrrolidin-1- yl)-propyl]-ureido}-1H- benzoimidazol-5-yl ester 557.23 2.94 59-q 18 4-[(Tetrahydro-furan-2- ylmethyl)-amino]-benzenesulfonic acid 2-{3-[2-(2-hydroxy- ethylamino)-ethyl]-ureido}- 1H-benzoimidazol-5-yl ester 519.21 2.64 59-r 18 4-[(Tetrahydro-furan-2- ylmethyl)-amino]-benzenesulfonic acid 2-[3-(2-piperidin-1-yl- ethyl)-ureido]-1H- benzoimidazol-5-yl ester 543.24 2.74
Example 60
[0743] By using a method similar to that for the preparation of example 56, combining 4-fluoro-benzenesulfonic acid 2-(cyclopropanecarbonyl-amino)-1H-benzoimidazol-5-yl ester (example 55) with suitable amine were obtained the following compounds that were characterized by analytical LC/MS ([M+H] + and retention time given in the following table).
n o Precursor Retention example example Amine compound [M + H] + time (min) 60-a 55 4-Benzylamino-benzenesulfonic acid 2-(cyclopropanecarbonyl- amino)-1H-benzoimidazol-5-yl ester 436.3 3.68 60-b 55 4-Methylamino-benzenesulfonic acid 2-(cyclopropanecarbonyl- amino)-1H-benzoimidazol-5-yl ester 387.3 3.18 60-c 55 4-(2-Hydroxy-ethylamino)- benzenesulfonic acid 2- (cyclopropanecarbonyl- amino)-1H-benzoimidazol-5-yl ester 417.3 2.98 60-d 55 4-(3-Hydroxy-propylamino)- benzenesulfonic acid 2- (cyclopropanecarbonyl- amino)-1H-benzoimidazo1-5-yl ester 431.35 3.04 60-e 55 4-(4-Hydroxy-butylamino)- benzenesulfonic acid 2- (cyclopropanecarbonyl- amino)-1H-benzoimidazol-5-yl ester 445.35 3.10 60-f 55 4-(2-Methoxy-1-methyl- ethylamino)-benzenesulfonic acid 2-(cyclopropanecarbonyl- amino)-1H-benzoimidazol-5-yl ester 445.35 3.41 60-g 55 4-(2-Pyrrolidin-1-yl- ethylamino)-benzenesulfonic acid 2-(cyclopropanecarbonyl- amino)-1H-benzoimidazol-5-yl ester 470.37 2.80 60-h 55 4-(1-Hydroxymethyl- propylamino)-benzenesulfonic acid 2-(cyclopropanecarbonyl- amino)-1H-benzoimidazol-5-yl ester 445.34 3.21 60-i 55 4-(2-Hydroxy-1-methyl- ethylamino)-benzenesulfonic acid 2-(cyclopropanecarbonyl- amino)-1H-benzoimidazol-5-yl ester 431.34 3.08 60-j 55 4-(2-Piperidin-1-yl- ethylamino)-benzenesulfonic acid 2-(cyclopropanecarbonyl- amino)-1H-benzoimidazol-5-yl ester 484.38 2.85 60-k 55 4-(3-Pyrrolidin-1-yl- propylamino)-benzenesulfonic acid 2-(cyclopropanecarbonyl- amino)-1H-benzoimidazol-5-yl ester 484.37 2.85 60-l 55 4-(3-Hydroxy-2,2- dimethyl-propylamino)- benzenesulfonic acid 2- (cyclopropanecarbonyl- amino)-1H-benzoimidazol-5-yl ester 459.34 3.30 60-m 55 4-[(Pyridin-3-yl- methyl)-amino]-benzenesulfonic acid 2-(cyclopropanecarbonyl- amino)-1H-benzoimidazol-5-yl ester 464.30 2.77 60-n 55 4-[3-(4-Methyl-piperazin- 1-yl)-propylamino]- benzenesulfonic acid 2- (cyclopropanecarbonyl- amino)-1H-benzoimidazol-5-yl ester 513.38 2.66 60-o 55 4-(2-Methoxy-benzylamino)- benzenesulfonic acid 2- (cyclopropanecarbonyl- amino)-1H-benzoimidazol-5-yl ester 493.32 3.74 60-p 55 4-(4-Hydroxy-cyclohexylamino)- benzenesulfonic acid 2- (cyclopropanecarbonyl- amino)-1H-benzoimidazol-5-yl ester 471.36 3.11 60-q 55 4-(2-Diethylamino-ethylamino)- benzenesulfonic acid 2- (cyclopropanecarbonyl- amino)-1H-benzoimidazol-5-yl ester 472.37 2.82 60-r 55 4-(1S-Hydroxymethyl- propylamino)-benzenesulfonic acid 2-(cyclopropanecarbonyl- amino)-1H-benzoimidazol-5-yl ester 445.32 3.19 60-s 55 4-(2-Ethylamino-ethylamino)- benzenesulfonic acid 2- (cyclopropanecarbonyl- amino)-1H-benzoimidazol-5-yl ester 444.34 2.75 60-t 55 4-(2-Diisopropylamino- ethylamino)-benzenesulfonic acid 2-(cyclopropanecarbonyl- amino)-1H-benzoimidazol-5-yl ester 500.38 2.91 60-u 55 4-(2-Morpholin-4-yl- ethylamino)-benzenesulfonic acid 2-(cyclopropanecarbonyl- amino)-1H-benzoimidazol-5-yl ester 486.34 2.76 60-v 55 4-(1-Aza-bicyclo[2.2.2]- oct-3-ylamino)-benzenesulfonic acid 2-(cyclopropane-carbonyl- amino)-1H-benzoimidazol-5-yl ester 482.35 2.82 60-w 55 4-(2-Phenylamino-ethylamino)- benzenesulfonic acid 2- (cyclopropanecarbonyl- amino)-1H-benzoimidazol-5-yl ester 492.34 3.34 60-x 55 4-(1-Benzyl-pyrrolidin-3- acid 2-(cyclopropane- carbonyl-amino)-1H- benzoimidazol-5-yl ester 532.35 3.05 60-y 55 4-(2R-Carbamoyl-pyrrolidin- 1-yl)-benzenesulfonic acid 2- (cyclopropanecarbonyl- amino)-1H-benzoimidazol-5-yl ester 470.32 3.00 60-z 55 4-(3-Dimethylamino- propylamino)-benzenesulfonic acid 2-(cyclopropanecarbonyl- amino)-1H-benzoimidazol-5-yl ester 458.36 2.79 60-aa 55 4-(2-Piperazin-1-yl- ethylamino)-benzene-sulfonic acid 2-(cyclopropanecarbonyl- amino)-1H-benzoimidazol-5-yl ester 485.37 2.63 60-ab 55 4-(2-Carbamoyl-cyclohexylamino)- benzenesulfonic acid 2- (cyclopropanecarbonyl- amino)-1H-benzoimidazol-5-yl ester 498.34 3.24 60-ac 55 4-(2-Acetylamino-ethylamino)- benzenesulfonic acid 2- (cyclopropanecarbonyl- amino)-1H-benzoimidazol-5-yl ester 458.32 2.95 60-ad 55 4-[2-(2-Amino-ethylamino)- ethylamino]-benzenesulfonic acid 2-(cyclopropanecarbonyl- amino)-1H-benzoimidazol-5-yl ester 459.34 2.60 60-ae 55 4-[3-(2-Oxo-pyrrolidin-1- yl)-propylamino]- benzenesulfonic acid 2- (cyclopropanecarbonyl- amino)-1H-benzoimidazol-5-yl ester 498.34 3.14 60-af 55 4-[2-(1H-Imidazol-4-yl)- ethylamino]-benzenesulfonic acid 2-(cyclopropanecarbonyl- amino)-1H-benzoimidazol-5-yl ester 467.31 2.79 60-ag 55 4-[(Pyridin-2-ylmethyl)- amino]-benzenesulfonic acid 2-(cyclopropane- carbonyl-amino)-1H- benzoimidazol-5-yl ester 464.31 2.80 60-ah 55 4-Cyclobutylamino- benzenesulfonic acid 2- (cyclopropanecarbonyl- amino)-1H-benzoimidazol-5-yl ester 427.31 3.63 60-ai 55 4-[2-(2-Hydroxy-ethoxy)- ethylamino]-benzenesulfonic acid 2-(cyclopropanecarbonyl- amino)-1H-benzoimidazol-5-yl ester 461.34 3.01 60-aj 55 4-(2,3-Dihydroxy-propylamino)- benzenesulfonic acid 2- (cyclopropanecarbonyl- amino)-1H-benzoimidazol-5-yl ester 447.31 2.84 60-ak 55 4-(2-Imidazol-1-yl-ethylamino)- benzenesulfonic acid 2- (cyclopropanecarbonyl- amino)-1H-benzoimidazol-5-yl ester 467.32 2.78 60-al 55 4-[2-(2-Hydroxy-ethylamino)- ethylamino]-benzenesulfonic acid 2-(cyclopropanecarbonyl- amino)-1H-benzoimidazol-5-yl ester 460.34 2.70 60-am 55 4-(2-Methoxy-ethylamino)- benzenesulfonic acid 2- (cyclopropanecarbonyl- amino)-1H-benzoimidazol-5-yl ester 431.32 3.27 60-an 55 4-(2-Dimethylamino-1- methyl-ethylamino)- benzenesulfonic acid 2- (cyclopropanecarbonyl- amino)-1H-benzoimidazol-5-yl ester 458.36 2.79 60-ao 55 4-(Pyrrolidin-3-ylamino)- benzenesulfonic acid 2- (cyclopropanecarbonyl- amino)-1H-benzoimidazol-5-yl ester 442.35 2.75 60-ap 55 4-[2-(1H-Indol-3-yl)- ethylamino]-benzenesulfonic acid 2-(cyclopropanecarbonyl- amino)-1H-benzoimidazol-5-yl ester 516.32 3.75 60-aq 55 4-(2-Dimethylamino- ethylamino)-benzenesulfonic acid 2-(cyclopropanecarbonyl- amino)-1H-benzoimidazol-5-yl ester 444.35 2.74 60-ar 55 4-(2-Phenoxy-ethylamino)- benzenesulfonic acid 2- (cyclopropanecarbonyl- amino)-1H-benzoimidazol-5-yl ester 493.32 3.78 60-as 55 4-(Bicyclo[2.2.1]hept-2R- ylamino)-benzenesulfonic acid 2-(cyclopropane- carbonyl-amino)-1H- benzoimidazol-5-yl ester 467.35 3.95 60-at 55 4-(2-Methylamino-ethylamino)- benzenesulfonic acid 2- (cyclopropanecarbonyl- amino)-1H-benzoimidazol-5-yl ester 430.35 2.74 60-au 55 4-(2-Propylamino-ethylamino)- benzenesulfonic acid 2- (cyclopropanecarbonyl- amino)-1H-benzoimidazol-5-yl ester 458.36 2.84 60-av 55 4-(1-Methyl-2-phenoxy- ethylamino)-benzenesulfonic acid 2-(cyclopropanecarbonyl- amino)-1H-benzoimidazol-5-yl ester 507.33 3.89 60-aw 55 4-[(Piperidin-4-ylmethyl)- amino]-benzenesulfonic acid 2-(cyclopropane- carbonyl-amino)-1H- benzoimidazol-5-yl ester 470.36 2.84 60-ax 55 4-(4-Methoxy-benzylamino)- benzenesulfonic acid 2- (cyclopropanecarbonyl- amino)-1H-benzoimidazol-5-yl ester 493.31 3.68 60-ay 55 4-(1H-Benzoimidazol-5- ylamino)-benzenesulfonic acid 2-(cyclopropanecarbonyl- amino)-1H-benzoimidazol-5-yl ester 489.29 2.80 60-az 55 4-(3-Methoxy-propylamino)- benzenesulfonic acid 2- (cyclopropanecarbonyl- amino)-1H-benzoimidazol-5-yl ester 445.10 3.17 60-ba 55 4-(2,2-Dimethoxy-ethylamino)- benzenesulfonic acid 2- (cyclopropanecarbonyl- amino)-1H-benzoimidazol-5-yl ester 461.11 3.20 60-bb 55 4-(4-Dimethylamino- phenylamino)-benzenesulfonic acid 2-(cyclopropanecarbonyl- amino)-1H-benzoimidazol-5-yl ester 492.12 2.87 60-bc 55 4-(3-Methoxy-benzylamino)- benzenesulfonic acid 2- (cyclopropanecarbonyl- amino)-1H-benzoimidazol-5-yl ester 493.10 3.69 60-bd 55 4-(4-Pyrrolidin-1-yl- butylamino)-benzenesulfonic acid 2-(cyclopropanecarbonyl- amino)-1H-benzoimidazol-5-yl ester 498.16 2.64 60-be 55 4-(2,3-Dimethoxy-benzylamino)- benzenesulfonic acid 2- (cyclopropanecarbonyl- amino)-1H-benzoimidazol-5-yl ester 523.11 3.80 60-bf 55 4-Prop-2-ynylamino- benzenesulfonic acid 2- (cyclopropanecarbonyl- amino)-1H-benzoimidazol-5-yl ester 411.07 3.15 60-bg 55 4-[4-(2-Hydroxy-ethyl)- piperazin-1-yl]- benzenesulfonic acid 2- (cyclopropanecarbonyl- amino)-1H-benzoimidazol-5-yl ester 464.09 2.48 60-bh 55 4-[(Pyridin-4-ylmethyl)- amino]-benzenesulfonic acid 2-(cyclopropane- carbonyl-amino)-1H- benzoimidazol-5-yl ester 464.09 2.48 60-bi 55 4-[2-(Ethyl-m-tolyl- amino)-ethylamino]- benzenesulfonic acid 2- (cyclopropanecarbonyl- amino)-1H-benzoimidazol-5-yl ester 534.18 3.10 60-bj 55 4-(2-Hydroxy-cyclohexylamino)- benzenesulfonic acid 2- (cyclopropanecarbonyl- amino)-1H-benzoimidazol-5-yl ester 471.13 3.25 60-bk 55 4-(3-Dimethylamino-2,2- dimethyl-propylamino)- benzenesulfonic acid 2- (cyclopropanecarbonyl- amino)-1H-benzoimidazol-5-yl ester 486.18 2.64 60-bl 55 4-[3-(2-Hydroxy-ethylamino)- propylamino]-benzenesulfonic acid 2-(cyclopropanecarbonyl- amino)-1H-benzoimidazol-5-yl ester 474.14 2.45 60-bm 55 4-[(Tetrahydro-furan-2RS- ylmethyl)-amino]-benzenesulfonic acid 2-(cyclopropanecarbonyl- amino)-1H-benzoimidazol-5-yl ester; 474.14 3.15 60-bn 55 4-[(Tetrahydro-furan-2R- ylmethyl)-amino]-benzenesulfonic acid 2-(cyclopropanecarbonyl- amino)-1H-benzoimidazol-5-yl ester; 456.87 3.23 60-bo 55 (Tetrahydro-furan-2S- ylmethyl)-amino]-benzenesulfonic acid 2-(cyclopropanecarbonyl- amino)-1H-benzoimidazol-5-yl ester; 456.88 3.48 60-bp 55 4-(2-Butylamino-ethylamino)- benzenesulfonic acid 2- (cyclopropanecarbonyl- amino)-1H-benzoimidazol-5-yl ester 471.92 2.80 60-bq 55 4-(3-Methylamino-propylamino)- benzenesulfonic acid 2- (cyclopropanecarbonyl- amino)-1H-benzoimidazol-5-yl ester 443.90 2.54 60-br 55 4-(1S,2-Dicarbamoyl- ethylamino)-benzenesulfonic acid 2-(cyclopropanecarbonyl- amino)-1H-benzoimidazol-5-yl ester 486.90 2.60 60-bs 55 2-{4-[2-(Cyclopropanecarbonyl- amino)-1H-benzoimidazol-5- yloxysulfonyl]-phenylamino}-3R- hydroxy-propionic acid methyl ester 474.83 2.81 60-bt 55 4-(2-Carbamoyl-ethylamino)- benzenesulfonic acid 2- (cyclopropanecarbonyl- amino)-1H-benzoimidazol-5-yl ester 443.86 2.71 60-bu 55 4-(3-Methoxy-propylamino)- benzenesulfonic acid 2- (cyclopropanecarbonyl- amino)-1H-benzoimidazol-5-yl ester 444.89 3.15 60-bv 55 4-(3,4,5-Trimethoxy-benzylamino)- benzenesulfonic acid 2- (cyclopropanecarbonyl- amino)-1H-benzoimidazol-5-yl ester 552.85 3.46 60-bw 55 4-(Carbamoylmethyl-amino)- benzenesulfonic acid 2- (cyclopropanecarbonyl- amino)-1H-benzoimidazol-5-yl ester 429.88 2.85 60-bx 55 1-{4-[2-(Cyclopropanecarbonyl- amino)-1H-benzoimidazol-5- yloxysulfonyl]-phenyl}- piperidine-4-carboxylic acid ethyl ester 512.87 3.81 60-by 55 4-(2-Amino-2-methyl- propylamino)-benzenesulfonic acid 2-(cyclopropanecarbonyl- amino)-1H-benzoimidazol-5-yl ester 443.92 2.48 60-bz 55 3-{4-[2-(Cyclopropanecarbonyl- amino)-1H-benzoimidazol-5- yloxysulfonyl]-phenylamino}- propionic acid methyl ester 458.88 3.13 60-ca 55 4-(3-Morpholin-4-yl-propylamino)- benzenesulfonic acid 2- (cyclopropanecarbonyl- amino)-1H-benzoimidazol-5-yl ester 499.91 2.56 60-cb 55 4-(5-Hydroxy-pentylamino)- benzenesulfonic acid 2- (cyclopropanecarbonyl- amino)-1H-benzoimidazol-5-yl ester 458.93 3.08 60-cc 55 4-[(5S-Amino-2,2,4S-trimethyl- cyclopentylmethyl)- amino]-benzenesulfonic acid 2-(cyclopropane-carbonyl- amino)-1H-benzoimidazol-5-yl ester 511.94 3.24 60-cd 55 4-(2-Hydroxymethyl- phenylamino)-benzenesulfonic acid 2-(cyclopropanecarbonyl- amino)-1H-benzoimidazol-5-yl ester 2.98 430.91 60-ce 55 4-(4-Ethoxy-phenylamino)- benzenesulfonic acid 2- (cyclopropanecarbonyl- amino)-1H-benzoimidazol-5-yl ester 493.17 3.97 60-cf 55 4-Ethylamino-benzenesulfonic acid 2-(cyclopropanecarbonyl- amino)-1H-benzoimidazol-5-yl ester 401.23 3.42 60-cg 55 4-(2-Sulfo-ethylamino)- benzenesulfonic acid 2- (cyclopropanecarbonyl- amino)-1H-benzoimidazol-5-yl ester 481.00 2.87 60-ch 55 4-{4-[2-(Cyclopropanecarbonyl- amino)-1H-benzoimidazol-5- yloxysulfonyl]-phenylamino}- piperidine-1-carboxylic acid ethyl ester 528.06 3.77 60-ci 55 4-({4-[2-(Cyclopropanecarbonyl- amino)-1H-benzoimidazol-5- yloxysulfonyl]-phenylamino}- methyl)-benzoic acid 507.00 3.30 60-cj 55 4-[(1-Carbamimidoyl-piperidin- 4-ylmethyl)-amino]-benzenesulfonic acid 2-(cyclopropanecarbonyl- amino)-1H-benzoimidazol-5-yl ester 512.10 2.73 60-ck 55 4-{4-[2-(Cyclopropanecarbonyl- amino)-1H-benzoimidazol-5- yloxysulfonyl]-phenyl}- piperazine-1-carboxylic acid tert-butyl ester 542.07 3.85 60-cl 55 3-{4-[2-(Cyclopropanecarbonyl- amino)-1H-benzoimidazol-5- yloxysulfonyl]-phenylamino}- 3-phenyl-propionic acid 521.03 3.38 60-cm 55 4-Piperidin-1-yl-benzenesulfonic acid 2-(cyclopropanecarbonyl- amino)-1H-benzoimidazol-5-yl ester 441.07 3.76 60-cn 55 4-(1-Methyl-4-oxo-imidazolidin-2- ylideneamino)-benzenesulfonic acid 2-(cyclopropanecarbonyl- amino)-1H-benzoimidazol-5-yl ester 468.93 2.45 60-co 55 4-(4-Methyl-piperazin-1- yl)-benzenesulfonic acid 2-(cyclopropanecarbonyl- amino)-1H-benzoimidazol-5-yl ester 456.21 2.94 60-cp 55 4-(3-Hydroxy-pyrrolidin- 1-yl)-benzenesulfonic acid 2-(cyclopropanecarbonyl- amino)-1H-benzoimidazol-5-yl ester 442.95 3.05 60-cq 55 4-(Cyclopropylmethyl- amino)-benzenesulfonic acid 2-(cyclopropanecarbonyl- amino)-1H-benzoimidazol-5-yl ester 426.97 3.61 60-cr 55 4-[(2-Dimethylamino-ethyl)- methyl-amino]-benzenesulfonic acid 2-(cyclopropanecarbonyl- amino)-1H-benzoimidazol-5-yl ester 457.98 2.51 60-cs 55 4-Isobutylamino-benzenesulfonic acid 2-(cyclopropanecarbonyl- amino)-1H-benzoimidazol-5-yl ester 428.99 3.96 60-ct 55 4-[Ethyl-(2-hydroxy-ethyl)- amino]-benzenesulfonic acid 2- (cyclopropanecarbonyl- amino)-1H-benzoimidazol-5-yl ester 444.97 2.96 60-cu 55 4-(2-Hydroxy-1-hydroxymethyl- ethylamino)-benzenesulfonic acid 2-(cyclopropanecarbonyl- amino)-1H-benzoimidazol-5-yl ester 446.93 2.61 60-cv 55 4-Propylamino-benzenesulfonic acid 2-(cyclopropanecarbonyl- amino)-1H-benzoimidazol-5-yl ester 414.96 3.45 60-cw 55 4-Cyclopropylamino- benzenesulfonic acid 2- (cyclopropanecarbonyl- amino)-1H-benzoimidazol-5-yl ester 412.95 3.38 60-cx 55 4-Morpholin-4-yl-benzenesulfonic acid 2-(cyclopropanecarbonyl- amino)-1H-benzoimidazol-5-yl ester 442.95 3.24 60-cy 55 4-[2-(1-Methyl-pyrrolidin- 2-yl)-ethylamino]-benzenesulfonic acid 2-(cyclopropanecarbonyl- amino)-1H-benzoimidazol-5-yl ester 483.99 2.63 60-cz 55 4-[(1,3-Dimethyl-1H-pyrazol- 4-ylmethyl)-amino]-benzenesulfonic acid 2-(cyclopropane-carbonyl- amino)-1H-benzoimidazol-5-yl ester 480.96 2.99 60-da 55 4-(4-Acetylamino-benzylamino)- benzenesulfonic acid 2- (cyclopropanecarbonyl- amino)-1H-benzoimidazol-5-yl ester 519.94 3.45 60-db 55 4-(3-Cyclohexylamino- propylamino)-benzenesulfonic acid 2-(cyclopropanecarbonyl- amino)-1H-benzoimidazol-5-yl ester 512.02 2.78 60-dc 55 4-(3-Ethoxy-propylamino)- benzenesulfonic acid 2- (cyclopropanecarbonyl- amino)-1H-benzoimidazol-5-yl ester 458.98 3.41 60-dd 55 4-Pyrrolidin-1-yl- benzenesulfonic acid 2- (cyclopropanecarbonyl- amino)-1H-benzoimidazol-5-yl ester 426.96 3.53 60-de 55 4-(4-Methyl-benzylamino)- benzenesulfonic acid 2- (cyclopropanecarbonyl- amino)-1H-benzoimidazol-5-yl ester 476.96 3.81 60-df 55 4-[1,4′]Bipiperidinyl-1′- yl-benzenesulfonic acid 2- (cyclopropanecarbonyl- amino)-1H-benzoimidazol-5-yl ester 524.01 2.76 60-dg 55 4-(2-Pyridin-3-yl-pyrrolidin- 1-yl)-benzenesulfonic acid 2- (cyclopropanecarbonyl- amino)-1H-benzoimidazol-5-yl ester 503.96 2.76 60-dh 55 4-(4-Hydroxy-piperidin-1- yl)-benzenesulfonic acid 2-(cyclopropanecarbonyl- amino)-1H-benzoimidazol-5-yl ester 456.97 2.90 60-di 55 4-[(2-Hydroxy-ethyl)- methyl-amino]-benzenesulfonic acid 2-(cyclopropanecarbonyl- amino)-1H-benzoimidazol-5-yl ester 430.97 2.85 60-dj 55 4-(3-Hydroxy-pyridin-2- ylamino)-benzenesulfonic acid 2-(cyclopropane- carbonyl-amino)-1H- benzoimidazol-5-yl ester 465.93 2.88 60-dk 55 4-[(1-Carbamoyl-piperidin-4- ylmethyl)-amino]-benzenesulfonic acid 2-(cyclopropane- carbonyl-amino)-1H- benzoimidazol-5-yl ester 513.00 2.96 60-dl 55 4-(2-Pyrrol-1-yl-ethylamino)- benzenesulfonic acid 2- cyclopropanecarbonyl- amino)-1H-benzoimidazol-5-yl ester 465.97 3.43 60-dm 55 4-(4-Cyclopentyl-piperazin-1- yl)-benzenesulfonic acid 2- (cyclopropanecarbonyl- amino)-1H-benzoimidazol-5-yl ester 510.01 2.88 60-dn 55 4-(2-Propoxy-ethylamino)- benzenesulfonic acid 2- (cyclopropanecarbonyl- amino)-1H-benzoimidazol-5-yl ester 458.99 3.43 60-do 55 4-(3-Cyclohexylamino- propylamino)-benzenesulfonic acid 2-(cyclopropanecarbonyl- amino)-1H-benzoimidazol-5-yl ester 512.03 2.86 60-dp 55 4-(1H-Indol-5-ylamino)- benzenesulfonic acid 2- (cyclopropanecarbonyl- amino)-1H-benzoimidazol-5-yl ester 487.96 2.76 60-dq 55 4-(4-Amino-benzylamino)- benzenesulfonic acid 2- (cyclopropanecarbonyl- amino)-1H-benzoimidazol-5-yl ester 477.94 2.80 60-dr 55 4-(2S-Methoxymethyl-pyrrolidin- 1-yl)-benzenesulfonic acid 2- (cyclopropanecarbonyl- amino)-1H-benzoimidazol-5-yl ester 470.99 3.65 60-ds 55 4-[4-(2-Hydroxy-ethyl)- piperidin-1-yl]-benzenesulfonic acid 2-(cyclopropanecarbonyl- amino)-1H-benzoimidazol-5-yl ester 485.01 3.21 60-dt 55 4-[2-(2-Hydroxy-ethyl)- piperidin-1-yl]-benzenesulfonic acid 2-(cyclopropanecarbonyl- amino)-1H-benzoimidazol-5-yl ester 485.02 3.23 60-du 55 4-(2-Isopropylamino- ethylamino)-benzenesulfonic acid 2-(cyclopropanecarbonyl- amino)-1H-benzoimidazol-5-yl ester 458.01 2.73 60-dv 55 3-{4-[2-(Cyclopropanecarbonyl- amino)-1H-benzoimidazol-5- yloxysulfonyl]-phenyl- amino}-propionic acid 444.95 2.81 60-dw 55 4-[Methyl-(2-methylamino-ethyl)- amino]-benzenesulfonic acid 2-(cyclopropane- carbonyl-amino)-1H- benzoimidazol-5-yl ester 443.99 2.46 60-dx 55 4-(3-Acetylamino-pyrrolidin- 1-yl)-benzenesulfonic acid 2- (cyclopropanecarbonyl- amino)-1H-benzoimidazol-5-yl ester 483.98 2.88 60-dy 55 {4-[2-(Cyclopropane-carbonyl- amino)-1H-benzoimidazol-5- yloxy-sulfonyl]-phenylamino}- acetic acid 430.94 2.88 60-dz 55 4-(4-Hydroxy-piperidin-1- yl)-benzenesulfonic acid 2-(cyclopropanecarbonyl- amino)-1H-benzoimidazol-5-yl ester 456.98 2.96 60-ea 55 4-(4-Dimethylamino-benzylamino)- benzenesulfonic acid 2- (cyclopropanecarbonyl- amino)-1H-benzoimidazol-5-yl ester 506.02 2.78 60-eb 55 4-(3-Imidazol-1-yl-propylamino)- benzenesulfonic acid 2- (cyclopropanecarbonyl- amino)-1H-benzoimidazol-5-yl ester 480.98 2.78 60-ec 55 4-(Quinoxalin-5-ylamino)- benzenesulfonic acid 2- (cyclopropane-carbonyl- amino)-1H-benzoimidazol-5-yl ester 500.96 3.41 60-ed 55 4-[4-(2-Hydroxy-ethyl)- piperazin-1-yl]-benzenesulfonic acid 2-(cyclopropanecarbonyl- amino)-1H-benzoimidazol-5-yl ester 486.00 2.48 60-ef 55 4-(2-Hydroxy-1,1-dimethyl- ethylamino)-benzenesulfonic acid 2-(cyclopropanecarbonyl- amino)-1H-benzoimidazol-5-yl ester 444.98 2.49 60-eg 55 1-{4-[2-(Cyclopropanecarbonyl- amino)-1H-benzoimidazol-5- yloxysulfonyl]-phenyl}- piperidine-4-carboxylic acid 484.98 3.11 60-eh 55 6-{4-[2-(Cyclopropanecarbonyl- amino)-1H-benzoimidazol-5- yloxysulfonyl]-phenylamino}- hexanoic acid methyl ester 500.99 3.70 60-ei 55 4-[4-(4-Methoxy-phenyl)- piperazin-1-yl]-benzenesulfonic acid 2-(cyclopropanecarbonyl- amino)-1H-benzoimidazol-5-yl ester 547.99 3.23 60-ej 55 4-[4-(2-Methoxy-ethyl)- piperazin-1-yl]-benzenesulfonic acid 2-(cyclopropanecarbonyl- amino)-1H-benzoimidazol-5-yl ester 500.01 2.51 60-ek 55 4-[(2-Hydroxy-ethyl)-phenyl- amino]-benzenesulfonic acid 2- (cyclopropanecarbonyl-amino)-1H- benzoimidazol-5-yl ester 492.96 3.65 60-el 55 4-[(Furan-2-ylmethyl)- amino]-benzenesulfonic acid 2-(cyclopropane-carbonyl-amino)- 1H-benzoimidazol-5-yl ester 452.94 3.38 60-em 55 4-(4-Carbamoyl-piperidin- 1-yl)-benzenesulfonic acid 2-(cyclopropanecarbonyl- amino)-1H-benzoimidazol-5-yl ester 483.98 2.90 60-en 55 4-(3-Methyl-piperazin-1- yl)-benzenesulfonic acid 2-(cyclopropanecarbonyl- amino)-1H-benzoimidazol-5-yl ester 456.00 2.54 60-eo 55 4-(2,6-Dimethyl-morpholin- 4-yl)-benzenesulfonic acid 2- (cyclopropanecarbonyl- amino)-1H-benzoimidazol-5-yl ester 471.01 3.61 60-ep 55 4-(4-Phenyl-piperazin-1- yl)-benzenesulfonic acid 2-(cyclopropanecarbonyl- benzoimidazol-5-yl ester 518.00 3.71 60-eq 55 4-(4-Pyridin-2-yl-piperazin- 1-yl)-benzenesulfonic acid 2-(cyclopropanecarbonyl- amino)-1H-benzoimidazol-5-yl ester 519.00 2.70 60-er 55 4-(4-Diethylamino-1-methyl- butylamino)-benzenesulfonic acid 2-(cyclopropanecarbonyl- amino)-1H-benzoimidazol-5-yl ester 514.06 2.98 60-es 55 4-{4-[2-(Cyclopropanecarbonyl- amino)-1H-benzoimidazol-5- yloxysulfonyl]-phenyl}- piperazine-1-carboxylic acid ethyl ester 513.99 3.38 60-et 55 4-(5-Hydroxy-naphthalen- 1-ylamino)-benzenesulfonic acid 2-(cyclopropanecarbonyl amino)-1H-benzoimidazol-5-yl ester 514.95 3.35 60-eu 55 4-[2-(4-Hydroxy-3-methoxy- phenyl)-ethylamino]- benzenesulfonic acid 2- (cyclopropanecarbonyl- amino)-1H-benzoimidazol-5-yl ester 52.97 2.88 60-ev 55 4-(9H-Purin-6-ylamino)- benzenesulfonic acid 2- (cyclopropanecarbonyl- amino)-1H-benzoimidazol-5-yl ester 490.94 2.71 60-ew 55 1-{4-[2-(Cyclopropanecarbonyl- amino)-1H-benzoimidazol-5- yloxysulfonyl]-phenyl}- piperidine-3-carboxylic acid 484.98 3.18 60-ex 55 4-(3,3-Dimethyl-piperidin- 1-yl)-benzenesulfonic acid 2-(cyclopropanecarbonyl- amino)-1H-benzoimidazol-5-yl ester 469.03 4.18 60-ey 55 4-(4-Methyl-piperidin-1- yl)-benzenesulfonic acid 2-(cyclopropanecarbonyl- amino)-1H-benzoimidazol-5-yl ester 455.02 3.83 60-ez 55 4-(2-Pyridin-2-yl-ethylamino)- benzenesulfonic acid 2- (cyclopropanecarbonyl- amino)-1H-benzoimidazol-5-yl ester 477.98 2.58 60-fa 55 4-(3-Hydroxymethyl-phenyl- amino)-benzene-sulfonic acid 2-(cyclopropanecarbonyl- amino)-1H-benzoimidazol-5-yl ester 478.98 2.80 60-fb 55 4-(2-Oxo-2,3-dihydro-1H- pyrimidin-4-ylideneamino)- benzenesulfonic acid 2- (cyclopropanecarbonyl- amino)-1H-benzoimidazol-5-yl ester 466.94 2.46 60-fc 55 4-(3-Piperidin-1-yl- propylamino)-benzenesulfonic acid 2-(cyclopropanecarbonyl- amino)-1H-benzoimidazol-5-yl ester 498.05 2.85 60-fd 55 4-[2-(1H-Indol-3-yl)- ethylamino]-benzenesulfonic acid 2-(cyclopropanecarbonyl- amino)-1H-benzoimidazol-5-yl ester 515.98 3.89 60-fe 55 4-(5-Carbamoyl-1H-imidazol- 4-ylamino)-benzenesulfonic acid 2-(cyclopropanecarbonyl- amino)-1H-benzoimidazol-5-yl ester 481.96 2.68 60-ff 55 4-(1-Hydroxymethyl-butylamino)- benzenesulfonic acid 2- (cyclopropanecarbonyl- amino)-1H-benzoimidazol-5-yl ester 459.01 3.33 60-fg 55 4-(1-Benzyl-piperidin-4- ylamino)-benzenesulfonic acid 2-(cyclopropane-carbonyl- amino)-1H-benzoimidazol-5-yl ester 546.04 2.81 60-fh 55 4-{4-[2-(2-Hydroxy-ethoxy)- ethyl)-ethyl]-piperazin- 1-yl}-benzenesulfonic acid 2-(cyclopropane-carbonyl- amino)-1H-benzoimidazol-5-yl ester 530.01 2.49 60-fi 55 4-(4-Methyl-[1,4]diazepan- 1-yl)-benzenesulfonic acid 2- (cyclopropanecarbonyl- amino)-1H-benzoimidazol-5-yl ester 470.03 2.48 60-fj 55 4-(3-Azepan-1-yl-propylamino)- benzenesulfonic acid 2- (cyclopropanecarbonyl- amino)-1H-benzoimidazol-5-yl ester 512.06 2.73 60-fk 55 4-(2,6-cis-Dimethyl-morpholin- 4-yl)-benzenesulfonic acid 2- (cyclopropanecarbonyl- amino)-1H-benzoimidazol-5-yl ester 512.04 3.73 60-fl 55 4-(2S-Hydroxymethyl-pyrrolidin- 1-yl)-benzenesulfonic acid 2- (cyclopropanecarbonyl- amino)-1H-benzoimidazol-5-yl ester 457.00 3.19 60-fm 55 4-[4-(3-Pyrrolidin-1-yl-propyl)- [1,4]diazepan-1-yl]- benzenesulfonic acid 2-(cyclopropanecarbonyl- amino)-1H-benzoimidazol-5-yl ester 567.07 2.39
Example 61
Preparation of 4-trifluoromethoxy-benzenesulfonic acid 2-methoxycarbonylamino-1H-benzoimidazol-5-yl ester
[0744]
[0745] step 1: 7.82 g of 4-amino-3-nitrophenol in 460 ml of methanol were hydrogenated with catalytic amount of palladium on carbon (800 mg, 10% Pd/C). After hydrogen uptake was complete, the catalyst was filtered off, washed with methanol and the filtrate was concentred under reduced pressure to give 6 g of crude 3,4-diaminophenol.
[0746] Step 2: 6 g of 3,4-diaminophenol were combined with 9.8 g of 1,3-bis(methoxycarbonyl)-2-methyl-2-thiopseudourea in 50 ml methanol and 30 ml acetic acid. The reaction mixture was refluxed for 4 hours. Solvents were then evaporated under reduce pressure yielding 10.8 g crude (5-hydroxy-1H-benzoimidazol-2-yl)-carbamic acid methyl ester. The residue was subjected to flash chromatography eluting with a mixture of dichloromethane-methanol (9:1; v/v) to give 5.6 g of a beige solid. Mass spectrum: 208 [M+H] + , retention time=0.56 minute.
[0747] Step 3: A stirred solution of (5-hydroxy-1H-benzoimidazol-2-yl)-carbamic acid methyl ester (100 mg) and 4-trifluoromethoxy-benzenesulfonyl chloride (126 mg) in acetone (3 ml) was treated with triethylamine (130 μl). After stirring at ambient temperature for 4 hours, the reaction mixture was evaporated. The residue was subjected to flash chromatography on silica eluting with a mixture of ethyl acetate and heptane (1:1, v/v) to give 4-trifluoromethoxy-benzenesulfonic acid 2-methoxycarbonylamino-1H-benzoimidazol-5-yl ester (65 mg) as an off-white solid Mass spectrum: 432 [M+H] + ; retention time=15.04 minutes.
Example 62
[0748] By using a method similar to that for the preparation of example 61, combining (5-hydroxy-1H-benzoimidazol-2-yl)-carbamic acid methyl ester with suitable benzene sulfonyl chloride were obtained the following compounds that were characterized by analytical LC/MS ([M+H] + and retention time given in the following table).
Retention time Example Benzene sulfonyl chloride Compound (minutes) Mass [M + H] + 62-a 3,5-Dimethyl-isoxazole-4- sulfonic acid 2- methoxycarbonylamino-1H- benzoimidazol-5-yl ester 15.87 367 62-b Thiophene-2-sulfonic acid 2- methoxycarbonylamino-1H- benzoimidazol-5-yl ester 14.95 354 62-c 5-Isoxazol-3-yl-thiophene-2- sulfonic acid 2- methoxycarbonylamino-1H- benzoimidazol-5-yl ester 12.58 421 62-d 2-Fluoro-benzenesulfonic acid 2-methoxycarbonylamino-1H- benzoimidazol-5-yl ester 10.37 366 62-e 5-(1-Methyl-5-trifluoromethyl- 1H-pyrazol-3-yl)-thiophene-2- sulfonic acid 2- methoxycarbonylamino-1H- benzoimidazol-5-yl ester 16.58 502 62-f 3-Trifluoromethoxy- benzenesulfonic acid 2- methoxycarbonylamino-1H- benzoimidazol-5-yl ester 4.06 432 62-g 2-Trifluoromethoxy- benzenesulfonic acid 2- methoxycarbonylamino-1H- benzoimidazol-5-yl ester 13.06 432 62-h 2,6-Difluoro-benzenesulfonic acid 2-methoxycarbonylamino- 1H-benzoimidazol-5-yl ester 9.76 384 62-i 3-Methoxy-benzenesulfonic acid 2-methoxycarbonylamino- 1H-benzoimidazol-5-yl ester 10.16 378 62-j 3-(2-Methoxycarbonylamino- 1H-benzoimidazol-5- yloxysulfonyl)-thiophene-2- carboxylic acid methyl ester 8.07 412 62-k 3,4-Dimethoxy- benzenesulfonic acid 2- methoxycarbonylamino-1H- benzoimidazol-5-yl ester 9.32 408 62-l 3-Nitro-benzenesulfonic acid 2- methoxycarbonylamino-1H- benzoimidazol-5-yl ester 11.56 393 62-m 3-Trifluoromethyl- benzenesulfonic acid 2- methoxycarbonylamino-1H- benzoimidazol-5-yl ester 14.19 416 62-n 2-Cyano-benzenesulfonic acid 2-methoxycarbonylamino-1H- benzoimidazol-5-yl ester 9.43 373 62-o 2-Trifluoromethyl- benzenesulfonic acid 2- methoxycarbonylamino-1H- benzoimidazol-5-yl ester 13.26 416 62-p 2,4-Difluoro-benzenesulfonic acid 2-methoxycarbonylamino- 1H-benzoimidazol-5-yl ester 11.35 384 62-q 5-Fluoro-2-methyl- benzenesulfonic acid 2- methoxycarbonylamino-1H- benzoimidazol-5-yl ester 12.93 380 62-r 3-Fluoro-benzenesulfonic acid 2-methoxycarbonylamino-1H- benzoimidazol-5-yl ester 11.19 366 62-s 4-Cyano-benzenesulfonic acid 2-methoxycarbonylamino-1H- benzoimidazol-5-yl ester 10.37 373 62-t 2-Methoxy-5-(2- methoxycarbonylamino-3H- benzoimidazol-5- yloxysulfonyl)-thiophene-3- carboxylic acid methyl ester 8.52 442 62-u 1,3,5-Trimethyl-1H-pyrazole-4- sulfonic acid 2- methoxycarbonylamino-3H- benzoimidazal-5-yl ester 6.96 380 62-v 6-Morpholin-4-yl-pyridine-3- sulfonic acid 2- methoxycarbonylamino-3H- benzoimidazol-5-yl ester 7.82 434 62-w 2,4,6-Trifluoro-benzenesulfonic acid 2-methoxycarbonylamino- 1H-benzoimidazol-5-yl ester 3.34 402
Example 63
Preparation of 4-benzyloxy-benzenesulfonic acid 2-methoxycarbonylamino-1H-benzoimidazol-5-yl ester
[0749]
[0750] Step 1: A stirred solution of 4-amino-3-nitro-phenol (3 g) and benzoic acid 4-chlorosulfonyl-phenyl ester (5.7 g) in acetone (80 ml) was treated with triethylamine (5.4 ml). After stirring at ambient temperature for 14 hours, the reaction mixture was evaporated. The residue was triturated with diisopropylic ether, filtered off and dried under vacuum to give 5.22 g of benzoic acid 4-amino-3-nitro-phenoxysulfonyl)-phenyl ester (5.22 g) as a yellow solid Mass spectrum: 401 [M+H] + ; retention time=4.59 minutes.
[0751] Step 2: A solution benzoic acid 4-amino-3-nitro-phenoxysulfonyl)-phenyl ester (3 g) and 2N aqueous solution of sodium hydroxyde in methanol (55 ml) was reluxed for 2 hours. The reaction mixture was concentrated and water (100 ml) and ethyl acetate (100 ml) were added. The organic layer was dried over magnesium sulfate then evaporated to give 1.77 g of crude 4-hydroxy-benzenesulfonic acid 4-amino-3-nitro-phenyl ester.
[0752] Step 3: A solution of cesium carbonate (156 mg) in water (0.3 ml) was added to a solution of 4-hydroxy-benzenesulfonic acid 4-amino-3-nitro-phenyl ester (150 mg) and benzyl bromide (58 μl) in dimethylformamide (3 ml). The reaction mixture was heated at 80° C. for 3 hours then allowed to cool to ambient temperature, poured into water (25 ml) and extracted three times with ethyl acetate (30 ml). The combined extracts were dried over magnesium sulfate then evaporated to give 189 mg of crude 4-benzyloxy-benzenesulfonic acid 4-amino-3-nitrophenyl ester.
[0753] Step 4: Sodium dithionite (624 mg) was added to a solution of 4-benzyloxy-benzenesulfonic acid 4-amino-3-nitrophenyl ester (180 mg) and sodium hydroxyde (0.5 N, 3.1 ml) in ethanol (6 ml) at 80° C. The reaction mixture was stirred at 80° C. for 10 minutes then filtered and the filtrate was evaporated. The residue was extracted three times with ethyl acetate (15 ml). The combined extracts were dried over magnesium sulfate then evaporated to 137 mg of crude 4-benzyloxy-benzenesulfonic acid 3,4-diamino-phenyl ester.
[heading-0754] Step 5: preparation of 4-Benzyloxy-benzenesulfonic acid 2-methoxycarbonylamino-1H-benzoimidazol-5-yl ester
[0755] To a solution of 4-benzyloxy-benzenesulfonic acid 3,4-diamino-phenyl ester (134 mg) in acetic acid (0.83 ml) and methanol (2.5 ml) at 80° C. was added 1,3-bis(methoxycarbonyl)-2-methyl-2-thiopseudourea (89 mg). The reaction mixture was refluxed for 2 hours then allowed to cool to ambient temperature and stirred at this temperature for 14 hours. The resultant precipitate was filtered, washed with diethyl ether and dried under vacuum to afford 4-benzyloxy-benzenesulfonic acid 2-methoxycarbonylamino-1H-benzoimidazol-5-yl ester as a beige solid.
[0756] Mass spectrum: 454 [M+H] + ; retention time=11.46 minutes.
Example 64
[0757] By using a method similar to that for the preparation of example 63, combining in step 3 the 4-hydroxy-benzenesulfonic acid 4-amino-3-nitro-phenyl ester with suitable alkyl halide were obtained the following compounds that were characterized by analytical LC/MS ([M+H] + and retention time given in the following table).
Retention time Example Alkyl halide Compound (minutes) Mass [M + H] + 64-a 4-Ethoxy-benzenesulfonic acid 2- methoxycarbonylamino-3H- benzoimidazol-5-yl ester 12.34 392 64-d 4-(2-Morpholin-4-yl-ethoxy)- benzenesulfonic acid 2- methoxycarbonylamino-3H- benzoimidazol-5-yl ester 3.24 477 64-c 4-(2-Methoxy-ethoxy)- benzenesulfonic acid 2- methoxycarbonylamino-3H- benzoimidazol-5-yl ester 9.97 422 64-d 4-(2-piperidin-1-yl-ethoxy)- benzenesulfonic acid 2- methoxycarbonylamino-3H- benzoimidazol-5-yl ester 3.94 475 64-e [4-(2-Methoxycarbonylamino-3H- benzoimidazol-5-yloxysulfonyl)- phenoxy]-acetic acid 7.23 422
Example 65
Preparation of 4-(2-oxo-2-pyrrolidin-1-yl-ethoxy)-benzenesulfonic acid 2-methoxycarbonylamino-1H-benzoimidazol-5-yl-ester
[0758]
[0759] A solution of [4-(2-methoxycarbonylamino-3H-benzoimidazol-5-yloxysulfonyl)-phenoxy]-acetic acid (40 mg, example 64-e) in dry dimethylformamide (3 ml) was treated with N-{(dimethylamino)(1H-1,2,3-triazolo[4,5-b]pyridin-1-yl)methylene}-N-methylmethanaminium hexafluorophosphate N-oxide (39 mg) and diisopropylethylamine (50 μl). After stirring at ambient temperature for 30 minutes, pyrrolidine (21 μl) was added and the mixture stirred at room temperature for a further 3 hours. The solvent was removed in vacuo and the residue was purified by triggered LC/MS to give 4-(2-oxo-2-pyrrolidin-1-yl-ethoxy)-benzenesulfonic acid 2-methoxycarbonylamino-1H-benzoimidazol-5-yl-ester as an off-white solid. Mass spectrum: 475[M+H] + ; retention time=8.39 minutes.
Example 66
[0760] By using a method similar to that for the preparation of example 65, combining [4-(2-methoxycarbonylamino-3H-benzoimidazol-5-yloxysulfonyl)-phenoxy]-acetic acid with suitable amine were obtained the following compounds that were characterized by analytical LC/MS ([M+H] + and retention time given in the following table).
Retention time Example Amine Compound (minutes) Mass [M + H]+ 66-a 4-[2-(4-Methyl-piperazin-1- yl)-2-oxo-ethoxy]- benzenesulfonic acid 2- methoxycarbonylamino-1H- benzoimidazol-5-yl ester 1.96 504 66-b 4-[(3-diethylamino- propylcarbamoyl)-methoxy]- benzenesulfonic acid 2- methoxycarbonylamino-1H- benzoimidazol-5-yl ester 1.96 534 66-c 4-{[(furan-2-ylmethyl)- carbamoyl]-methoxy}- benzenesulfonic acid 2- methoxycarbonylamino-1H- benzoimidazol-5-yl ester 10.89 501
Example 67
Preparation of 4-(cyclopropylmethyl-amino)-benzene sulfonic acid 2-methoxycarbonylamino-1H-benzoimidazol-5-yl ester
[0761]
Step 1: preparation of 4-(cyclopropylmethyl-amino)-benzenesulfonic acid 4-amino-3-nitro-phenyl ester
[0763] A solution of 4-fluoro-benzenesulfonic acid 4-amino-3-nitro-phenyl ester (800 mg) and cyclopropylmethylamine (890 μl) in N-methylpyrrolidinone (8 ml) was heated at 110° C. in a sealed tube for 14 hours. The reaction mixture was then poured into water (150 ml) and extracted three times with ethyl acetate (40 ml). The combined extracts were dried over magnesium sulfate and then evaporated. The residue was subjected to flash chromatography on silica eluting with a mixture of ethyl acetate and heptane (50:50, v/v) to give 4-(cyclopropylmethyl-amino)-benzenesulfonic acid 4-amino-3-nitro-phenyl ester (786 mg) as a yellow solid.
[0764] Step 2: Sodium dithionite (3 g) was added to a solution of 4-(cyclopropylmethyl-amino)-benzenesulfonic acid 4-amino-3-nitro-phenyl ester (783 mg) and sodium hydroxyde (0.5 N, 15 ml) in ethanol (30 ml) at 80° C. The reaction mixture was stirred at 80° C. for 10 minutes then filtered then the filtrate was evaporated. The residue was extracted three times with ethyl acetate (30 ml). The combined extracts were dried over magnesium sulfate then evaporated to give 652 mg of 4-(cyclopropylmethyl-amino)-benzenesulfonic acid 3,4-diamino-phenyl ester.
[0765] Step 3: To a solution of 4-(cyclopropylmethyl-amino)-benzenesulfonic acid 3,4-diamino-phenyl ester (648 mg) in acetic acid (4.5 ml) and methanol (40 ml) at 80° C. was added 1,3-bis(methoxycarbonyl)-2-methyl-2-thiopseudourea (580 mg). The reaction mixture was refluxed for 4 hours then allowed to cool to ambient temperature and stirred at this temperature for 14 hours. The resultant precipitate was filtered, washed with diethyl ether and dried under vacuum to afford 4-(cyclopropylmethyl-amino)-benzene sulfonic acid 2-methoxycarbonylamino-1H-benzoimidazol-5-yl ester (378 mg) as a beige solid. Mass spectrum: 417 [M+H] + ; retention time=13.16 minutes.
Example 68
[0766] By using a method similar to that for the preparation of example 67, combining 4-fluoro-benzenesulfonic acid 4-amino-3-nitro-phenyl ester with suitable amine in step 1 were obtained the following compounds that were characterized by analytical LC/MS ([M+H] + and retention time given in the following table).
Retention time Mass Example Amine Compound (minutes) [M + H]+ 68-a 4-(2-methoxy-ethylamino)- benzenesulfonic acid 2- methoxycarbonylamino-1H- benzoimidazol-5-yl ester 8.89 421 68-b 4-(2-hydroxy-1-methyl- ethylamino)-benzenesulfonic acid 2-methoxycarbonylamino- 1H-benzoimidazol-5-yl ester 6.84 421 68-c 4-(benzylamino)- benzenesulfonic acid 2- methoxycarbonylamino-1H- benzoimidazol-5-yl ester 4.4 453 68-d 4-(2-Morpholin-4-yl- ethylamino)-benzenesulfonic acid 2-methoxycarbonylamino- 1H-benzoimidazol-5-yl ester 2.44 476 68-e 4-(2-Piperidin-4-yl-ethylamino)- benzenesulfonic acid 2-[3-(2- piperidin-1-yl-ethyl)-ureido]- 3H-benzoimidazol-5-yl ester 2.77 460 68-f 4-[(1-Ethyl-pyrrolidin-2- ylmethyl)-amino]-benzenesulfonic acid 2-[3-(2-piperidin-1-yl-ethyl)- ureido]-3H-benzoimidazol-5-yl ester 2.3 474
Example 69
Preparation of 4-cyclopentylamino-benzenesulfonic acid 2-(3,4-dimethoxy-phenylamino)-1H-benzoimidazol-5-yl ester
[0767]
[0768] Step 1: A solution of 1-benzyl-6-methoxy-1H-benzoimidazole (3 g) in dry tetrahydrofuran (65 ml), cooled to −78° C., was treated with a solution of n-butyllithium in hexanes (12 ml, 15%). After stirring for 45 minutes the mixture was treated with N-chlorosuccinimide (2.24 g in 65 ml of tetrahydrofuran) then allowed to warm slowly to ambient temperature. The reaction mixture was allowed to stir at ambient temperature for 2 hours then treated with a saturated aqueous solution of ammonium chloride (100 ml) and extracted three times with ethyl acetate (65 ml). The combined extracts were dried over magnesium sulfate and then evaporated. The residue was subjected to flash column chromatography on silica eluting with a mixture of ethyl acetate and hexane (1:1, v/v) to 1-benzyl-2-chloro-6-methoxy-1H-benzoimidazole (2.09 g) as a yellow solid. Mass spectrum: 273 [M+H] + , retention time=3.93 minutes.
[0769] Step 2: A mixture of 1-benzyl-2-chloro-6-methoxy-1H-benzoimidazole (600 mg), hydrobromic acid (48%, 11 ml) and glacial acetic acid (6 ml) was heated under reflux for 1 hour. After cooling the mixture was neutralised by addition of 10% sodium bicarbonate solution then extracted 3 times with dichloromethane (30 ml). The combined extracts were dried over magnesium sulfate and then evaporated to give 3-benzyl-2-chloro-3H-benzoimidazol-5-ol (470 mg) as a yellow solid. Mass spectrum: 259 [M+H] + retention time=3.4 minutes.
[0770] Step 3: A mixture of 3-benzyl-2-chloro-3H-benzoimidazol-5-ol (250 mg) and 4-amino veratrole (296 mg) in N-methylpyrrolidinone (3 ml) was heated at 150° C. in a sealed tube for 4 hours then allowed to cool. The reaction mixture was then poured into water (30 ml) and extracted three times with ethyl acetate (30 ml). The combined extracts were dried over magnesium sulfate and then evaporated. The residue was subjected to flash chromatography on silica eluting with a mixture of dichloromethane and methanol (95:5, v/v) to give 3-benzyl-2-(3,4-dimethoxy-phenylamino)-3H-benzoimidazol-5-ol (141 mg) as a yellow solid.
[0771] Mass spectrum: 376 [M+H] + retention time: 3.44 minutes.
[0772] Step 4: A stirred solution of 3-benzyl-2-(3,4-dimethoxy-phenylamino)-3H-benzoimidazol-5-ol (141 mg) and 4-fluoro-benzenesulfonyl chloride (190 mg) in acetone (8 ml) was treated with triethylamine (258 μl). After stirring at ambient temperature for 4 hours, the reaction mixture was evaporated. The residue was subjected to flash chromatography on silica eluting with a mixture of ethyl acetate and heptane (1:1, v/v) to give 4-fluoro-benzenesulfonic acid 3-benzyl-2-(3,4-dimethoxy-phenylamino)-3H-benzoimidazol-5-yl ester (157 mg) as a yellow solid. Mass spectrum: 534 [M+H] + , retention time: 3.7 minutes.
[0773] Step 5: A solution of 4-fluoro-benzenesulfonic acid 3-benzyl-2-(3,4-dimethoxy-phenylamino)-3H-benzoimidazol-5-yl ester (151 mg) and cyclopentylamine (118 μl) in N-methylpyrrolidinone (1.5 ml) was heated at 110° C. in a sealed tube for 3 hours. The reaction mixture was allowed to cool then poured into water (30 ml) and extracted three times with ethyl acetate. The combined extracts were dried over magnesium sulfate then evaporated. The residue was subjected to flash chromatography on silica eluting with a mixture of ethyl acetate and heptane (1:1, v/v) to give 4-cyclopentylamino-benzenesulfonic acid 3-benzyl-2-(3,4-dimethoxy-phenylamino)-3H-benzoimidazol-5-yl ester (122 mg) as a brown solid. Mass spectrum: 599 [M+H] + , retention time=4.0 minutes.
Example 70
[0774] By using a method similar to that for the preparation of example 69, combining 3-benzyl-2-chloro-3H-benzoimidazol-5-ol with suitable amine in step 3 were obtained the following compounds that were characterized by analytical LC/MS ([M+H] + and retention time given in the following table).
Retention time Mass Example Amine Compound (minute) [M + H] + 70-a 4-Cyclopentylamino- benzenesulfonic acid 2- phenylamino-1H- benzoimidazol-5-yl ester 12.31 449 70-b 4-Cyclopentylamino- benzenesulfonic acid 2- (4-morpholin-4-yl-phenylamino)- 1H-benzoimidazol-5-yl ester 11.58 534 70-c 4-Cyclopentylamino- benzenesulfonic acid 2- (3,5-dimethyl-phenylamino)-1H- benzoimidazol-5-yl ester 9.55 477 70-d 4-Cyclopentylamino- benzenesulfonic acid 2- (4-methoxy-phenylamino)-1H- benzoimidazol-5-yl ester 8.69 479 70-e 4-Cyclopentylamino- benzenesulfonic acid 2- (4-dimethylamino- phenylamino)-1H- benzoimidazol-5-yl ester 8.59 492 70-f 4-Cyclopentylamino- benzenesulfonic acid 2- (3-methoxy-5-trifluoromethyl- phenylamino)-1H- benzoimidazol-5-yl ester 11.94 547 70-g 3-[5-(4-Cyclopentylamino- benzenesulfonyloxy)-1H- benzoimidazol-2-ylamino]- benzoic acid ethyl ester 10.13 521 70-h 4-Cyclopentylamino- benzenesulfonic acid 2- [(4-(4-methyl-piperazin-1- yl)-phenylamino)-1H- benzoimidazol-5-yl ester 6.64 547
Example 71
Preparation of 4-cyclopentylamino-benzenesulfonic acid 2-(3-phenyl-propionylamino)-1H-benzoimidazol-5-yl ester
[0775]
[0776] A solution of 3-phenyl propionic acid (9.7 mg) in dry dimethylformamide (0.6 ml) was treated with N-{(dimethylamino)(1H-1,2,3-triazolo[4,5-b]pyridin-1-yl) methylene}-N-methylmethanaminium hexafluorophosphate N-oxide (21 mg) and diisopropylethylamine (12 μl). After stirring at ambient temperature for 30 minutes, 4-cyclopentylamino-benzenesulfonic acid 2-amino-3H-benzoimidazol-5-yl ester (20 mg) was added and the mixture stirred at room temperature for a further 3 hours. The solvent was removed under vacuo and the residue was purified by triggered LC/MS to give 4-cyclopentylamino-benzenesulfonic acid 2-(3-phenyl-propionylamino)-1H-benzoimidazol-5-yl ester as an off-white solid (11 mg). Mass spectrum: 505 [M+H] + ; retention time=4.59 minutes.
Example 72
Preparation of 4-cyclopentylamino-benzenesulfonic acid 2-[2-2-methoxy-ethoxy)-acetylamino]-1H-benzoimidazol-5-yl ester
[0777]
[0778] By proceeding in a manner similar to example 71 above but using (2-methoxy-ethoxy)-acetic acid there was prepared 4-cyclopentylamino-benzenesulfonic acid 2-[2-2-methoxy-ethoxy)-acetylamino]-1H-benzoimidazol-5-yl ester as an off-white solid. Mass spectrum: 489 [M+H] + ; retention time=4.06 minutes.
Example 73
Preparation of 4-fluoro-benzenesulfonic acid 2-(3(chloro-4-methoxy-benzylamino)-3H-benzoimidazol-5-yl ester
[0779]
[0780] Step 1: A stirred solution of 4-fluoro-benzenesulfonic acid 2-tert-butoxycarbonylamino-3H-benzoimidazol-5-yl ester (Example 55 (step 3), 200 mg) in dry dimethylformamide (3 ml) was treated with sodium hydride (12 mg, 60% dispersion in mineral oil). After stirring for 30 minutes the mixture was treated with a solution of 3-chloro-4-methoxy-benzyl bromide (94 mg) in dimethylformamide (1 ml) and stirring was continued for a further 3 hours. The reaction mixture was poured into water (10 ml) and then extracted three times with ethyl acetate (10 ml). The combined extracts were dried over magnesium sulfate and then evaporated. The residue was subjected to flash chromatography on silica eluting with a mixture of ethyl acetate and heptane (1:2, v/v) to give 4-fluoro-benzenesulfonic acid 2-[tert-butoxycarbonyl-(3-chloro-4-methoxy-benzyl)-amino]-3H-benzoimidazol-5-yl ester (70 mg) as a beige solid.
[heading-0781] Step 2: preparation of 4-fluoro-benzenesulfonic acid 2-(3-(chloro-4-methoxy-benzylamino)-3H-benzoimidazol-5-yl ester
[0782] Trifluoroacetic acid (1 ml) was added to a solution of 4-fluoro-benzenesulfonic acid 2-[tert-butoxycarbonyl-(3-chloro-4-methoxy-benzyl)-amino]-3H-benzoimidazol-5-yl ester (67 mg) in dichloromethane (4 ml). After cooling, the mixture was neutralised by addition of saturated sodium bicarbonate solution. Water (10 ml) was added and the solution extracted three times with dichloromethane (10 ml). The combined extracts were dried over magnesium sulfate and then evaporated. The residue was subjected to flash chromatography on silica eluting with a mixture of ethyl acetate and heptane (1:1, v/v) to give 4-fluoro-benzenesulfonic acid 2-(3-(chloro-4-methoxy-benzylamino)-3H-benzoimidazol-5-yl ester (53 mg) as an off-white solid. Mass spectrum: 462 [M+H] + ; retention time=7.69 minutes.
Example 74
[0783] By using a method similar to that for the preparation of example 73, combining 4-fluoro-benzenesulfonic acid 2-tert-butoxycarbonylamino-3H-benzoimidazol-5-yl ester with suitable benzyl halide were obtained the following compounds that were characterized by analytical LC/MS ([M+H] + and retention time given in the following table).
Retention time Mass Example Benzyl halide Compound (minute) [M + H] + 74-a 4-Fluoro-benzenesulfonic acid 2-[(3-phenyl-[1,2,4]- oxadiazol-5-ylmethyl)-amino]- 3H-benzoimidazol-5-yl ester 8.13 466 74-b 4-Fluoro-benzenesulfonic acid 2-(3-chloro-benzylamino)- 3H-benzoimidazol-5-yl ester 7.72 432 74-c 4-Fluoro-benzenesulfonic acid 2-(3-methoxy-benzylamino)- 3H-benzoimidazol-5-yl ester 7.31 428 74-d 4-Fluoro-benzenesulfonic acid 2-benzylamino-3H- benzoimidazol-5-yl ester 7.43 398
Example 75
Preparation of 4-cyclopentylamino-benzenesulfonic acid 2-benzylamino-3H-benzoimidazol-5-yl ester
[0784]
[0785] A solution of 4-fluoro-benzenesulfonic acid 2-benzylamino-3H-benzoimidazol-5-yl ester (20 mg) and cyclopentylamine (21 μl) in N-methylpyrrolidinone (0.5 ml) was heated at 110° C. in a sealed tube for 2 hours. The reaction mixture was then purified by triggered LC/MS to give 4-cyclopentylamino-benzenesulfonic acid 2-benzylamino-3H-benzoimidazol-5-yl ester as an off-white solid (4 mg). Mass spectrum: 463[M+H] + ; retention time=8.35 minutes.
Example 76
[0786] By using a method similar to that for the preparation of example 75, combining cyclopentylamine with suitable 4-fluoro-benzenesulfonic acid 2-benzylamino-3H-benzoimidazol-5-yl ester (example 73, 74a-74c) were obtained the following compounds that were characterized by analytical LC/MS ([M+H] + and retention time given in the following table).
Retention time Mass Example Precursor Compound (minute) [M + H] + 76-a 74-a 4-Cyclopentylamino- 3.91 531 benzenesulfonic acid 2- [(3-phenyl- [1,2,4]oxadiazol-5- ylmethyl)-amino]-3H- benzoimidazol-5-yl ester 76-b 74-c 4-Cyclopentylamino- 8.41 493 benzenesulfonic acid 2- (3-methoxy- benzylamino)-3H- benzoimidazol-5-yl ester 76-c 73 4-Cyclopentylamino- 3.58 527 benzenesulfonic acid 2- (3-chloro-4-methoxy- benzylamino)-3H- benzoimidazol-5-yl ester
Example 77
Preparation of 4-(Cyclopropylmethyl-amino)-benzenesulfonic acid 2-[3-(2-morpholin-4-yl-ethyl)-ureido]-1H-benzoimidazol-5-yl ester
[0787]
[0788] A solution of 4-(cyclopropylmethyl-amino)-benzenesulfonic acid 2-methoxy-carbonylamino-3H-benzoimidazol-5-yl ester (example 67, 40 mg) and 2-(aminoethyl)-morpholine (125 mg) in tetrahydrofuran (2 ml) and N-methylpyrrolidinone (0.2 ml) was heated at 90° C. for 36 hours. The reaction mixture was then evaporated and purified by triggered LC/MS to give 4-(cyclopropylmethyl-amino)-benzenesulfonic acid 2-[3-(2-morpholin-4-yl-ethyl)-ureido]-1H-benzoimidazol-5-yl ester as an off-white solid (27 mg). Mass spectrum: 515[M+H] + ; retention time=5.97 minutes.
Example 78
[0789] By using a method similar to that for the preparation of example 77, combining 4-(substituted-amino)-benzenesulfonic acid 2-methoxycarbonylamino-3H-benzo-imidazol-5-yl ester [example 63, 67, 68] with suitable amine were obtained the following compounds that were characterized by analytical LC/MS ([M+H] + and retention time given in the following table).
Retention time Mass Example Precursor Amine Compound (minutes) [M + H] + 78-a 67 4-(Cyclopropylmethyl-amino)- benzenesulfonic acid 2-[3-(2- morpholin-4-yl-ethyl)-ureido]- 1H-benzoimidazol-5-yl ester 5.97 515 78-b 67 4-(Cyclopropylmethyl-amino)- benzenesulfonic acid 2-(3- pyridin-2-ylmethyl)-ureido]- 1H-benzoimidazol-5-yl ester 8.55 493 78-c 67 4-(Cyclopropylmethyl-amino)- benzenesulfonic acid 2-[3-(2- methoxy-ethyl)-ureido]-1H- benzoimidazol-5-yl ester 10.66 460 78-d 67 4-(Cyclopropylmethyl-amino)- benzenesulfonic acid 2-[3-(2- ethyl)-ureido]-1H- benzoimidazol-5-yl ester 11.07 430 78-e 68-a 4-(2-Methoxy-ethylamino)- benzenesulfonic acid 2-[3-(2- morpholin-4-yl-ethyl)-ureido]- 1H-benzoimidazol-5-yl ester 5.74 519 78-f 68-a 4-(2-Methoxy-ethylamino)- benzenesulfonic acid 2-(3- pyridin-2-ylmethyl)-ureido]- 1H-benzoimidazol-5-yl ester 6.62 497 78-g 68-a 4-(2-Methoxy-ethylamino)- benzenesulfonic acid 2-[3-(2- methoxy-ethyl)-ureido]-1H- benzoimidazol-5-yl ester 7.39 464 78-h 68-a 4-(2-Methoxy-ethylamino)- benzenesulfonic acid 2-[3-(2- ethyl)-ureido]-1H- benzoimidazol-5-yl ester 7.53 434 78-i 68-b 4-(2-Hydroxy-1-methyl- ethylamino)-benzenesulfonic acid 2-[3-(2-morpholin-4-yl- ethyl)-ureido]-1H- benzoimidazol-5-yl ester 5.36 519 78-j 68-b 4-(2-Hydroxy-1-methyl- ethylamino)-benzenesulfonic acid 2-(3-pyridin-2-ylmethyl)- ureido]-1H-benzoimidazol-5- yl ester 6.11 497 78-k 68-b 4-(2-Hydroxy-1-methyl- ethylamino)-benzenesulfonic acid 2-[3-(2-methoxy-ethyl)- ureido]-1H-benzoimidazol-5- yl ester 6.81 464 78-l 68-b 4-(2-Hydroxy-1-methyl- ethylamino)-benzenesulfonic acid 2-[3-(2-ethyl)-ureido]- 1H-benzoimidazol-5-yl ester 6.94 434 78-m 63 4-Benzyloxybenzenesulfonic acid 2-[3-(2-morpholin-4-yl- ethyl)-ureido]-1H- benzoimidazol-5-yl ester 7.55 552 78-n 63 4-Benzyloxy-benzenesulfonic acid 2-(3-pyridin-2-ylmethyl)- ureido]-1H-benzoimidazol-5- yl ester 8.99 530 78-o 63 4-Benzyloxy-benzenesulfonic acid 2-[3-(2-methoxy-ethyl)- ureido]-1H-benzoimidazol-5- yl ester 13.97 497 78-p 63 4-benzyloxy-benzenesulfonic acid 2-[3-(2-ethyl)-ureido]- 1H-benzoimidazol-5-yl ester 10.12 467 78-r 68-d 4-(2-Morpholin-4-yl- ethylamino)-benzenesulfonic acid 2-(3-pyridin-2-ylmethyl)- ureido]-1H-benzoimidazol-5- yl ester 4.61 552 78-s 68-d 4-(2-Morpholin-4-yl- ethylamino)-benzenesulfonic acid 2-[3-(2-methoxy-ethyl)- ureido]-1H-benzoimidazol-5- yl ester 1.47 519 78-t 68-e 4-[(Piperidin-4-ylmethyl)- amino)-benzenesulfonic acid 2-[3-(2-morpholin-4-yl-ethyl)- ureido]-1H-benzoimidazol-5- yl ester 4.47 558 78-u 68-e 4-[(Piperidin-4-ylmethyl)- amino]-benzenesulfonic acid 2-(3-pyridin-2-ylmethyl)- ureido]-1H-benzoimidazol-5- yl ester 5.12 536 78-v 68-e 4-[(Piperidin-4-ylmethyl)- amino]-benzenesulfonic acid 2-[3-(2-methoxy-ethyl)- ureido]-1H-benzoimidazol-5- yl ester 1.47 503 78-w 68-c 4-Benzylamino- benzenesulfonic acid 2-[3-(2- morpholin-4-yl-ethyl)-ureido]- 1H-benzoimidazol-5-yl ester 7.16 551 78-x 68-c 4-Benzylamino- benzenesulfonic acid 2-(3- pyridin-2-ylmethyl)-ureido]- 1H-benzoimidazol-5-yl ester 8.52 529 78-y 68-c 4-Benzylamino- benzenesulfonic acid 2-[3-(2- methoxy-ethyl)-ureido]-1H- benzoimidazol-5-yl ester 9.29 496 78-z 68-c 4-Benzylamino- benzenesulfonic acid 2-[3-(2- ethyl)-ureido]-1H- benzoimidazol-5-yl ester 9.35 466 78-aa 68-f 4-[(1-ethyl-pyrrolidin- 2ylmethyl)-amino]- benzenesulfonic acid 2-(3- pyridin-2-ylmethyl)-ureido]- 1H-benzoimidazol-5-yl ester 2.14 549
Example 79
Preparation of 4-(4-hydroxy-piperidin-1-yl)-benzenesulfonic acid 2-[(4-hydroxy-piperidine-1-carbonyl)-amino]-1H-benzoimidazol-5-yl ester
[0790]
[0791] A solution of 4-fluoro-benzenesulfonic acid 2-tert-butoxycarbonylamino-3H-benzoimidazol-5-yl ester (200 mg, example 55 (Step 3) and 4-hydroxypiperidine (554 mg) in N-methylpyrrolidinone (6 ml) was heated at 110° C. for 24 hours. The reaction mixture was then poured into water (120 ml) and extracted three times with ethyl acetate (50 ml). The combined extracts were dried over magnesium sulfate and then evaporated. The residue was subjected to flash chromatography on silica eluting with a mixture of dichloromethane and methanol (95 C: 5, v/v) to give (4-hydroxy-piperidin-1-yl)-benzenesulfonic acid 2-[(4-hydroxy-piperidine-1-carbonyl)-amino]-1H-benzoimidazol-5-yl ester (125 mg) as a beige solid. Mass Spectrum: 516 [M+H] + , retention time=6.51 minutes.
Example 80
[0792] By using a method similar to that for the preparation of example 79, combining 4-fluoro-benzenesulfonic acid 2-tert-butoxycarbonylamino-3H-benzoimidazol-5-yl ester with suitable amine were obtained the following compounds that were characterized by analytical LC/MS ([M+H] + and retention time given in the following table).
Retention time Mass Example Amine Compound (minutes) [M + H]+ 80-a 4-(4-Methyl-piperazin-1-yl)- benzenesulfonic acid 2-[(4-methyl- piperazin-1-carbonyl)-amino]-3H- benzoimidazol-5-yl ester 0.53 514 80-b 4-[(tetrahydro-pyran-4-ylmethyl)- amino]-benezenesulfonic acid 2-[3- (tetrahydro-pyran-4-ylmethyl)-ureido]- 3H-benzoimidazol-5-yl ester 8.14 544 80-c 4-(2-Fluoro-ethylamino)- benzenesulfonic acid 2-[3-(2-fluoro- ethyl)-ureido]-3H-benzoimidazol-5-yl ester 7.82 440 80-d 4-(2-piperidin-1-yl-ethylamino)- benzenesulfonic acid 2-[3-(2-piperidin- 1-yl-ethyl)-ureido]-3H-benzoimidazol- 5-yl ester 0.5 440 80-e 4-phenethylamino-benzenesulfonic acid 2-(3-phenethyl-ureido)-3H- benzoimidazol-5-yl ester 4.4 556 80-f 4-[3-(2-oxo-pyrrolidin-1-yl)- propylamino]-benzenesulfonic acid 2- {3-[3-(2-owo-pyrrolidin-1-yl)-propyl]- ureido}-3H-benzoimidazol-5-yl ester 3.09 598 80-g 4-(4-fluoro-benzylamino)- benzenesulfonic acid 2-[3-(4-fluoro- benzyl)-ureido]-3H-benzoimidazol-5- yl ester 4.25 564 80-h 4-(2-hydroxy-2-methyl-propylamino)- benzenesulfonic acid 2-[3-(2-hydroxy- 3-methyl-propyl)-ureido]-3H- benzoimidazol-5-yl ester 7.02 492 80-i 4-(3-hydroxy-propylamino)- benzenesulfonic acid 2-[3-(3-hydroxy- propyl)-ureido]-3H-benzoimidazol-5-yl ester 2.7 464 80-j 4-(2,2,6,6-tetramethyl-piperidin-4- ylamino)-benzenesulfonic acid 2-[3- (2,2,6,6-tetramethyl-piperidin-4-yl)- ureido]-3H-benzoimidazol-5-yl ester 2.44 626 80-k 4-(2-dimethylamino-ethylamino)- benzene sulfonic acid 2-[3-(2- dimethylamino-ethyl)-ureido]-3H- benzoimidazol-5-yl ester 0.70 490 80-l 4-morpholin-4-yl-benzenesulfonic acid 2-[(morpholine-4-carbonyl)-amino]- 3H-benzoimidazol-5-yl ester 3.16 488 80-m 4-(2-Hydroxy-3-methoxy- propylamino)-benzenesulfonic acid 2- [3-(2-hydroxy-3-methoxy-propyl)- ureido]-3H-benzoimidazol-5-yl ester 4.71 524 80-n 4-[(Pyridin-2-ylmethyl)-amino]- benzenesulfonic acid 2-(3-pyridin-2- ylmethyl-ureido)-3H-benzoimidazol-5- yl ester 5.53 530 80-o 4-(2-hydroxy-propylamino)- benzenesulfonic acid 2-[3-(2-hydroxy- propyl)-ureido]-3H-benzoimidazol-5-yl ester 2.7 463 80-p 4-(4-methoxy-benzylamino)- benzenesulfonic acid 2-[3-(4-methoxy- benzyl)-ureido]-3H-benzoimidazol-5-yl ester 4.43 588 80-q 4-(2-pyrrolidin-1-yl-ethylamino)- benzenesulfonic acid 2-[3-(2- pyrrolidin-1-yl-ethyl)-ureido]-3H- benzoimidazol-5-yl ester 2.19 542 80-r 4-(1-phenyl-ethylamino)- benzenesulfonic acid 2-[3-(1-phenyl- ethyl)-ureido]-3H-benzoimidazol-5-yl ester 4.63 556 80-s 4-(2-diethylamino-ethylamino)- benzene sulfonic acid 2-[3-(2- diethylamino-ethyl)-ureido]-3H- benzoimidazol-5-yl ester 2.75 546 80-t 4-(1-hydroxymethyl- acid 2-[3-(1-hydroxymethyl- cyclopentyl)-ureido]-3H- benzoimidazol-5-yl ester 3.45 544 80-u 3-(4-{2-[3-(3-Methoxycarbonyl- ethyl)-ureido]-1H-benzoimidazol-5- yloxysulfonyl}-phenylamino)- propionic acid methyl ester 3.26 520
Example 81
Preparation of 4-(4-Hydroxy-piperidin-1-yl)-benzenesulfonic acid 2-[3-(2-morpholin-4-yl-ethyl)-ureido]-1H-benzoimidazol-5-yl ester
[0793]
[0794] A solution of 4-(4-hydroxy-piperidin-1-yl)-benzenesulfonic acid 2-[(4-hydroxy-piperidine-1-carbonyl)-amino]-1H-benzoimidazol-5-yl ester (example 79, 20 mg) and 2-(aminomethyl)-morpholine (50 mg) in tetrahydrofuran (1 ml) and N-methylpyrrolidinone (0.2 ml) was heated at 95° C. for 22 hours. The reaction mixture was then evaporated and purified by triggered LC/MS to give 4-(4-hydroxy-piperidin-1-yl)-benzenesulfonic acid 2-[3-(2-morpholin-4-yl-ethyl)-ureido]-1H-benzoimidazol-5-yl ester as an off-white solid (7 mg). Mass spectrum: 545[M+H] + ; retention time=5.47 minutes.
Example 82
[0795] By using a method similar to that for the preparation of example 81, combining [example 80a-u] with suitable amine was obtained the following compounds that were characterized by analytical LC/MS ([M+H] + and retention time given in the following table).
Retention time Mass Example Precursor Amine Compound (minutes) [M + H]+ 82-a 80-a 4-(4-methyl-piperazin-1- yl)-benzene sulfonic acid 2-[3-(2-morpholin-4-yl- ethyl)-ureido]-3H- benzimidazol-5-yl ester 5.12 544 82-b 80-a 4-(4-methyl-piperazin-1- yl)-benzene sulfonic acid 2-(3-pyridin-2-ylmethyl- ureido)-3H-benzimidazol- 5-yl ester 4.46 522 82-c 80-a 4-(4-methyl-piperazin-1- yl)-benzene sulfonic acid 2-[3-(2-methoxy-ethyl)- ureido]-3H-benzimidazol- 5-yl ester 5.86 489 82-d 79 4-(4-hydroxy-piperidin-1- yl)-benzene sulfonic acid 2-[3-(2-morpholin-4-yl- ethyl)-ureido]-3H- benzimidazol-5-yl ester 5.47 545 82-e 79 4-(4-hydroxy-piperidin-1- yl)-benzene sulfonic acid 2-(3-pyridin-2-ylmethyl- ureido)-3H-benzimidazol- 5-yl ester 6.4 523 82-f 79 4-(4-hydroxy-piperidin-1- yl)-benzene sulfonic acid 2-[3-(2-methoxy-ethyl)- ureido]-3H-benzimidazol- 5-yl ester 7.06 490 82-g 79 4-(4-hydroxy-piperidin-1- yl)-benzene sulfonic acid 2-(3-ethyl-ureido)-3H- benzimidazol-5-yl ester 3.3 460 82-h 80-n 4-[(Pyridin-2-ylmethyl)- amino]-benzene sulfonic acid 2-[3-(2-morpholin-4- yl-ethyl)-ureido]-3H- benzimidazol-5-yl ester 4.83 552 82-i 80-n 4-[(Pyridin-2-ylmethyl)- amino]-benzene sulfonic acid 2-(3-pyridin-2- ylmethyl-ureido)-3H- benzimidazol-5-yl ester 5.53 530 82-j 80-n 4-[(Pyridin-2-ylmethyl)- amino]-benzene sulfonic acid 2-[3-(2-methoxy- ethyl)-ureido]-3H- benzimidazol-5-yl ester 6.6 497 82-k 80-n 4-[(Pyridin-2-ylmethyl)- amino]-benzene sulfonic acid 2-[3-(2-methoxy- ethyl)-ureido]-3H- benzimidazol-5-yl ester 6.2 467 82-l 80-i 4-(3-Hydroxy-propylamino)- benzenesulfonic acid 2-[3-(2- morpholin-4-yl-ethyl)- ureido]-3H-benzimidazol-5- yl ester 6.2 497 82-m 80-i 4-(3-Hydroxy-propylamino)- benzenesulfonic acid 2-(3- pyridin-2-ylmethyl-ureido)- 3H-benzimidazol-5-yl ester 5.48 519 82-n 80-i 4-(3-Hydroxy-propylamino)- benzenesulfonic acid 2-[3-(2- methoxy-ethyl)-ureido]-3H- benzimidazol-5-yl ester 6.84 464 82-o 80-i 4-(3-Hydroxy-propylamino)- benzenesulfonic acid 2-(3- ethyl-ureido)-3H- benzimidazol-5-yl ester 82-p 80-j 4-(2,2,6,6-tetramethyl- piperidin-4-ylamino)- benzenesulfonic acid 2-[3-(2- morpholin-4-yl-ethyl)-ureido]- 3H-benzimidazol-5-yl ester 0.41 600 82-q 80-j 4-(2,2,6,6-tetramethyl- pipendin-4-ylamino)- benzenesulfonic acid 2-(3- pyridin-2-ylmethyl-ureido)-3H- benzimidazol-5-yl ester 0.42 576 82-r 80-k 4-(2-dimethylamino- ethylamino)-benzenesulfonic acid 2-[3-(2-morpholin-4-yl- ethyl)-ureido]-3H- benzimidazol-5-yl ester 0.41 532 82-s 80-k 4-(2-dimethylamino- ethylamino)-benzenesulfonic acid 2-(3-pyridin-2-ylmethyl- ureido)-3H-benzimidazol-5-yl ester 0.41 510 82-t 80-l 4-morpholin-4-yl- benzenesulfonic acid 2-[3-(2- morpholin-4-yl-ethyl)-ureido]- 3H-benzimidazol-5-yl ester 0.4 531 82-u 80-l 4-morpholin-4-yl- benzenesulfonic acid 2-(3- pyridin-2-ylmethyl-ureido)-3H- benzimidazol-5-yl ester 2.9 509 82-v 80-f 4-[3-(2-oxo-pyrrolidin-1-yl)- propylamino]- benzenesulfonic acid 2-[3-(2- morpholin-4-yl-ethyl)-ureido]- 3H-benzimidazol-5-yl ester 2.6 586 82-w 80-f 4-[3-(2-oxo-pyrrolidin-1-yl)- propylamino]- benzenesulfonic acid 2-(3- pyridin-2-ylmethyl-ureido)-3H- benzimidazol-5-yl ester 2.46 485 82-x 80-g 4-(4-fluoro-benzylamino)- benzenesulfonic acid 2-(3- ethyl-ureido)-3H- benzimidazol-5-yl ester 9.29 514 82-y 80-h 4-(2-Hydroxy-2-methyl- propylamino)- benzenesulfonic acid 2-[3-(2- morpholin-4-yl-ethyl)- ureido]-3H-benzimidazol-5- yl ester 6.61 511 82-z 80-h 4-(2-Hydroxy-2-methyl- propylamino)- benzenesulfonic acid 2-(3- pyridin-2-ylmethyl-ureido)- 3H-benzimidazol-5-yl ester 6.29 533 82-aa 80-h 4-(2-Hydroxy-2-methyl- propylamino)- benzenesulfonic acid 2-[3-(2- methoxy-ethyl)-ureido]-3H- benzimidazol-5-yl ester 2.89 478 82-ab 80-h 4-(2-Hydroxy-2-methyl- propylamino)- benzenesulfonic acid-2-[3-(3- hydroxy-propyl)-ureido]-3H- benzimidazol-5-yl ester 7.33 478 82-ac 80-b 4-[(Tetrahydro-pyran-4- ylmethyl)-amino]- benzenesulfonic acid 2-[3-(2- morpholin-4-yl-ethyl)- ureido]-3H-benzimidazol-5- yl ester 7.28 537 82-ad 80-b 4-[(Tetrahydro-pyran-4- ylmethyl)-amino]- benzenesulfonic acid 2-(3- pyridin-2-ylmethyl-ureido)- 3H-benzimidazol-5-yl ester 6.88 559 82-ae 80-b 4-[(Tetrahydro-pyran-4- ylmethyl)-amino]- benzenesulfonic acid 2-[3-(2- methoxy-ethyl)-ureido]-3H- benzimidazol-5-yl ester 8.67 504 82-af 80-b 4-[(Tetrahydro-pyran-4- ylmethyl)-amino]- benzenesulfonic acid 2-[3-(3- hydroxy-propyl)-ureido]-3H- benzimidazol-5-yl ester 8.03 504 82-ag 80-c 4-(2-fluoro-ethylamino)- benzenesulfonic acid 2-[3-(2- morpholin-4-yl-ethyl)-ureido]- 3H-benzimidazol-5-yl ester 2.5 507 82-ah 80-c 4-(2-fluoro-ethylamino)- benzenesulfonic acid 2-(3- pyridin-2-ylmethyl-ureido)-3H- benzimidazol-5-yl ester 2.46 485 82-ai 80-d 4-(2-Piperidin-1-yl- ethylamino)-benzenesulfonic acid 2-[3-(2-morpholin-4-yl- ethyl)-ureido]-3H- benzimidazol-5-yl ester 5.47 550 82-aj 80-d 4-(2-Piperidin-1-yl- ethylamino)-benzenesulfonic acid 2-(3-pyridin-2-ylmethyl- ureido)-3H-benzimidazol-5- yl ester 4.25 572 82-ak 80-e 4-phenethylamino- benzenesulfonic acid 2-[3-(2- morpholin-4-yl-ethyl)-ureido]- 3H-benzimidazol-5-yl ester 3.14 565 82-al 80-e 4-phenethylamino- benzenesulfonic acid 2-[3-(2- methoxy-ethyl)-ureido]-3H- benzimidazol-5-yl ester 3.78 510 82-am 80-e 4-phenethylamino- benzenesulfonic acid 2-(3- ethyl-ureido)-3H- benzimidazol-5-yl ester 3.83 480 82-an 80-e 4-phenethylamino- benzenesulfonic acid 2-[3-(3- hydroxy-propyl)-ureido]-3H- benzimidazol-5-yl ester 3.57 510 82-ao 80-o 4-(2-hydroxy-propylamino)- benzenesulfonic acid 2-[3-(2- morpholin-4-yl-ethyl)-ureido]- 3H-benzimidazol-5-yl ester 2.36 519 82-ap 80-o 4-(2-hydroxy-propylamino)- benzenesulfonic acid 2-(3- ethyl-ureido)-3H- benzimidazol-5-yl ester 2.91 434 82-aq 80-p 4-(4-methoxy-benzylamino)- benzenesulfonic acid 2-[3-(2- morpholin-4-yl-ethyl)-ureido]- 3H-benzimidazol-5-yl ester 3.03 581 82-ar 80-p 4-(4-methoxy-benzylamino)- benzenesulfonic acid 2-(3- ethyl-ureido)-3H- benzimidazol-5-yl ester 3.67 496 82-as 80-p 4-(4-methoxy-benzylamino)- benzenesulfonic acid 2-(3- pyridin-2-ylmethyl-ureido)-3H- benzimidazol-5-yl ester 3.41 559 82-at 80-p 4-(4-methoxy-benzylamino)- benzenesulfonic acid 2-[3-(3- hydroxy-propyl)-ureido]-3H- benzimidazol-5-yl ester 3.41 526 82-au 80-p 4-(4-methoxy-benzylamino)- benzenesulfonic acid 2-[3-(2- methoxy-ethyl)-ureido]-3H- benzimidazol-5-yl ester 3.61 526 82-av 80-q 4-(2-pyrrolidin-1-yl- ethylamino)-benzenesulfonic acid 2-(3-ethyl-ureido)-3H- benzimidazol-5-yl ester 2.26 473 82-aw 80-q 4-(2-pyrrolidin-1-yl- ethylamino)-benzenesulfonic acid 2-(3-pyridin-2-ylmethyl- ureido)-3H-benzimidazol-5-yl ester 2.08 536 82-ax 80-q 4-(2-pyrrolidin-1-yl- ethylamino)-benzenesulfonic acid 2-[3-(2-methoxy-ethyl)- ureido]-3H-benzimidazol-5-yl ester 2.25 503 82-ay 80-r 4-(1-phenyl-ethylamino)- benzenesulfonic acid 2-(3- ethyl-ureido)-3H- benzimidazol-5-yl ester 3.76 480 82-az 80-s 4-(2-diethylamino- ethylamino)-benzenesulfonic acid 2-(3-pyridin-2-ylmethyl- ureido)-3H-benzimidazol-5-yl ester 3.5 543
Example 83
Preparation of 1-(6-hydroxy-1H-benzoimidazol-2-yl)-3-(2-methoxy-ethyl)-urea
[0796]
[0797] A solution of (6-hydroxy-1H-benzoimidazol-2-yl)-carbamic acid methyl ester (300 mg, example 61) and 2-methoxy-ethylamine (630 IA) in N-methylpyrrolidinone (8 ml) was heated at 90° C. in a sealed tube for 20 hours. The reaction mixture was poured into water (160 ml) and extracted three times with ethyl acetate (40 ml). The combined extracts were dried over magnesium sulfate and then evaporated. The residue was subjected to flash chromatography on silica eluting with a mixture of dichloromethane and methanol (95 C:5 C, v/v) to 1-(6-hydroxy-1H-benzoimidazol-2-yl)-3-(2-methoxy-ethyl)-urea as a yellow solid (180 mg). Mass spectrum: 251[M+H] + ; retention time=0.55 minutes.
Example 84(a)
Preparation of 1-(6-hydroxy-1H-benzoimidazol-2-yl)-3-pyridin-2-ylmethyl-urea
[0798]
[0799] By proceeding in a manner similar to example 83 above but using 2-(aminomethyl)-pyridine there was prepared 1-(6-hydroxy-1H-benzoimidazol-2-yl)-3pyridin-2-ylmethyl-urea as a beige solid. Mass spectrum: 284 [M+H] + ; retention time=0.55 minutes.
Example 84(b)
Preparation of 1-(6-hydroxy-1H-benzoimidazol-2-yl)-3-(2-morpholin-4-yl-ethyl)-urea
[0800]
[0801] By proceeding in a manner similar to example 83 above but using 2-(aminoethyl)-morpholine there was prepared 1-(6-hydroxy-1H-benzoimidazol-2-yl)-3-(2-morpholin-4-yl-ethyl)-urea as a beige solid. Mass spectrum: 306 [M+H] + ; retention time=1.02 minute.
Example 84(c)
Preparation of 1-(6-hydroxy-1H-benzoimidazol-2-yl)-3-(ethyl)-urea
[0802]
[0803] By proceeding in a manner similar to example 83 above but using ethylamine there was prepared 1-(6-hydroxy-1H-benzoimidazol-2-yl)-3-(ethyl)-urea as a beige solid. Mass spectrum: 367 [M+H] + ; retention time=1.36 minute.
Example 85
Preparation of thiophene-2-sulfonic acid 2-[3-(2-ethyl)-ureido]-1H-benzoimidazol-5-yl ester
[0804]
[0805] A stirred solution of 1-ethyl-3-(6-hydroxy-1H-benzoimidazol-2-yl)-urea (35 mg, example 84-c) and thiophene-2-sulfonyl chloride (18 mg) in acetone (3 ml) was treated with triethylamine (25 el). After stirring at ambient temperature for 4 hours, the reaction mixture was evaporated. The residue was filtered and the filtrate evaporated. The residue was directly purified by LCMS triggered purification to give thiophene-2-sulfonic acid 2-[3-(2-ethyl)-ureido]-1H-benzoimidazol-5-yl ester (14 mg) as a off-white solid Mass spectrum: 367 [M+H] + ; retention time=7.88 minutes.
Example 86
[0806] By using a method similar to that for the preparation of example 85, combining thiophene-2-sulfonyl chloride with suitable 1-(6-hydroxy-1H-benzoimidazol-2-yl)-urea (example 83, 84) were obtained the following compounds that were characterized by analytical LC/MS ([M+H] + and retention time given in the following table).
Example 1-(6-hydroxy-1H-benzoimidazol-2-yl)-urea Compound Retention time (minutes) Masse [M + H]+ 86-a Thiophene-2-sulfonic acid 2-[3-(2-methoxy-eth- yl)-ureido]-1H-benzo- imidazol-5-yl ester 2.99 397 86-b Thiophene-2-sulfonic acid 2-[3-(2-morpholin-4-yl-eth- yl)-ureido]-1H-benzo- imidazol-5-yl ester 2.8 452 86-c Thiophene-2-sulfonic acid 2-(3-pyridin-2-ylmeth- yl)-ureido]-1H-benzo- imidazol-5-yl ester 6.52 430
Example 87
Preparation of benzoic acid 4-{2-[3-(2-methoxy-ethyl)-ureido]-1H-benzoimidazol-5-yloxysulfonyl}-phenyl ester
[0807]
[0808] A stirred solution of 1-(6-hydroxy-1H-benzoimidazol-2-yl)-3-(2-methoxy-ethyl)-urea (31 mg, example 82) and benzoic acid 4-chlorosulfonyl-phenyl ester (37 mg) in acetone (0.6 ml) was treated with triethylamine (33 μl). After stirring at ambient temperature for 4 hours, the reaction mixture was evaporated. The residue was filtered and the filtrate evaporated. The residue was directly purified by LCMS triggered purification to give benzoic acid 4-{2-[3-(2-methoxy-ethyl)-ureido]-1H-benzoimidazol-5-yloxysulfonyl}-phenyl ester (7.2 mg) as a off-white solid Mass spectrum: 511 [M+H] + ; retention time=9.90 minutes.
Example 88
[0809] By using a method similar to that for the preparation of example 87, combining benzoic acid 4-chlorosulfonyl-phenyl ester with suitable 1-(6-hydroxy-1H-benzoimidazol-2-yl)-urea (example 83,84) were obtained the following compounds that were characterized by analytical LC/MS ([M+H] + and retention time given in the following table).
Example 1-(6-hydroxy-1H-benzoimidazol-2-yl)-urea Compound Retention time (minutes) Masse [M + H]+ 88-a Benzoic acid 4-{2-[3-(2-morpho- lin-4-yl-ethyl)-urei- do}-1H-benzoimidazol-5-yl- oxysulfonyl}-phenyl ester 7.44 566 88-b Benzoic acid 4-[2-([3-pyri- din-2-ylmethyl)-ureido)-1H-benzo- imidazol-5-yl- oxysulfonyl]-phenyl ester 8.91 544
Example 89 (a)
Preparation of 2,6-difluoro-benzenesulfonic acid 2-(3-pyridin-2-ylmethyl-ureido)-3H-benzoimidazol-5-yl ester
[0810]
[0811] A stirred solution of 1-(6-hydroxy-1H-benzoimidazol-2-yl)-3-pyridin-2-ylmethyl-urea (50 mg, example 83-a) and 2,6-difluoro-benzene-sulfonyl chloride (38 mg) in acetone (1 ml) was treated with triethylamine (48 μl). After stirring at ambient temperature for 4 hours, the reaction mixture was evaporated. The residue was filtered and the filtrate evaporated. The residue was directly purified by LC/MS triggered purification to give benzoic acid 2,6-difluoro-benzenesulfonic acid 2-(3-pyridin-2-ylmethyl-ureido)-3H-benzoimidazol-5-yl ester (29.6 mg) as a off-white solid Mass spectrum: 427 [M+H] + ; retention time=7.86 minutes.
Example 89(b)
Preparation of 2,6-difluoro-benzenesulfonic acid 2-[3-(2-methoxy-ethyl)-ureido]-3H-benzoimidazol-5-yl ester
[0812] By proceeding in a manner similar to example 89(a) above but using 1-(6-hydroxy-1H-benzoimidazol-2-yl)-3-(2-methoxy-ethyl)-urea there was prepared 2,6-difluoro-benzenesulfonic acid 2-[3-(2-methoxy-ethyl)-ureido]-3H-benzoimidazol-5-yl ester as an off-white solid. Mass spectrum: 427[M+H] + ; retention time=7.86 minutes.
Biological Tests
[0813] The experiments described in this report were designed to evaluate the cytotoxicity of “in vitro” Cdk4 inhibitors in comparison with Staurosporine, a non-specific Serine-Threonine kinase inhibitor.
[0814] Stock solutions of compounds were made in DMSO at 10 mM and stored at −20° C. Subsequent dilutions were made in 28% DMSO and used to add 3 μl of the drugs at varied concentrations to the HeLa cells.
[0815] All cell lines were cultured at 37° C. in a humidified atmosphere containing 5% CO 2 .
[0816] HeLa human epithelial cell line was obtained from the American Type Culture Collection (Rockville, Md., USA). Cells were grown as monolayers in Dubelcco's Modified Eagle Medium containing 2 mM L-glutamine, 200 I.U./ml penicillin, 200 μg/ml streptomycin, and supplemented with 10% (v/v) heat inactivated foetal calf serum. Cells were transferred twice a week at 10 5 cells/ml in 75 cm 2 flasks after trypsinisation. Different flasks were done to prepare two preparations the day of experiment.
Cell Growth Inhibition
[0817] Cells in exponential phase of growth were trypsinised and resuspended in their culture medium at 2.5 10 4 cells/ml, in two independent preparations. Cell suspension was distributed in 96 well Cytostar microplates (Amersham) (0.2 ml/well, 5000 cells). Hela cells were coated for 4 hours at 37° C. [ 14 C]-thymidine (0.1 μCi/well) and ten final concentrations of molecules (3 μl) ranging from 20 to 0.03 μM were then added. The uptake of [ 14 C]-thymidine was measured 48 h after the labelling had been started using a Microbeta Trilux counter (Wallac).
[0818] Staurosporine, the reference compound, was evaluated using the same procedure.
[0819] CPM measured 48 hours after the test substance had been added to the media, were compared to those obtained with 0.4% final DMSO, in the control wells.
[0820] IC 50 , obtained from a dose response curve of 10 concentrations in duplicate is the concentration of drug wich diminishes half the specific signal. It is determined by non-linear regression analysis and calculated as a concentration at middle of curve.
[0821] IC 50 values result from 2 independent experiments for all tested molecules.
CDK4/CyclinD1 Flashplate Assay: 96-Well Format
[0822] This is a CDK4/CyclinD1 kinase assay in a 96-well Streptavidin-coated Flashplate with a biotinylated-Rb peptide substrate.
[0823] Each point is tested in duplicate
[0824] Biotinylated-Rb: Biotin-RPPTLSPIPHIPRSPYKFPSSPLR
Kinase Buffer: HEPES, pH 8 50 mM MgCl 2 6H 2 O, pH 7 10 mM DTT 1 mM
1. Prepare substrate: 1 mg/ml solution made fresh in PBS. 2. Add 100 μg per well to the Flashplate. 3. Incubate for 2 hours at RT. 4. From 10 mM inhibitor stocks in DMSO, make 1 mM, 300 μM, 100 μM, 30 μM and 10 μM series of dilution in DMSO. 5. Wash the Flashplate 3 times with 300 μl PBS to remove unbound peptide substrate. 6. Add the CDK4/CyclinD1 kinase: 70 ng per well, in a volume of 90 μl in kinase buffer (except for “no enzyme” control wells). 7. Add 1 μl 1 per well of inhibitor to test 10 μM, 3 μM, 1 μM, 0.3 μM and 0.1 μM in final concentration per 100 μl in each well. 8. Shake gently the Flashplate 1 minute. 9. Incubate 30 minutes on wet ice. 10. Initiate the reaction with 10 μl kinase buffer containing 1 μM final cold ATP and 1 μCi final 33 P-ATP per well. 11. Shake gently the Flashplate 1 minute. 12. Incubate 45 minutes at RT (no shaking). 13. Wash the Flashplate 3 times with 300 μl PBS 14. Count to detect the incorporation of 33 P-ATP by the kinase to the Rb phosphorylation site.
CDK2/CyclinE Flashplate Assay: 96-Well Format
[0839] This is a CDK2/CyclinE kinase assay in a 96-well Streptavidin-coated Flashplate with a biotinylated-Rb peptide substrate.
Each point is tested in duplicate
[0840] Biotinylated-Rb: Biotin-SACPLNLPLQNNHTAADMYLSPVRSPKKKGSTTR-OH
Kinase Buffer: HEPES, pH 8.0 50 mM MgCl 2 6H 2 O 10 mM DTT 1 mM
1. Prepare substrate: 1 mg/ml solution made fresh in PBS. 2. Add 4 μg per well to the Flashplate. 3. Incubate for 2 hours at RT. 4. From 10 mM inhibitor stocks in DMSO, make 1 mM, 300 μM, 100 μM, 30 μM and 10 μM series of dilution in DMSO. 5. Was the Flashplate 3 times with 300 μl PBS to remove unbound peptide substrate. 6. Add the CDK2/CyclinE kinase: 200 ng per well, in a volume of 90 μl in kinase buffer (except for “no enzyme” control wells). 7. Add 1 μl per well of inhibitor to test 10 μM, 3 μM, 1 μM, 0.3 μM and 0.1 μM in final concentration per 100 μl in each well. 8. Shake gently the Flashplate 1 minute. 9. Incubate 30 minutes on wet ice. 10. Initiate the reaction with 10 μl kinase buffer containing 1 μM final cold ATP and 1 μCi final 33 P-ATP per well. 11. Shake gently the Flashplate 1 minute. 12. Incubate 45 minutes at RT (no shaking). 13. Wash the Flashplate 3 times with 300 μl PBS
[0854] 14. Count to detect the incorporation of 33 P-ATP by the kinase to the Rb phosphorylation site.
IC50 CDK4/cyclinD1 IC50 CDK2/cyclinE Example N° (μM) (μM) 1 1.5 0.6 2 2 0.7 3 2.4 0.5 4 6.3 1.5 5 1.12 2.2 6 0.84 0.3 7 0.47 2 8 1.1 Nd 9 2 Nd 10 0.7 0.8 11 0.93 0.5 12 14% inhibition at 10 μM Nd 13 0.4 2 14 0.3 0.2 15 0.3 1.8 16 0.37 1.8 17 6.3 2 18 1.3 0.6 19 2.92 0.7 20 >3 >10 22 1.77 Nd 23 3.1 0.4 24 0.6 0.4 25 0.13 0.08 26 0.68 0.13 27 0.6 0.042 28 1.03 0.6 29 1.7 0.6 30 1.8 0.9 31 0.5 0.1 32 >5 1.1 33 0.64 0.06 34 1.18 0.12 35 1.1 0.12 36 0.77 0.53 37 0.57 0.45 38 1.25 4.3 39 1.62 0.29 40 3.71 1.09 41 2.8 0.06 42 84% inhibition at 10 μM 0.91 43 1.9 0.2 44 O.6 0.13 45 0.6 0.06 46 0.012 0.06 47 0.8 0.16 48 0.3 0.04 49 88% inhibition at 10 μM 0.4 50 0.3 0.04 51 0.8 0.14 52 1 0.08 53 83% inhibition at 10 μM 0.8 54 0.5 0.005 57-a 1 0.24 57-b 51% inhibition at 10 μM 1.9 57-c 60% inhibition at 10 μM 0.6 57-d 70% inhibition at 10 μM 0.5 57-e 90% inhibition at 10 μM 0.3 57-f 88% inhibition at 10 μM 0.5 57-g 52% inhibition at 10 μM 0.6 57-h 4.4 0.1 57-i 27% inhibition at 10 μM 5.2 57-j 3 0.1 57-k 49% inhibition at 10 μM 0.6 57-l 1 0.07 58-a 96% inhibition at 10 μM 0.38 58-b 70% inhibition at 10 μM 0.9 58-c 60% inhibition at 10 μM 0.6 58-d 84% inhibition at 10 μM 1.6 58-e 0.1 0.04 58-f 91% inhibition at 10 μM 0.7 58-g 69% inhibition at 10 μM 1 58-h 3 0.1 58-i 81% inhibition at 10 μM 0.3 58-j 0.5 0.009 58-k 0.5 0.04 58-l 1 0.03 58-m 0.24 0.03 58-n 0.6 Nd 58-o 0.029 0.02 58-p 0.6 Nd 58-q 1 Nd 58-r 80% inhibition at 10 μM 0.02 58-s 0.012 0.02 58-t 9 Nd 58-u 0.29 0.01 58-v 0.11 0.1 58-w 0.19 0.25 58-x 0.31 0.04 58-y 0.27 0.01 58-z 2.23 Nd 58-aa 0.34 0.1 58-ab 0.22 0.002 58-ac 0.17 0.013 58-ad 0.13 0.016 58-ae 1.49 Nd 58-af 0.21 0.18 58-ag 0.39 0.04 58-ah 0.33 0.03 58-ai 0.33 0.15 58-aj 0.38 0.37 58-ak 0.18 0.1 58-al 0.25 0.15 58-am 0.24 0.08 58-an 0.2 0.1 59-a 0.1 0.008 59-b 0.3 0.007 59-c 1 0.007 59-d 0.5 0.015 59-e 1.6 0.1 59-f 1.8 0.06 59-g 1.8 0.2 59-h 1.1 0.2 59-i 1.2 0.04 59-j 0.9 0.007 59-k 0.3 0.02 59-l 0.3 0.004 59-m 1.2 0.03 59-n 0.13 0.036 59-o 0.8 0.04 59-p 0.18 0.017 59-q 0.75 0.11 59-r 1.8 0.22 60-a 0.8 Nd 60-b 0.15 Nd 60-c 0.34 Nd 60-d 0.9 Nd 60-e 0.9 Nd 60-f 1 Nd 60-g 1.5 Nd 60-h Nd Nd 60-i 0.3 Nd 60-j Nd Nd 60-k Nd Nd 60-l 0.4 Nd 60-m 0.5 Nd 60-n 2 Nd 60-o 5 Nd 60-p 1.2 Nd 60-q 1.8 Nd 60-r 0.6 Nd 60-s 8 Nd 60-t 2 Nd 60-u Nd Nd 60-v 4.2 Nd 60-w 0.5 Nd 60-x 5 Nd 60-y 2.5 Nd 60-z 3 Nd 60-aa 3.9 Nd 60-ab 4 Nd 60-ac 0.8 Nd 60-ad 1.3 Nd 60-ae 2.2 Nd 60-af Nd Nd 60-ag Nd Nd 60-ah 0.55 Nd 60-ai 1.6 Nd 61 2.06 Nd 62-a 50% inhibition at 10 μM Nd 62-b 0.44 0.2 62-c 3 0.8 62-d 1.3 Nd 62-e 4.6 1 62-f 3 1.5 62-g 3 1 62-h 0.8 0.07 62-i 1.5 1 62-j 3 1.5 62-k 3 Nd 62-l 2.5 Nd 62-m 1.2 Nd 62-n 1 Nd 62-o 1 Nd 62-p 0.7 Nd 62-q 1.6 Nd 62-r 2.5 Nd 62-s 1.75 Nd 63 1.5 Nd 64-a 1 Nd 64-b 50% at 10 μM Nd 64-c 4.37 Nd 64-d 50% at 10 μM Nd 64-e Nd Nd 65 Nd 1 66-a 19% inhibition at 10 μM Nd 66-b 3.05 Nd 66-c Nd 1 67 91% inhibition at 10 μM Nd 68-a 97% inhibition at 10 μM Nd 68-b 78% inhibition at 10 μM Nd 69 0.84 0.13 70-a 1.18 Nd 70-b 0.67 3 70-c 2 0.8 70-d 0.65 0.3 70-e 0.5 0.8 70-f Nd 5 70-g 5 1.5 70-h 0.14 0.25 78-e 0.6 Nd 78-f 0.1 Nd 78-h 90% inhibition at 10 μM Nd 78-i 97% inhibition at 10 μM Nd 78-k 78% inhibition at 10 μM Nd 78-l 100% inhibition at 10 μM Nd 78-n 54% inhibition at 10 μM Nd 78-o 54% inhibition at 10 μM Nd 78-q 94% inhibition at 10 μM Nd 78-s 88% inhibition at 10 μM Nd 78-t 55% inhibition at 10 μM Nd 78-u 93% inhibition at 10 μM Nd 78-v 46% inhibition at 10 μM Nd 78-w 90% inhibition at 10 μM Nd 80-c 100% inhibition at 10 μM Nd 80-m 103% inhibition at 10 μM Nd 82-h 92% inhibition at 10 μM Nd | The present invention discloses and claims benzimidazole compounds of formula (I):
in which A is aryl or heteroaryl; R 1 is sleceted from optionally substituted alkyl, alkoxy, aryl or heteroaryl, NH-lower alkyl or NH-cycloalkyl, or halogen, NH 2 ; 1-imidazolyl or SO 2 Me; R 2 is selected from optionally substituted —CO-alkyl, —CO-cycloalkyl, —CO-aralkyl, —CO-aryl, —CO-alkoxy, aryl or aralkyl, or —O-amino, CO—NHR 3 or CO—R 3 R 4 wherein R 3 and R 4 are selecteded independently from hydrogen, alkyl, hydroxyalkyl, alkoxyalkyl, fluoroalkyl, alkynyl, heteroalkyl, alkylheteroalkyl, aryl, aralkyl or together form an alkylene chain optionally containing one to 4 heteroatoms; a pharmaceutically acceptable salt or a prodrug thereof; the use of compounds of formula (I) for the treatment of cancer, and pharmaceutical compositions comprising a compound of formula (I) and one or more pharmaceutically acceptable adjuvants or diluents. | 2 |
TECHNICAL FIELD
The present invention relates to a novel lead-free piezoelectric composition containing no lead. The present invention further relates to a lead-free piezoelectric element containing no lead and a method for producing the same, an ultrasonic probe including the lead-free piezoelectric element, and a diagnostic imaging apparatus including the ultrasonic probe.
BACKGROUND ART
Heretofore, various lead-free piezoelectric compositions have been studied, including, for example, (Bi 0.5 K 0.5 )TiO 3 (hereinafter, also referred to as BKT) and BKT-BiFeO 3 (hereinafter, also BiFeO 3 referred to as BFO) binary lead-free piezoelectric compositions. Their piezoelectric constants, however, are still small compared with those of lead-based piezoelectric compositions under the present circumstances (see, for example, PTL 1 and PTL 2 and NPL 1 and NPL 2). In addition, a solid solution of BKT and Bi(Fe,Co)O 3 (hereinafter, also referred to as BFCO) which is derived from BiFeO 3 by the replacement of Fe with Co is just beginning to be studied (for example, PTL 3). On the other hand, a complex oxide Bi(Mg 0.5 Ti 0.5 )O 3 (hereinafter, also referred to as BMT) is known as a composition that is difficult to synthesize at normal pressure and yields a single phase only at high temperature and high pressure, and this hard-to-prepare composition is also known to be so unstable that the composition, even once prepared, is decomposed at hundreds of ° C. at normal pressure (for example, NPL 3). For this reason, conventional lead-free piezoelectrics have been little studied as to their combination with a BaTiO 3 (hereinafter, also referred to as BT) system (see, for example, PTL 4 and NPL 6), but have not been studied as to their application to a BKT-BFO system.
Lead-free piezoelectric elements including a BFO-based piezoelectric composition presumably have a large spontaneous polarization (approximately 100 μC/cm 2 ) (NPL 4) and thus, have been studied actively in recent years. According to the report, however, such piezoelectric compositions having a large spontaneous polarization are difficult to actually obtain on the grounds that, for example, leak current is large and pinning hinders the spontaneous polarization from appearing (NPL 5). Various solutions thereto have been proposed, including, for example, a method involving sintering from very fine starting materials (PTL 1 and NPL 2), a method involving dipping in hot water starting at high temperature, followed by quenching at a very fast rate (NPL 5 and NPL 6), a method involving temperature elevation at a rate as fast as 100° C./second (in order to suppress the evaporation of a highly volatile element such as Bi), followed by sintering in a short time (NPL 7), and a method involving sintering at a temperature near the melting point of a piezoelectric composition to prepare a closely packed sintered body, thereby improving the properties of a lead-free piezoelectric element (PTL 2). Also, a BFO-based lead-free piezoelectric ceramic rich in Co in addition to Fe has been reported (PTL 3).
CITATION LIST
Patent Literature
PTL 1
Japanese Patent Application Laid-Open No. 2008-69051
PTL 2
Japanese Patent Application Laid-Open No. 2010-126421
PTL 3
WO2012/013956
PTL 4
Japanese Patent Application Laid-Open No. 2010-235442
Non-Patent Literature
NPL 1
Japanese Journal of Applied Physics, Vol. 44, No. 7A, pp. 5040-5044 (2005)
NPL 2
Journal of Applied Physics, Vol. 108, 104103 (2010)
NPL 3
Japanese Journal of Applied Physics, Vol. 50, 09NE06 (2011)
NPL 4
C. Ederer et al., Phys. Rev. B, 71 224103 (2005)
NPL 5
Journal of Applied Physics, Vol. 108, 074107 (2010)
NPL 6
Japanese Journal of Applied Physics, Vol. 50, 09ND07 (2011)
NPL 7
G. L. Yuan et al., Solid State communication, Vol. 138, pp. 76-81 (2006)
SUMMARY OF INVENTION
Technical Problem
As mentioned above, BKT alone fails to yield a piezoelectric composition having a sufficiently large piezoelectric constant. BKT alone or BKT-BFO is difficult to sinter and thus requires using a nanopowder synthesized from a vapor phase, as a starting material (PTL 1 and NPL 2). Moreover BKT-BFCO or the like unfortunately fails to exert great piezoelectric performance with high reproducibility due to large leak current or because spontaneous polarization or remnant polarization is subject to pinning by various defects.
Lead-free piezoelectric elements including the aforementioned BFO-based piezoelectric composition present the following problems: defects such as Bi vacancy or oxygen vacancy are increased, because the amount of highly volatile Bi increases with an increase in the amount of BFO. In addition, a large spontaneous polarization or remnant polarization cannot be obtained in an electric field-polarization curve, because domains or domain walls are pinned by various defects or defect pairs. Moreover, high voltage cannot be applied to the elements, because the influence of oxygen vacancy or the like changes the valence of Fe from Fe 3+ to Fe 2+ to increase the leak current of the elements. As a result, disadvantageously, originally expected ferroelectricity or piezoelectric properties cannot be obtained (for example, NPL 5). Alternatively, the lead-free piezoelectric ceramic described in PTL 3, which is rich in Co in addition to Fe, unfortunately fails to exert great piezoelectric properties with high reproducibility due to larger leak current or because domains or domain walls are pinned by defects, etc.
An object of the present invention is to solve the problems mentioned above and to provide a lead-free piezoelectric composition and a lead-free piezoelectric element having a large piezoelectric constant with high reproducibility by a convenient process.
Solution to Problem
According to a first aspect, a piezoelectric composition is a piezoelectric composition having a perovskite structure represented by general formula ABO 3 and having a composition represented by compositional formula x(Bi 0.5 K 0.5 )TiO 3 -yBi(Mg 0.5 Ti 0.5 )O 3 -zBiFeO 3 , in which x+y+z=1, and also represented by a region, in triangle coordinates using x, y, and z in the compositional formula, enclosed by pentagon ABCDE with vertices of point A (1,0,0), point B (0.7,0.3,0), point C (0.1,0.3,0.6), point D (0.1,0.1,0.8), and point E (0.2,0,0.8) but exclusive of segment AE joining point A (1,0,0) and point E (0.2,0,0.8).
According to a first aspect, a first method for producing a piezoelectric composition is a method for producing the aforementioned piezoelectric composition of the first aspect, including a starting material preparation step, a temperature elevation step, a heat treatment step, and a cooling step in the order presented.
According to a first aspect, a second method for producing a piezoelectric composition is a method for producing the aforementioned piezoelectric composition of the first aspect, including a starting material preparation step, a temperature elevation step, a first heat treatment step, a temperature lowering step, a second heat treatment step, and a cooling step in the order presented.
According to a first aspect, a third method for producing a piezoelectric composition is a method for producing the aforementioned piezoelectric composition of the first aspect, including a starting material preparation step, a first temperature elevation step, a first heat treatment step, a first cooling step, a second temperature elevation step, a second heat treatment step, and a second cooling step in the order presented.
According to a first aspect, a piezoelectric element includes the aforementioned piezoelectric composition of the first aspect and an electrode that applies voltage to the piezoelectric composition.
According to a second aspect, a lead-free piezoelectric element is a lead-free piezoelectric element including a piezoelectric composition and an electrode that applies voltage to the piezoelectric composition, the piezoelectric composition having a perovskite structure represented by general compositional formula ABO 3 and containing BiFeO 3 and a Bi complex oxide, the BiFeO 3 having a content of 3 to 80 mol % with respect to the whole piezoelectric composition, and the Bi complex oxide containing, in the general compositional formula, Bi at site A and a plurality of elements differing in valence at site B, in which the lead-free piezoelectric element has a relative permittivity ∈r of 400 or larger and a dielectric loss tan δ of 0.2 or smaller at 25° C., and has a piezoelectric constant d33* of 250 pm/V or higher determined from an electric field-strain curve.
According to a second aspect, an ultrasonic probe includes the aforementioned lead-free piezoelectric element of the second aspect.
According to a second aspect, a diagnostic imaging apparatus includes the aforementioned ultrasonic probe of the second aspect.
According to a second aspect, a first method for producing a lead-free piezoelectric element is a method for producing the aforementioned lead-free piezoelectric element of the second aspect, including a starting material preparation step, a temperature elevation step, a first heat treatment step, a temperature lowering step, a second heat treatment step, and a cooling step in the order presented to produce a piezoelectric composition contained in the lead-free piezoelectric element.
According to a second aspect, a second method for producing a lead-free piezoelectric element is a method for producing the aforementioned lead-free piezoelectric element of the second aspect, including a starting material preparation step, a first temperature elevation step, a first heat treatment step, a first cooling step, a second temperature elevation step, a second heat treatment step, and a second cooling step in the order presented to produce a piezoelectric composition contained in the lead-free piezoelectric element.
Advantageous Effects of Invention
According to a first aspect, the present invention can provide a piezoelectric composition having a larger piezoelectric constant than that of each of BKT alone, BMT alone (which is difficult to synthesize at normal pressure), and BFO alone. In addition, BKT-BMT-BFO complex composition provides a convenient way to produce a piezoelectric composition.
According to a second aspect, the present invention can provide a lead-free piezoelectric element including a BFO-based piezoelectric composition and having a large spontaneous polarization or remnant polarization, small leak current, and high piezoelectric properties, and a method for producing the same.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1 illustrates triangle coordinates that define a composition region of the piezoelectric composition of the first aspect;
FIG. 2 illustrates triangle coordinates that define a more preferred composition region of the piezoelectric composition of the first aspect;
FIG. 3 schematically illustrates a first method for producing the piezoelectric composition of the first aspect except for a starting material preparation step;
FIG. 4 schematically illustrates a second method for producing the piezoelectric composition of the first aspect except for a starting material preparation step;
FIG. 5 schematically illustrates a third method for producing the piezoelectric composition of the first aspect except for a starting material preparation step;
FIG. 6 is a perspective view illustrating one example of the piezoelectric element of the first aspect;
FIG. 7 illustrates triangle coordinates that indicate compositions of piezoelectric compositions of Examples 1-1 to 1-6 and Comparative Examples 1-1 and 1-2;
FIG. 8 illustrates the relationship between the ratio of BMT in a piezoelectric composition and a piezoelectric constant;
FIG. 9 illustrates triangle coordinates that indicate compositions of piezoelectric compositions of Examples 1-7 to 1-26 and Comparative Examples 1-3 to 1-6;
FIG. 10 illustrates the relationship between the ratio of BFO in a piezoelectric composition and a piezoelectric constant;
FIG. 11 illustrates the relationship between the amount of Mn added in a piezoelectric composition and a piezoelectric constant;
FIG. 12 illustrates the relationship between the amount of Mn added in a piezoelectric composition and a dielectric loss;
FIG. 13 illustrates triangle coordinates that define composition regions of piezoelectric compositions based on Examples 1-1 to 1-31 and Comparative Examples 1-1 to 1-6;
FIG. 14 illustrates triangle coordinates that define more preferred composition regions of piezoelectric compositions based on Examples 1-1 to 1-31 and Comparative Examples 1-1 to 1-6;
FIG. 15 is a perspective view illustrating one example of the lead-free piezoelectric element of the second aspect;
FIG. 16 is a perspective view illustrating another example of the lead-free piezoelectric element of the second aspect;
FIGS. 17A and 17B schematically illustrate the domain pinning of a lead-free piezoelectric element including a piezoelectric composition containing BiFeO 3 , and a state where the domain pinning is avoided;
FIG. 18 schematically illustrates a first method for producing the lead-free piezoelectric element of the second aspect except for a starting material preparation step;
FIG. 19 schematically illustrates a second method for producing the lead-free piezoelectric element of the second aspect except for a starting material preparation step;
FIG. 20 is a cross-sectional view schematically illustrating the ultrasonic probe of the second aspect;
FIG. 21 is a perspective view schematically illustrating the diagnostic imaging apparatus of the second aspect;
FIG. 22 illustrates the relationship between the relative permittivity of a piezoelectric element of Example 2-1 according to the second aspect and a temperature;
FIG. 23 illustrates the relationship between the dielectric loss of the piezoelectric element of Example 2-1 according to the second aspect and a temperature;
FIG. 24 illustrates the electric field-strain properties of the piezoelectric element of Example 2-1 according to the second aspect;
FIG. 25 illustrates the electric field-polarization properties of the piezoelectric element of Example 2-1 according to the second aspect;
FIG. 26 illustrates the relationship between the relative permittivity of a piezoelectric element of Example 2-2 according to the second aspect and a temperature;
FIG. 27 illustrates the relationship between the dielectric loss of the piezoelectric element of Example 2-2 according to the second aspect and a temperature;
FIG. 28 illustrates the electric field-strain properties of the piezoelectric element of Example 2-2 according to the second aspect;
FIG. 29 illustrates the electric field-polarization properties of the piezoelectric element of Example 2-2 according to the second aspect;
FIG. 30 illustrates the relationship between the relative permittivity of a piezoelectric element of Comparative Example 2-1 and a temperature;
FIG. 31 illustrates the relationship between the dielectric loss of the piezoelectric element of Comparative Example 2-1 and a temperature;
FIG. 32 illustrates the electric field-strain properties of the piezoelectric element of Comparative Example 2-1;
FIG. 33 illustrates the electric field-polarization properties of the piezoelectric element of Comparative Example 2-1;
FIG. 34 illustrates the relationship between the amount of BFO and d33*;
FIG. 35 illustrates the relationship between the relative permittivity of a piezoelectric element of Example 2-8 according to the second aspect and a temperature;
FIG. 36 illustrates the relationship between the dielectric loss of the piezoelectric element of Example 2-8 according to the second aspect and a temperature;
FIG. 37 schematically illustrates a method for producing a piezoelectric element of Example 2-9 except for a starting material preparation step;
FIG. 38 illustrates the relationship between the relative permittivity of a piezoelectric element of Example 2-9 according to the second aspect and a temperature; and
FIG. 39 illustrates the relationship between the dielectric loss of the piezoelectric element of Example 2-9 according to the second aspect and a temperature.
DESCRIPTION OF EMBODIMENTS
First Aspect
Hereinafter, the first aspect will be described.
Embodiment 1-1
First, the piezoelectric composition of the first aspect will be described.
The piezoelectric composition of the first aspect has a perovskite structure represented by general formula ABO 3 and is represented by compositional formula x(Bi 0.5 K 0.5 )TiO 3 -yBi(Mg 0.5 Ti 0.5 )O 3 -zBiFeO 3 . In the compositional formula, x+y+z=1. The piezoelectric composition has a composition represented by a region, in triangle coordinates using x, y, and z in the compositional formula, enclosed by pentagon ABCDE with vertices of point A (1,0,0), point B (0.7,0.3,0), point C (0.1,0.3,0.6), point D (0.1,0.1,0.8), and point E (0.2,0,0.8) but exclusive of segment AE joining point A (1,0,0) and point E (0.2,0,0.8).
The BKT-BMT-BFO complex composition can yield a piezoelectric composition having a larger piezoelectric constant than that of each of BKT alone, BMT alone, and BFO alone, and provides a convenient way to produce this piezoelectric composition.
FIG. 1 illustrates composition region 1 that is enclosed by pentagon ABCDE with vertices of point A (1,0,0), point B (0.7,0.3,0), point C (0.1,0.3,0.6), point D (0.1,0.1,0.8), and point E (0.2,0,0.8) in triangle coordinates using x, y, and z in the compositional formula. However, the composition region according to the first aspect is exclusive of segment AE joining point A (1,0,0) and point E (0.2,0,0.8).
Starting materials for the piezoelectric composition indicated by composition region 1 can be relatively easily sintered, and the piezoelectric composition indicated by composition region 1 has a large piezoelectric constant d33* determined from the maximum slope of electric field-strain properties.
On the other hand, a composition with an amount of BFO exceeding 0.8 (composition with z>0.8) is not preferred because such composition increases leak current or emphasizes a phenomenon in which domain movement is pinned; thus the resulting piezoelectric composition does not exhibit great piezoelectric properties.
In the case of z=0, the composition of the first aspect is indicated by segment AB joining point A (1,0,0) and point B (0.7,0.3,0) but exclusive of point A (1,0,0). The composition is exclusive of point A (1,0,0) because y=z=0 at point A yields a composition consisting of BKT alone, resulting in a not much large value of d33* and remarkably strict sintering conditions during production. For example, BKT alone can be sintered at approximately 1,060° C. By contrast, a temperature a few ° C. lower than the temperature cannot improve sintered density, whereas a temperature a few ° C. higher than the temperature partially melts starting materials. Thus, the optimum range of sintering temperatures for producing the piezoelectric composition becomes narrower, and sintering is thus rendered difficult. The present inventors have found that the dissolution of BMT or BMT-BFO in BKT remarkably facilitates sintering.
A composition with an amount of BMT exceeding 0.3 (composition with y>0.3) often generates a heterogeneous phase other than the perovskite structure or decreases a piezoelectric constant d33*. A composition with an amount of BMT less than 0.02 (composition with y<0.02) is disadvantageously too similar to the composition of BKT-BFO to achieve sintering, as in BKT-BFO.
Next, more preferred forms of the piezoelectric composition of the first aspect will be described.
BKT has a tetragonal structure, and BFO has a rhombohedral structure. Thus, a phase boundary exists between these structures. In this context, the phase boundary refers to a composition region in which at least 2 types of crystal structures coexist with each other. In conventional approaches, BMT can be produced only under conditions of high temperature and high pressure and as such, may also be difficult to produce as a solid solution. Combination BKT-BMT or BKT-BMT-BFO has not yet been studied. Thus, its phase boundary has also been totally unknown. The present inventors have revealed for the first time that a tetragonal-pseudocubic phase boundary and a rhombohedral-pseudocubic phase boundary also exist in a BKT-BMT-BFO solid solution composition. The present inventors have further found for the first time that, in proximity to the phase boundary, a piezoelectric composition having drastically great piezoelectric properties compared with those of a piezoelectric composition produced by a usual method can be achieved by annealing treatment or relatively rapid air cooling, as shown later in a method for producing the piezoelectric composition of the first aspect.
Specifically, the piezoelectric composition of the first aspect preferably has a composition represented by a region, in the triangle coordinates, enclosed by pentagon AFGHI with vertices of point A (1,0,0), point F (0.8,0.2,0), point G (0.7,0.2,0.1), point H (0.7,0.1,0.2), and point I (0.8,0,0.2) but exclusive of segment AI joining point A (1,0,0) and point I (0.8,0,0.2). More preferably, the piezoelectric composition of the first aspect has a composition including a tetragonal-pseudocubic phase boundary or a composition located in proximity to the phase boundary.
Alternatively, the piezoelectric composition of the first aspect preferably has a composition represented by a region, in the triangle coordinates, enclosed by pentagon JKLMN with vertices of point J (0.6,0,0.4), point K (0.5,0.2,0.3), point L (0.2,0.2,0.6), point M (0.2,0.1,0.7), and point N (0.3,0,0.7) but exclusive of segment JN joining point J (0.6,0,0.4) and point N (0.3,0,0.7). More preferably, the piezoelectric composition of the first aspect has a composition including a rhombohedral-pseudocubic phase boundary or a composition located in proximity to the phase boundary.
FIG. 2 illustrates composition region 2 that is enclosed by pentagon AFGHI with vertices of point A (1,0,0), point F (0.8,0.2,0), point G (0.7,0.2,0.1), point H (0.7,0.1,0.2), and point I (0.8,0,0.2) in the triangle coordinates, and composition region 3 that is enclosed by pentagon JKLMN with vertices of point J (0.6,0,0.4), point K (0.5,0.2,0.3), point L (0.2,0.2,0.6), point M (0.2,0.1,0.7), and point N (0.3,0,0.7) in the triangle coordinates. However, composition region 2 according to the first aspect is exclusive of segment AI joining point A (1,0,0) and point I (0.8,0,0.2), and composition region 3 according to the first aspect is exclusive of segment JN joining point J (0.6,0,0.4) and point N (0.3,0,0.7).
The piezoelectric composition of the first aspect has a perovskite structure which is represented by general compositional formula ABO 3 . The standard molar ratio of the site-A element, the site-B element, and oxygen is 1:1:3. The molar ratio of these moieties may fall outside the standard molar ratio within a range that can form the perovskite structure.
For the piezoelectric composition of the first aspect, Mg in the compositional formula is preferably partially replaced with Zn, and Bi in the compositional formula is preferably partially replaced with at least one type selected from La, Sm, and Nd. Furthermore, Ti in the compositional formula is preferably partially replaced with Zr. The replacement of these elements can lower curie temperature (Tc) or maximum temperature (Tm) of permittivity. Tc (or Tm) thus lowered can be expected to produce a large piezoelectric constant and a large permittivity in the piezoelectric composition of the first aspect that exhibits relaxor properties.
Preferably, the piezoelectric composition of the first aspect further contains 2 wt % or less of at least one element selected from the group consisting of Mn, Co, Ni, V, Nb, Ta, W, Si, Ge, Ca, and Sr. Mn, Co, Ni, or V thus contained therein can bring the changed valence of Fe back to trivalence and can be expected to reduce leak current. Since Nb, Ta, V, or W makes a contribution as a donor, these elements thus contained therein can be expected to soften materials. Si or Ge thus contained therein can be expected to improve sintered density and to improve an electromechanical coupling coefficient. Sr or Ca thus contained therein can be expected to reduce the evaporation of Bi or K and consequently, can improve properties or reliability.
At least one element selected from the group consisting of Mn, Co, Ni, V, Nb, Ta, W, Si, Ge, Ca, and Sr mentioned above does not have to be dissolved in the crystal of the piezoelectric composition and may be deposited in crystal grains or grain boundary or may be segregated.
Embodiment 1-2
Next, a method for producing the piezoelectric composition of the first aspect will be described with reference to the accompanying drawings. The production method given below can conveniently produce the piezoelectric composition described above in Embodiment 1-1.
[First Production Method]
FIG. 3 schematically illustrates a first method for producing the piezoelectric composition of the first aspect except for a starting material preparation step. The first method for producing the piezoelectric composition of the first aspect includes a starting material preparation step, a temperature elevation step, a heat treatment step, and a cooling step in the order presented.
<Starting Material Preparation Step>
First, oxide, carbonate, bicarbonate, various acid salts, or the like of each element constituting the piezoelectric composition of the first aspect is prepared as a starting material. For example, Bi 2 O 3 , Fe 2 O 3 , TiO 2 , and MgO can be used as oxides. Also, K 2 CO 3 or KHCO 3 can be used as carbonate.
As mentioned above, K 2 CO 3 or KHCO 3 can be used as a potassium source for the piezoelectric composition of the first aspect. Preferably, KHCO 3 is used. This is because KHCO 3 has much smaller hygroscopicity than that of K 2 CO 3 and can therefore reduce weighing errors as a starting material.
Next, a mixture of starting material powders is prepared using necessary amounts of weighed starting materials. The method for preparing the mixture can be any of dry and wet methods. Wet grinding using, for example, a ball mill or a jet mill can be appropriately used. In the case of performing the wet grinding using a ball mill, the starting materials are mixed with a dispersion medium, and this mixture is added to a grinding apparatus. Any of various alcoholic materials (e.g., methanol and ethanol), any of various organic liquids, or pure water can be used as the dispersion medium. Since water-soluble K 2 CO 3 or KHCO 3 is used as a starting material, an alcoholic material is desirable from the viewpoint of liquid waste disposal or the absence of water. A grinding medium such as zirconia balls or alumina balls is further added to the grinding apparatus where mixing and grinding are then carried out until the grain size of the starting materials becomes fine and uniform. Next, the grinding medium is removed, and the dispersion medium is removed by use of suction filtration or a dryer. Then, the obtained starting material powders are placed in a container such as a crucible, followed by preliminary firing. The preliminary firing can be carried out at a temperature of, for example, 600 to 1,000° C. This can achieve homogeneous composition of the mixture and improvement in sintered density after sintering. However, the preliminary firing is not necessarily required. Instead, a compact preparation step mentioned below may be carried out using the starting material powders from which the dispersion medium has been removed by drying. On the other hand, the preliminary firing may be performed twice or more in order to improve homogeneity or sintered density.
In the case of performing the preliminary firing, preliminarily fired powders after the preliminary firing are ground again in the same way as in the grinding of the starting material powders using a grinding apparatus. In the grinding step following the preliminary firing, a binder or the like is added thereto at any of initial, intermediate, and final stages, followed by drying again to prepare starting material powders. For example, polyvinyl alcohol (PVA) or polyvinyl butyral (PVB) can be used as the binder.
Next, the obtained mixed powder of organic components and a ceramic is formed into cylindrical pellets of approximately 10 mm in diameter and approximately 1 mm in thickness to approximately 50 mm in diameter and approximately 5 mm in thickness using, for example, a press machine. Finally, the obtained compact is placed in an electric furnace and heated at 500 to 750° C. for a few hours to approximately 20 hours for binder removal treatment to obtain a starting material compact.
The starting material preparation step is described above with reference to the usual solid-phase method. However, the starting material preparation step is not limited by the solid-phase method and may be carried out by, for example, a hydrothermal synthesis method or a method using alkoxide as a starting material.
<Temperature Elevation Step>
Next, as illustrated in FIG. 3 , the obtained starting material compact is placed again in a crucible or the like, and the temperature is elevated to the temperature of the heat treatment step. The rate of temperature rise is usually set to 50 to 300° C./hr, though differing depending on the size of the starting material compact. For the purpose of removing water, for example, the temperature may be kept at 100 to 200° C. for a given time, or the rate of temperature rise may be slowed down. Such cases are also included in the temperature elevation step of the first aspect.
<Heat Treatment Step>
Next, as illustrated in FIG. 3 , the starting material compact is heat-treated at 900 to 1,080° C. for 5 minutes to 4 hours.
<Cooling Step>
Finally, as illustrated in FIG. 3 , the compact thus heat-treated is cooled to room temperature. This cooling step is carried out in order to prevent various defects of the piezoelectric composition from gathering at domain walls. The rate of cooling is preferably 0.01 to 200° C./second, more preferably 5 to 100° C./second. A rate of cooling of 200° C./second or slower can be on the order of 1/10 to 1/100 or less of the rate of cooling in, for example, ultrahigh-speed quenching from a temperature of 800° C. by dipping in hot water of 70° C. and thus, can avoid destroying the piezoelectric composition.
[Second Production Method]
FIG. 4 schematically illustrates a second method for producing the piezoelectric composition of the first aspect except for a starting material preparation step. The second method for producing the piezoelectric composition of the first aspect includes a starting material preparation step, a temperature elevation step, a first heat treatment step, a temperature lowering step, a second heat treatment step, and a cooling step in the order presented.
<Starting Material Preparation Step>
The starting material preparation step in the second production method is carried out in the same way as in the starting material preparation step in the first production method.
<Temperature Elevation Step>
As illustrated in FIG. 4 , the temperature elevation step in the second production method is carried out in the same way as in the temperature elevation step in the first production method.
<First Heat Treatment Step>
Next, as illustrated in FIG. 4 , the starting material compact is heat-treated at 900 to 1,080° C. When the piezoelectric composition of interest is a ceramic, the heat treatment time is 2 to 300 hours, more preferably 6 to 200 hours. In the case of obtaining a ceramic as the piezoelectric composition, this first heat treatment step serves as a sintering step for the starting material compact. This heat treatment time can be controlled to thereby control the particle size of the ceramic. The ceramic obtained as the piezoelectric composition has a particle size of preferably 0.5 to 200 μm, more preferably 1 to 100 μm. This preferred particle size of the piezoelectric composition can be achieved by the heat treatment time (sintering time) set to 6 to 300 hours.
When the piezoelectric composition of interest is a single crystal, the heat treatment temperature is 6 to 3,000 hours. In the case of obtaining a single crystal as the piezoelectric composition, this first heat treatment step serves as a crystal growth step for the starting material compact.
<Temperature Lowering Step>
As mentioned later, the second heat treatment step serves as an annealing step. As illustrated in FIG. 4 , the temperature lowering step therefore intervenes between the first heat treatment step and the second heat treatment step. The rate of temperature drop is not particularly limited and can be set to 50 to 1,000° C./hr for the ceramic and to 0.1 to 200° C./hr for the single crystal.
<Second Heat Treatment Step>
Next, as illustrated in FIG. 4 , the second heat treatment step is carried out for the starting material compact. This second heat treatment step serves as an annealing step. The annealing temperature is set to 300 to 900° C., more preferably 400 to 800° C. The annealing time is set to 5 minutes to 100 hours. This annealing step is carried out in order to remove various defects of the piezoelectric composition.
Also preferably, the annealing step is carried out in two or more rounds at different temperatures respectively. This is because various defects are removed at temperatures that are not the same among the defects.
<Cooling Step>
As illustrated in FIG. 4 , the cooling step in the second production method is carried out in the same way as in the cooling step in the first production method.
[Third Production Method]
FIG. 5 schematically illustrates a third method for producing the piezoelectric composition of the first aspect except for a starting material preparation step. The third method for producing the piezoelectric composition of the first aspect includes a starting material preparation step, a first temperature elevation step, a first heat treatment step, a first cooling step, a second temperature elevation step, a second heat treatment step, and a second cooling step in the order presented.
<Starting Material Preparation Step>
The starting material preparation step in the third production method is carried out in the same way as in the starting material preparation step in the first production method.
<First Temperature Elevation Step>
As illustrated in FIG. 5 , the first temperature elevation step in the third production method is carried out in the same way as in the temperature elevation step in the first production method.
<First Heat Treatment Step>
As illustrated in FIG. 5 , the first heat treatment step in the third production method is carried out in the same way as in the first heat treatment step in the second production method.
<First Cooling Step>
Next, as illustrated in FIG. 5 , the compact thus heat-treated is cooled to room temperature. The first cooling step can be carried out at substantially the same rate of cooling as that in the cooling step in the first production method. Although not shown in FIG. 5 , the step of processing the compact after the first cooling step into a compact having a smaller shape may be additionally carried out. This enables the second heat treatment step (annealing step) mentioned later to be carried out for the compact having a smaller shape and consequently, can reliably prevent the piezoelectric composition from being destroyed by thermal shock in the second cooling step mentioned later.
<Second Temperature Elevation Step>
As mentioned later, the second heat treatment step serves as an annealing step. As illustrated in FIG. 5 , the temperature elevation step is therefore carried out after the first cooling step. The rate of temperature rise is not particularly limited and can be set to 50 to 1,000° C./hr.
<Second Heat Treatment Step>
As illustrated in FIG. 5 , the second heat treatment step in the third production method is carried out in the same way as in the second heat treatment step in the second production method.
<Second Cooling Step>
As illustrated in FIG. 5 , the second cooling step in the third production method is carried out in the same way as in the cooling step in the second production method.
Embodiment 1-3
Next, the piezoelectric element of the first aspect will be described with reference to the accompanying drawings. FIG. 6 is a perspective view illustrating one example of the piezoelectric element of the first aspect. The piezoelectric element of the first aspect includes the piezoelectric composition described above in Embodiment 1-1 and an electrode that applies voltage to the piezoelectric composition. Specifically, as illustrated in FIG. 6 , piezoelectric element 10 of the first aspect includes piezoelectric composition 11 and electrode 12 that applies voltage to piezoelectric composition 11 .
The piezoelectric element of the first aspect has a piezoelectric constant d33* of preferably 140 pm/V or higher, more preferably 200 pm/V or higher, most preferably 250 pm/V or higher, determined from an electric field-strain curve.
Hereinafter, the first aspect will be described with reference to Examples. In Examples shown below, a bulk ceramic was used as a piezoelectric composition. However, the form of the piezoelectric composition of the first aspect is not limited to a ceramic, and the piezoelectric composition of the first aspect may be in the form of an oriented ceramic, a thick film, or a single crystal.
First, Examples based on the first method for producing the piezoelectric composition of the first aspect will be described.
Example 1-1
Starting Material Preparation Step
30 g in total of Bi 2 O 3 , KHCO 3 , TiO 2 , and MgO was weighed such that the composition of the resulting piezoelectric composition satisfied compositional formula 0.95(Bi 0.5 K 0.5 )TiO 3 -0.05Bi(Mg 0.5 Ti 0.5 )O 3 [x=0.95, y=0.05, and z=0] to prepare starting materials. Next, the weighed starting materials were placed in a pot together with ethanol and zirconia balls and ground for 16 hours using a ball mill. Then, the starting materials were dried. The starting material powders were further preliminarily fired at 800° C. for 6 hours. The obtained starting material powders were placed again in a pot together with ethanol and zirconia balls and ground again for 16 hours using a ball mill. Then, PVB was added thereto as a binder, followed by drying. Next, a pressure of approximately 200 to 250 MPa was applied to the obtained starting material powders using a uniaxial press apparatus to prepare pellets of 10 mm in diameter and 1.5 mm in thickness. The obtained pellets were heated at 700° C. for 10 hours for removal of the binder to obtain a starting material compact.
<Temperature Elevation Step>
Next, the temperature of the obtained starting material compact was elevated to 1,060° C. at a rate of temperature rise of 300° C./hr.
<Heat Treatment Step>
Subsequently, the starting material compact was sintered at 1,060° C. for 2 hours.
<Cooling Step>
Finally, the compact thus sintered was cooled to room temperature at a rate of cooling of 1,060° C./5 hours (0.058° C./second) to obtain a piezoelectric composition.
Next, the obtained piezoelectric composition was processed into a thickness of approximately 0.4 mm by polishing. Then, gold electrodes were formed on both sides of the piezoelectric composition by sputtering to obtain a piezoelectric element.
Example 1-2
A piezoelectric composition and a piezoelectric element were produced in the same way as in Example 1-1 except that: the starting materials used were 30 g in total of Bi 2 O 3 , KHCO 3 , TiO 2 , and MgO weighed such that the composition of the piezoelectric composition satisfied compositional formula 0.9(Bi 0.5 K 0.5 )TiO 3 -0.1Bi(Mg 0.5 Ti 0.5 )O 3 [x=0.9, y=0.1, and z=0]; and the sintering temperature was set to 1,070° C.
Example 1-3
A piezoelectric composition and a piezoelectric element were produced in the same way as in Example 1-1 except that: the starting materials used were 30 g in total of Bi 2 O 3 , KHCO 3 , TiO 2 , and MgO weighed such that the composition of the piezoelectric composition satisfied compositional formula 0.85(Bi 0.5 K 0.5 )TiO 3 -0.15Bi(Mg 0.5 Ti 0.5 )O 3 [x=0.85, y=0.15, and z=0]; and the sintering temperature was set to 1,080° C.
Example 1-4
A piezoelectric composition and a piezoelectric element were produced in the same way as in Example 1-1 except that: the starting materials used were 30 g in total of Bi 2 O 3 , KHCO 3 , TiO 2 , and MgO weighed such that the composition of the piezoelectric composition satisfied compositional formula 0.8(Bi 0.5 K 0.5 )TiO 3 -0.2Bi(Mg 0.5 Ti 0.5 )O 3 [x=0.8, y=0.2, and z=0]; and the sintering temperature was set to 1,080° C.
Example 1-5
A piezoelectric composition and a piezoelectric element were produced in the same way as in Example 1-1 except that: the starting materials used were 30 g in total of Bi 2 O 3 , KHCO 3 , TiO 2 , and MgO weighed such that the composition of the piezoelectric composition satisfied compositional formula 0.7(Bi 0.5 K 0.5 )TiO 3 -0.3Bi(Mg 0.5 Ti 0.5 )O 3 [x=0.7, y=0.3, and z=0]; and the sintering temperature was set to 1,070° C.
Example 1-6
A piezoelectric composition and a piezoelectric element were produced in the same way as in Example 1-1 except that: the starting materials used were 30 g in total of Bi 2 O 3 , KHCO 3 , TiO 2 , and MgO weighed such that the composition of the piezoelectric composition satisfied compositional formula 0.98(Bi 0.5 K 0.5 )TiO 3 -0.02Bi(Mg 0.5 Ti 0.5 )O 3 [x=0.98, y=0.02, and z=0]; and the sintering temperature was set to 1,063° C.
Comparative Example 1-1
A piezoelectric composition and a piezoelectric element were produced in the same way as in Example 1-1 except that: the starting materials used were 30 g in total of Bi 2 O 3 , KHCO 3 , and TiO 2 weighed such that the composition of the piezoelectric composition satisfied compositional formula (Bi 0.5 K 0.5 )TiO 3 [x=1, y=0, and z=0]; and the sintering temperature was set to 1,060±5° C.
Comparative Example 1-2
A piezoelectric composition and a piezoelectric element were produced in the same way as in Example 1-1 except that: the starting materials used were 30 g in total of Bi 2 O 3 , KHCO 3 , TiO 2 , and MgO weighed such that the composition of the piezoelectric composition satisfied compositional formula 0.6(Bi 0.5 K 0.5 )TiO 3 -0.4Bi(Mg 0.5 Ti 0.5 )O 3 [x=0.6, y=0.4, and z=0]; and the sintering temperature was set to 1,080° C.
Next, the following measurement was performed using the piezoelectric compositions and the piezoelectric elements of Examples 1-1 to 1-6 and Comparative Examples 1-1 and 1-2.
<Crystal Structure Analysis of Piezoelectric Composition>
The crystal structure of each obtained piezoelectric composition was analyzed by powder X-ray diffraction.
<Measurement of Piezoelectric Constant d33* of Piezoelectric Element>
The electric field-strain curve of each obtained piezoelectric element was prepared by use of a ferroelectric property evaluation system “FCE-3” manufactured by TOYO Corp. or a self-made evaluation system using a contact-type displacement gauge. The piezoelectric constant d33* was measured from this electric field-strain curve. This measurement was performed after calibration with the value of PZT having a known piezoelectric constant d33*.
These results are shown in Table 1 and FIGS. 7 and 8 . Table 1 also shows triangle coordinates using x, y, and z in the compositional formula of each piezoelectric composition.
TABLE 1
Triangle coordinates
d33*
(x, y, z)
(pm/V)
Crystal structure
Example 1-1
(0.95, 0.05, 0)
237
Coexistence of tetragonal
and pseudocubic structures
Example 1-2
(0.9, 0.1, 0)
285
Pseudocubic structure
Example 1-3
(0.85, 0.15, 0)
278
Pseudocubic structure
Example 1-4
(0.8, 0.2, 0)
191
Pseudocubic structure
Example 1-5
(0.7, 0.3, 0)
145
Pseudocubic structure
Example 1-6
(0.98, 0.02, 0)
180
Tetragonal structure
Comparative
(1, 0, 0)
100
Tetragonal structure
Example 1-1
Comparative
(0.6, 0.4, 0)
64
Coexistence of pseudocubic
Example 1-2
structure and heterogeneous
phase
The piezoelectric constants of these piezoelectric elements were measured along arrow 30 shown in FIGS. 7 and 8 . As is evident from Table 1, the piezoelectric elements of Examples 1-1 to 1-6 can achieve larger piezoelectric constants than those of the piezoelectric elements of Comparative Examples 1-1 and 1-2. As is evident from Table 1 and FIG. 8 , the piezoelectric elements of Examples 1-1, 1-2, and 1-3 in which y in the triangle coordinates of their piezoelectric compositions falls within the range of 0.05≦y≦0.15 have a particularly large piezoelectric constant d33*. This is presumably because, in FIG. 7 , the compositions of the piezoelectric compositions of Examples 1-1, 1-2, and 1-3 include tetragonal-pseudocubic phase boundary 35 or have composition located in proximity to phase boundary 35 .
Example 1-7
A piezoelectric composition and a piezoelectric element were produced in the same way as in Example 1-1 except that: the starting materials used were 30 g in total of Bi 2 O 3 , KHCO 3 , TiO 2 , MgO, and Fe 2 O 3 weighed such that the composition of the piezoelectric composition satisfied compositional formula 0.85(Bi 0.5 K 0.5 )TiO 3 -0.1Bi(Mg 0.5 Ti 0.5 )O 3 -0.05BiFeO 3 [x=0.85, y=0.1, and z=0.05]; and the sintering temperature was set to 1,070° C.
Example 1-8
A piezoelectric composition and a piezoelectric element were produced in the same way as in Example 1-1 except that: the starting materials used were 30 g in total of Bi 2 O 3 , KHCO 3 , TiO 2 , MgO, and Fe 2 O 3 weighed such that the composition of the piezoelectric composition satisfied compositional formula 0.8(Bi 0.5 K 0.5 )TiO 3 -0.1Bi(Mg 0.5 Ti 0.5 )O 3 -0.1BiFeO 3 [x=0.8, y=0.1, and z=0.1]; and the sintering temperature was set to 1,055° C.
Example 1-9
A piezoelectric composition and a piezoelectric element were produced in the same way as in Example 1-1 except that: the starting materials used were 30 g in total of Bi 2 O 3 , KHCO 3 , TiO 2 , MgO, and Fe 2 O 3 weighed such that the composition of the piezoelectric composition satisfied compositional formula 0.7(Bi 0.5 K 0.5 )TiO 3 -0.1Bi(Mg 0.5 Ti 0.5 )O 3 -0.2BiFeO 3 [x=0.7, y=0.1, and z=0.2]; and the sintering temperature was set to 1,030° C.
Example 1-10
A piezoelectric composition and a piezoelectric element were produced in the same way as in Example 1-1 except that: the starting materials used were 30 g in total of Bi 2 O 3 , KHCO 3 , TiO 2 , MgO, and Fe 2 O 3 weighed such that the composition of the piezoelectric composition satisfied compositional formula 0.6(Bi 0.5 K 0.5 )TiO 3 -0.1Bi(Mg 0.5 Ti 0.5 )O 3 -0.3BiFeO 3 [x=0.6, y=0.1, and z=0.3]; and the sintering temperature was set to 1,000° C.
Example 1-11
A piezoelectric composition and a piezoelectric element were produced in the same way as in Example 1-1 except that: the starting materials used were 30 g in total of Bi 2 O 3 , KHCO 3 , TiO 2 , MgO, and Fe 2 O 3 weighed such that the composition of the piezoelectric composition satisfied compositional formula 0.5(Bi 0.5 K 0.5 )TiO 3 -0.1Bi(Mg 0.5 Ti 0.5 )O 3 -0.4BiFeO 3 [x=0.5, y=0.1, and z=0.4]; and the sintering temperature was set to 1,000° C.
Example 1-12
A piezoelectric composition and a piezoelectric element were produced in the same way as in Example 1-1 except that: the starting materials used were 30 g in total of Bi 2 O 3 , KHCO 3 , TiO 2 , MgO, and Fe 2 O 3 weighed such that the composition of the piezoelectric composition satisfied compositional formula 0.45(Bi 0.5 K 0.5 )TiO 3 -0.1Bi(Mg 0.5 Ti 0.5 )O 3 -0.45BiFeO 3 [x=0.45, y=0.1, and z=0.45]; and the sintering temperature was set to 1,000° C.
Example 1-13
A piezoelectric composition and a piezoelectric element were produced in the same way as in Example 1-1 except that: the starting materials used were 30 g in total of Bi 2 O 3 , KHCO 3 , TiO 2 , MgO, and Fe 2 O 3 weighed such that the composition of the piezoelectric composition satisfied compositional formula 0.4(Bi 0.5 K 0.5 )TiO 3 -0.1Bi(Mg 0.5 Ti 0.5 )O 3 -0.5BiFeO 3 [x=0.4, y=0.1, and z=0.5]; and the sintering temperature was set to 1,000° C.
Example 1-14
A piezoelectric composition and a piezoelectric element were produced in the same way as in Example 1-1 except that: the starting materials used were 30 g in total of Bi 2 O 3 , KHCO 3 , TiO 2 , MgO, and Fe 2 O 3 weighed such that the composition of the piezoelectric composition satisfied compositional formula 0.3(Bi 0.5 K 0.5 )TiO 3 -0.1Bi(Mg 0.5 Ti 0.5 )O 3 -0.6BiFeO 3 [x=0.3, y=0.1, and z=0.6]; and the sintering temperature was set to 1,000° C.
Example 1-15
A piezoelectric composition and a piezoelectric element were produced in the same way as in Example 1-1 except that: the starting materials used were 30 g in total of Bi 2 O 3 , KHCO 3 , TiO 2 , MgO, and Fe 2 O 3 weighed such that the composition of the piezoelectric composition satisfied compositional formula 0.2(Bi 0.5 K 0.5 )TiO 3 -0.1Bi(Mg 0.5 Ti 0.5 )O 3 -0.7BiFeO 3 [x=0.2, y=0.1, and z=0.7]; and the sintering temperature was set to 950° C.
Example 1-16
A piezoelectric composition and a piezoelectric element were produced in the same way as in Example 1-1 except that: the starting materials used were 30 g in total of Bi 2 O 3 , KHCO 3 , TiO 2 , MgO, and Fe 2 O 3 weighed such that the composition of the piezoelectric composition satisfied compositional formula 0.1(Bi 0.5 K 0.5 )TiO 3 -0.1Bi(Mg 0.5 Ti 0.5 )O 3 -0.8BiFeO 3 [x=0.1, y=0.1, and z=0.8]; and the sintering temperature was set to 950° C.
Comparative Example 1-3
A piezoelectric composition and a piezoelectric element were produced in the same way as in Example 1-1 except that: the starting materials used were 30 g in total of Bi 2 O 3 , KHCO 3 , TiO 2 , MgO, and Fe 2 O 3 weighed such that the composition of the piezoelectric composition satisfied compositional formula 0.05(Bi 0.5 K 0.5 )TiO 3 -0.1Bi(Mg 0.5 Ti 0.5 )O 3 -0.85BiFeO 3 [x=0.05, y=0.1, and z=0.85]; and the sintering temperature was set to 900° C.
Comparative Example 1-4
A piezoelectric composition and a piezoelectric element were produced in the same way as in Example 1-1 except that: the starting materials used were 30 g in total of Bi 2 O 3 , KHCO 3 , TiO 2 , MgO, and Fe 2 O 3 weighed such that the composition of the piezoelectric composition satisfied compositional formula 0.2(Bi 0.5 K 0.5 )TiO 3 -0.4Bi(Mg 0.5 Ti 0.5 )O 3 -0.4BiFeO 3 [x=0.2, y=0.4, and z=0.4]; and the sintering temperature was set to 1,000° C.
(Comparative Example 1-5)
A piezoelectric composition and a piezoelectric element were produced in the same way as in Example 1-1 except that: the starting materials used were 30 g in total of Bi 2 O 3 , KHCO 3 , TiO 2 , MgO, and Fe 2 O 3 weighed such that the composition of the piezoelectric composition satisfied compositional formula 0.1(Bi 0.5 K 0.5 )TiO 3 -0.4Bi(Mg 0.5 Ti 0.5 )O 3 -0.5BiFeO 3 [x=0.1, y=0.4, and z=0.5]; and the sintering temperature was set to 1,000° C.
Next, the piezoelectric compositions and the piezoelectric elements of Examples 1-7 to 1-16 and Comparative Examples 1-3 to 1-5 were used to perform the crystal structure analysis of the piezoelectric compositions and the measurement of piezoelectric constants d33* of the piezoelectric elements in the same way as in Example 1-1. The results are shown in Table 2 and FIGS. 9 and 10 (“Without annealing step”). Table 2 also shows triangle coordinates using x, y, and z in the compositional formula of each piezoelectric composition.
TABLE 2
Triangle coordinates
d33*
(x, y, z)
(pm/V)
Crystal structure
Example 1-7
(0.85, 0.1, 0.05)
225
Pseudocubic structure
Example 1-8
(0.8, 0.1, 0.1)
230
Pseudocubic structure
Example 1-9
(0.7, 0.1, 0.2)
220
Pseudocubic structure
Example 1-10
(0.6, 0.1, 0.3)
175
Pseudocubic structure
Example 1-11
(0.5, 0.1, 0.4)
160
Pseudocubic structure
Example 1-12
(0.45, 0.1, 0.45)
131
Coexistence of pseudo-
cubic and rhombohedral
structures
Example 1-13
(0.4, 0.1, 0.5)
98
Rhombohedral structure
Example 1-14
(0.3, 0.1, 0.6)
60
Rhombohedral structure
Example 1-15
(0.2, 0.1, 0.7)
58
Rhombohedral structure
Example 1-16
(0.1, 0.1, 0.8)
30
Rhombohedral structure
Comparative
(0.05, 0.1, 0.85)
21
Rhombohedral structure
Example 1-3
Comparative
(0.2, 0.4, 0.4)
15
Coexistence of pseudo-
Example 1-4
cubic structure and
heterogeneous phase
Comparative
(0.1, 0.4, 0.5)
15
Coexistence of pseudo-
Example 1-5
cubic structure and
heterogeneous phase
The piezoelectric constants of these piezoelectric elements were measured along arrow 40 shown in FIGS. 9 and 10 . As is evident from Table 2, the piezoelectric elements of Examples 1-7 to 1-16 can achieve larger piezoelectric constants than those of the piezoelectric elements of Comparative Examples 1-3 to 1-5.
Next, Examples based on the second method for producing the piezoelectric composition of the first aspect will be described.
Example 1-17
Starting Material Preparation Step
A starting material compact was obtained in the same way as in Example 1-1 except that the starting materials used were 30 g in total of Bi 2 O 3 , KHCO 3 , TiO 2 , MgO, and Fe 2 O 3 weighed such that the composition of the resulting piezoelectric composition satisfied compositional formula 0.85(Bi 0.5 K 0.5 )TiO 3 -0.1Bi(Mg 0.5 Ti 0.5 )O 3 -0.05BiFeO 3 [x=0.85, y=0.1, and z=0.05].
<Temperature Elevation Step>
Next, the temperature of the obtained starting material compact was elevated to 1,070° C. at a rate of temperature rise of 300° C./hr.
<First Heat Treatment Step>
Next, the starting material compact was sintered at 1,070° C. for 2 hours.
<Temperature Lowering Step>
Next, the temperature of the compact thus sintered was lowered to 800° C. at a rate of 300° C./hr.
<Second Heat Treatment Step (Annealing Step)>
Subsequently, the temperature-lowered compact was annealed at 800° C. for 20 hours.
<Cooling Step>
Finally, the compact thus annealed was cooled to room temperature at a rate of cooling of 40 to 100° C./second to obtain a piezoelectric composition.
Next, the obtained piezoelectric composition was processed into a thickness of approximately 0.4 mm by polishing. Then, gold electrodes were formed on both sides of the piezoelectric composition by sputtering to obtain a piezoelectric element.
Example 1-18
A piezoelectric composition and a piezoelectric element were produced in the same way as in Example 1-17 except that: the starting materials used were 30 g in total of Bi 2 O 3 , KHCO 3 , TiO 2 , MgO, and Fe 2 O 3 weighed such that the composition of the piezoelectric composition satisfied compositional formula 0.8(Bi 0.5 K 0.5 )TiO 3 -0.1Bi(Mg 0.5 Ti 0.5 )O 3 -0.1BiFeO 3 [x=0.8, y=0.1, and z=0.1]; and the sintering temperature was set to 1,055° C.
Example 1-19
A piezoelectric composition and a piezoelectric element were produced in the same way as in Example 1-17 except that: the starting materials used were 30 g in total of Bi 2 O 3 , KHCO 3 , TiO 2 , MgO, and Fe 2 O 3 weighed such that the composition of the piezoelectric composition satisfied compositional formula 0.7(Bi 0.5 K 0.5 )TiO 3 -0.1Bi(Mg 0.5 Ti 0.5 )O 3 -0.2BiFeO 3 [x=0.7, y=0.1, and z=0.2]; and the sintering temperature was set to 1,030° C.
Example 1-20
A piezoelectric composition and a piezoelectric element were produced in the same way as in Example 1-17 except that: the starting materials used were 30 g in total of Bi 2 O 3 , KHCO 3 , TiO 2 , MgO, and Fe 2 O 3 weighed such that the composition of the piezoelectric composition satisfied compositional formula 0.6(Bi 0.5 K 0.5 )TiO 3 -0.1Bi(Mg 0.5 Ti 0.5 )O 3 -0.3BiFeO 3 [x=0.6, y=0.1, and z=0.3]; and the sintering temperature was set to 1,000° C.
Example 1-21
A piezoelectric composition and a piezoelectric element were produced in the same way as in Example 1-17 except that: the starting materials used were 30 g in total of Bi 2 O 3 , KHCO 3 , TiO 2 , MgO, and Fe 2 O 3 weighed such that the composition of the piezoelectric composition satisfied compositional formula 0.5(Bi 0.5 K 0.5 )TiO 3 -0.1Bi(Mg 0.5 Ti 0.5 )O 3 -0.4BiFeO 3 [x=0.5, y=0.1, and z=0.4]; and the sintering temperature was set to 1,000° C.
Example 1-22
A piezoelectric composition and a piezoelectric element were produced in the same way as in Example 1-17 except that: the starting materials used were 30 g in total of Bi 2 O 3 , KHCO 3 , TiO 2 , MgO, and Fe 2 O 3 weighed such that the composition of the piezoelectric composition satisfied compositional formula 0.45(Bi 0.5 K 0.5 )TiO 3 -0.1Bi(Mg 0.5 Ti 0.5 )O 3 -0.45BiFeO 3 [x=0.45, y=0.1, and z=0.45]; and the sintering temperature was set to 1,000° C.
Example 1-23
A piezoelectric composition and a piezoelectric element were produced in the same way as in Example 1-17 except that: the starting materials used were 30 g in total of Bi 2 O 3 , KHCO 3 , TiO 2 , MgO, and Fe 2 O 3 weighed such that the composition of the piezoelectric composition satisfied compositional formula 0.4(Bi 0.5 K 0.5 )TiO 3 -0.1Bi(Mg 0.5 Ti 0.5 )O 3 -0.5BiFeO 3 [x=0.4, y=0.1, and z=0.5]; and the sintering temperature was set to 1,000° C.
Example 1-24
A piezoelectric composition and a piezoelectric element were produced in the same way as in Example 1-17 except that: the starting materials used were 30 g in total of Bi 2 O 3 , KHCO 3 , TiO 2 , MgO, and Fe 2 O 3 weighed such that the composition of the piezoelectric composition satisfied compositional formula 0.3(Bi 0.5 K 0.5 )TiO 3 -0.1Bi(Mg 0.5 Ti 0.5 )O 3 -0.6BiFeO 3 [x=0.3, y=0.1, and z=0.6]; and the sintering temperature was set to 1,000° C.
Example 1-25
A piezoelectric composition and a piezoelectric element were produced in the same way as in Example 1-17 except that: the starting materials used were 30 g in total of Bi 2 O 3 , KHCO 3 , TiO 2 , MgO, and Fe 2 O 3 weighed such that the composition of the piezoelectric composition satisfied compositional formula 0.2(Bi 0.5 K 0.5 )TiO 3 -0.1Bi(Mg 0.5 Ti 0.5 )O 3 -0.7BiFeO 3 [x=0.2, y=0.1, and z=0.7]; and the sintering temperature was set to 1,000° C.
Example 1-26
A piezoelectric composition and a piezoelectric element were produced in the same way as in Example 1-17 except that: the starting materials used were 30 g in total of Bi 2 O 3 , KHCO 3 , TiO 2 , MgO, and Fe 2 O 3 weighed such that the composition of the piezoelectric composition satisfied compositional formula 0.1(Bi 0.5 K 0.5 )TiO 3 -0.1Bi(Mg 0.5 Ti 0.5 )O 3 -0.8BiFeO 3 [x=0.1, y=0.1, and z=0.8]; and the sintering temperature was set to 950° C.
Comparative Example 1-6
A piezoelectric composition and a piezoelectric element were produced in the same way as in Example 1-17 except that: the starting materials used were 30 g in total of Bi 2 O 3 , KHCO 3 , TiO 2 , MgO, and Fe 2 O 3 weighed such that the composition of the piezoelectric composition satisfied compositional formula 0.05(Bi 0.5 K 0.5 )TiO 3 -0.1Bi(Mg 0.5 Ti 0.5 )O 3 -0.85BiFeO 3 [x=0.05, y=0.1, and z=0.85]; and the sintering temperature was set to 900° C.
Next, the piezoelectric compositions and the piezoelectric elements of Examples 1-17 to 1-26 and Comparative Example 1-6 were used to perform the crystal structure analysis of the piezoelectric compositions and the measurement of piezoelectric constants d33* of the piezoelectric elements in the same way as in Example 1-1. The results are shown in Table 3 and FIGS. 9 and 10 (“With annealing step”). Table 3 also shows triangle coordinates using x, y, and z in the compositional formula of each piezoelectric composition.
TABLE 3
Triangle coordinates
d33*
(x, y, z)
(pm/V)
Crystal structure
Example 1-17
(0.85, 0.1, 0.05)
240
Coexistence of tetragonal
and pseudocubic
structures
Example 1-18
(0.8, 0.1, 0.1)
262
Pseudocubic structure
Example 1-19
(0.7, 0.1, 0.2)
236
Pseudocubic structure
Example 1-20
(0.6, 0.1, 0.3)
250
Pseudocubic structure
Example 1-21
(0.5, 0.1, 0.4)
302
Pseudocubic structure
Example 1-22
(0.45, 0.1, 0.45)
351
Coexistence of pseudo-
cubic and rhombohedral
structures
Example 1-23
(0.4, 0.1, 0.5)
170
Coexistence of pseudo-
cubic and rhombohedral
structures
Example 1-24
(0.3, 0.1, 0.6)
130
Rhombohedral structure
Example 1-25
(0.2, 0.1, 0.7)
98
Rhombohedral structure
Example 1-26
(0.1, 0.1, 0.8)
83
Rhombohedral structure
Comparative
(0.05, 0.1, 0.85)
30
Rhombohedral structure
Example 1-6
The piezoelectric constants of these piezoelectric elements were measured along arrow 40 shown in FIGS. 9 and 10 . As is evident from Table 3, the piezoelectric elements of Examples 1-17 to 1-26 can achieve larger piezoelectric constants than those of the piezoelectric element of Comparative Example 1-6. As is evident from Table 3 and FIG. 10 , the piezoelectric elements of Examples 1-21 and 1-22 in which z in the triangle coordinates of their piezoelectric compositions falls within the range of 0.4≦z≦0.45 have a particularly large piezoelectric constant. This is presumably because, in FIG. 9 , the compositions of the piezoelectric compositions of Examples 1-21 and 1-22 include pseudocubic-rhombohedral phase boundary 45 or have composition located in proximity to phase boundary 45 .
When the sintering time of the first heat treatment step in Example 1-22 was further increased to 20 to 300 hours, greater piezoelectric properties (d33*: 378 to 410 pm/V) were successfully obtained.
Next, the influence of an additive on the piezoelectric composition of the first aspect will be discussed.
Example 1-27
A piezoelectric composition and a piezoelectric element were produced in the same way as in Example 1-17 except that: the starting materials used were 30 g in total of Bi 2 O 3 , KHCO 3 , TiO 2 , MgO, and Fe 2 O 3 weighed such that the composition of the piezoelectric composition satisfied compositional formula 0.45(Bi 0.5 K 0.5 )TiO 3 -0.1Bi(Mg 0.5 Ti 0.5 )O 3 -0.45BiFeO 3 [x=0.45, y=0.1, and z=0.45]; 0.2 wt % (0.06 g) of MnCO 3 was further added to this 30 g of the starting materials; the sintering temperature was set to 1,000° C.; and the sintering time was set to 20 hours.
In addition, piezoelectric compositions and piezoelectric elements were produced in the same way as above except that the amount of MnCO 3 added was changed to 0.05 to 0.5 wt %.
Next, the produced piezoelectric elements were used to measure the piezoelectric constants d33* of the piezoelectric elements in the same way as in Example 1-1. The results are shown in FIG. 11 . Also, the dielectric losses (tan δ) of the produced piezoelectric elements were measured at a frequency of 100 Hz and a temperature of 150° C. using an LCR meter (model 6440B) manufactured by Wayne Kerr Electronics. The results are shown in FIG. 12 .
As is evident from FIG. 11 , the value of the piezoelectric constant d33* rarely drops until the amount of MnCO 3 added reaches 0.3 wt %. As is evident from FIG. 12 , the dielectric loss (tan δ) drops rapidly by the addition of MnCO 3 . This means that leak current is reduced during application of high voltage. These results demonstrated that the addition of MnCO 3 is very advantageous for polarization treatment, because this addition reduces leak current during application of high voltage and, even in a small amount, rarely causes a drop in piezoelectric constant d33*. The Mn additive used in this Example was MnCO 3 . Likewise, use of MnO, Mn 2 O 3 , MnO 2 , Mn 3 O 4 , or the like can also reduce dielectric loss (tan δ) at a low frequency and 150° C.
Example 1-28
A piezoelectric composition and a piezoelectric element were produced in the same way as in Example 1-1 except that: the starting materials used were 30 g in total of Bi 2 O 3 , KHCO 3 , TiO 2 , MgO, and Fe 2 O 3 weighed such that the composition of the piezoelectric composition satisfied compositional formula 0.427(Bi 0.5 K 0.5 )TiO 3 -0.05Bi(Mg 0.5 Ti 0.5 )O 3 -0.523BiFeO 3 [x=0.427, y=0.05, and z=0.523]; the sintering temperature was set to 1,000° C.; and the sintering time was set to 20 hours.
Example 1-29
A piezoelectric composition and a piezoelectric element were produced in the same way as in Example 1-17 except that: the starting materials used were 30 g in total of Bi 2 O 3 , KHCO 3 , TiO 2 , MgO, and Fe 2 O 3 weighed such that the composition of the piezoelectric composition satisfied compositional formula 0.427(Bi 0.5 K 0.5 )TiO 3 -0.05Bi(Mg 0.5 Ti 0.5 )O 3 -0.523BiFeO 3 [x=0.427, y=0.05, and z=0.523]; the sintering temperature was set to 1,000° C.; and the sintering time was set to 20 hours.
Next, the piezoelectric compositions and the piezoelectric elements of Examples 1-28 and 1-29 were used to perform the crystal structure analysis of the piezoelectric compositions and the measurement of piezoelectric constants d33* of the piezoelectric elements in the same way as in Example 1-1. The results are shown in Table 4. Table 4 also shows triangle coordinates using x, y, and z in the compositional formula of each piezoelectric composition.
TABLE 4
Triangle coordinates
d33*
(x, y, z)
(pm/V)
Crystal structure
Example 1-28
(0.427, 0.05, 0.523)
290
Coexistence of pseudo-
cubic and rhombohedral
structures
Example 1-29
(0.427, 0.05, 0.523)
288
Coexistence of pseudo-
cubic and rhombohedral
structures
As is evident from Table 4, the piezoelectric elements of Examples 1-28 and 1-29 in which the sintering time was merely changed to a long time in comparison with Comparative Examples 1-3 to 1-5 and 1-6 can achieve large piezoelectric constants even without the second heat treatment step. This is presumably because, as illustrated in FIGS. 13 and 14 mentioned later, the compositions of the piezoelectric compositions of Examples 1-28 and 1-29 include pseudocubic-rhombohedral phase boundary 45 .
Example 1-30
A piezoelectric composition and a piezoelectric element were produced in the same way as in Example 1-17 except that: the starting materials used were 30 g in total of Bi 2 O 3 , KHCO 3 , TiO 2 , MgO, and Fe 2 O 3 weighed such that the composition of the piezoelectric composition satisfied compositional formula 0.427(Bi 0.5 K 0.5 )TiO 3 -0.05Bi(Mg 0.5 Ti 0.5 )O 3 -0.523BiFeO 3 [x=0.427, y=0.05, and z=0.523]; 0.1 wt % (0.03 g) of Nb 2 O 5 was further added to this 30 g of the starting materials; the sintering temperature was set to 1,000° C.; and the sintering time was set to 20 hours.
Example 1-31
A piezoelectric composition and a piezoelectric element were produced in the same way as in Example 1-17 except that: the starting materials used were 30 g in total of Bi 2 O 3 , KHCO 3 , TiO 2 , MgO, and Fe 2 O 3 weighed such that the composition of the piezoelectric composition satisfied compositional formula 0.427(Bi 0.5 K 0.5 )TiO 3 -0.05Bi(Mg 0.5 Ti 0.5 )O 3 -0.523BiFeO 3 [x=0.427, y=0.05, and z=0.523]; 0.1 wt % (0.03 g) of WO3 was further added to this 30 g of the starting materials; the sintering temperature was set to 1,000° C.; and the sintering time was set to 20 hours.
Next, the piezoelectric elements of Examples 1-30 and 1-31 were used to measure their piezoelectric constants d33* in the same way as in Example 1-1. The results are shown in Table 5. Table 5 also shows triangle coordinates using x, y, and z in the compositional formula of each piezoelectric composition.
TABLE 5
Triangle coordinates
(x, y, z)
d33* (pm/V)
Additive
Example 1-30
(0.427, 0.05, 0.523)
320
Nb 2 O 5
Example 1-31
(0.427, 0.05, 0.523)
297
WO 3
As is evident from Table 5, the piezoelectric elements of Examples 1-30 and 1-31 in which the piezoelectric composition of Example 1-29 was merely supplemented with an additive can achieve large piezoelectric constants. The additives used in Examples 1-27 to 1-31 were MnCO 3 , Nb 2 O 5 , and WO 3 each separately added. The simultaneous addition of these additives can achieve a piezoelectric composition and a piezoelectric element having high insulation properties and high piezoelectricity.
FIGS. 13 and 14 summarize the composition regions of Examples 1-1 to 1-31 and Comparative Examples 1-1 to 1-6. In FIG. 13 , the piezoelectric compositions in composition region 1 that is enclosed by pentagon ABCDE but exclusive of segment AE have a large piezoelectric constant d33*. In FIG. 14 , the piezoelectric compositions in composition region 2 that is enclosed by pentagon AFGHI but exclusive of segment AI and composition region 3 that is enclosed by pentagon JKLMN but exclusive of segment JN have a particularly large piezoelectric constant d33*.
As described above, the piezoelectric composition of the first aspect is a lead-free piezoelectric composition that has a large piezoelectric constant and can be produced with high reproducibility by a convenient method. Thus, the piezoelectric composition of the first aspect can be expected to be applied as an environment-responsive piezoelectric composition containing no lead to ultrasonic probes, transducers, and sensors.
Second Aspect
Hereinafter, the second aspect will be described.
Embodiment 2-1
First, the lead-free piezoelectric element of the second aspect will be described.
The lead-free piezoelectric element of the second aspect includes a piezoelectric composition and an electrode that applies voltage to the piezoelectric composition. The piezoelectric composition has a perovskite structure represented by general compositional formula ABO 3 and contains BiFeO 3 and a Bi complex oxide. The BiFeO 3 has a content of 3 to 80 mol % with respect to the whole piezoelectric composition. The Bi complex oxide contains Bi at site A in the general compositional formula and a plurality of elements differing in valence at site B therein. The lead-free piezoelectric element has a relative permittivity er of 400 or larger and a dielectric loss tan δ of 0.2 or smaller at 25° C. (room temperature), and has a piezoelectric constant d33* of 250 pm/V or higher determined from an electric field-strain curve.
Use of this piezoelectric composition can provide a lead-free piezoelectric element having a large spontaneous polarization or remnant polarization, small leak current, and high piezoelectric properties.
The piezoelectric composition has a perovskite structure which is represented by general compositional formula ABO 3 . The standard molar ratio of the site-A element, the site-B element, and oxygen is 1:1:3. The molar ratio of these moieties may fall outside the standard molar ratio within a range that can form the perovskite structure. In the second aspect, site B is composed of a plurality of elements differing in valence. Examples of the site-B elements include Mg, Zn, Ti, Zr, Fe, Mn, Co, Ni, Nb, Ta, and W.
Preferably, the composition of the piezoelectric composition includes a phase boundary between at least 2 types of crystal structures or has composition located in proximity to the phase boundary. This can further improve the piezoelectric properties of the lead-free piezoelectric element. In this context, the phase boundary refers to a composition region in which at least 2 types of crystal structures coexist with each other. The composition located in proximity to the phase boundary according to the second aspect is defined as a composition region that includes at least the phase boundary within 15 mol % from the predetermined composition and further involves the maximum value of piezoelectric constant d33* determined from an electric field-strain curve. Specifically, the phase boundary may be a composition region in which a rhombohedral structure coexists with any one crystal structure selected from the group consisting of pseudocubic, tetragonal, orthorhombic, and monoclinic structures, or may be a composition region in which tetragonal and pseudocubic structures coexist with each other.
The piezoelectric constant d33* is preferably 330 pm/V or higher. The BiFeO 3 content is preferably 30 to 80 mol % with respect to the whole piezoelectric composition. This can further improve the piezoelectric properties of the lead-free piezoelectric element.
The piezoelectric composition is preferably made of a relaxor material. The relaxor according to the second aspect refers to a complex oxide that has a perovskite structure represented by general compositional formula ABO 3 with site A or site B composed of a plurality of elements and has a broad peak of permittivity in response to change in temperature. The lead-free piezoelectric element having a broad peak of permittivity in terms of relaxor properties exhibits high permittivity even at a temperature different from the peak temperature. Such a piezoelectric element that exhibits relaxor properties is useful for devices required to have high permittivity, such as ultrasonic probes.
The piezoelectric composition is preferably made of a ceramic having a particle size of 0.5 μm or larger and 200 μm or smaller, more preferably made of a ceramic having a particle size of 1 μm or larger and 100 μm or smaller. The particle size set to 0.5 μm or larger can increase a relative permittivity em at maximum temperature Tm. This is advantageous for increasing a permittivity at room temperature or a remnant polarization. The upper limit of the particle size is based on the workability of the piezoelectric composition. The particle size set to 200 μm or smaller can prevent a fracture in the ceramic.
The piezoelectric composition may be composed of a single crystal. The particle size of the single crystal does not matter. The single crystal needs to have strength that resists processing as a piezoelectric material.
Preferably, the piezoelectric composition further includes (Bi 0.5 K 0.5 )TiO 3 and Bi(Mg 0.5 Ti 0.5 )O 3 . More specifically, the piezoelectric composition is represented by compositional formula x(Bi 0.5 K 0.5 )TiO 3 -yBi(Mg 0.5 Ti 0.5 )O 3 -zBiFeO 3 . In the compositional formula, x+y+z=1 is preferred. The BKT-BMT-BFO complex composition can yield a piezoelectric composition having a larger piezoelectric constant than that of each of BKT alone, BMT alone, and BFO alone.
For the piezoelectric composition, Mg in the compositional formula is preferably partially replaced with Zn, and Bi in the compositional formula is preferably partially replaced with at least one type selected from La, Sm, and Nd. Furthermore, Ti in the compositional formula is preferably partially replaced with Zr. The replacement of these elements can lower curie temperature (Tc) or maximum temperature (Tm) of permittivity. Tc (or Tm) thus lowered can be expected to produce a large piezoelectric constant and a large permittivity in the piezoelectric composition of the second aspect that exhibits relaxor properties.
Preferably, the piezoelectric composition further contains 2 wt % or less of at least one element selected from the group consisting of Mn, Co, Ni, V, Nb, Ta, W, Si, Ge, Ca, and Sr. Mn, Co, Ni, or V thus contained therein can enhance insulation properties and can be expected to reduce leak current. In this context, MnCO 3 , MnO, Mn 2 O 3 , Mn 3 O 4 , MnO 2 , or the like can be used as a Mn source. V, Nb, Ta, or W is preferred as a dopant advantageous for softening the piezoelectric composition. Si or Ge thus contained therein is advantageous for improving sintered density and for improving an electromechanical coupling coefficient. Ca or Sr thus contained therein can be expected to reduce the evaporation of Bi or K and consequently, can improve properties or reliability.
At least one element selected from the group consisting of Mn, Co, Ni, V, Nb, Ta, W, Si, Ge, Ca, and Sr mentioned above does not have to be dissolved in the crystal of the piezoelectric composition and may be deposited in crystal grains or grain boundary or may be segregated.
The lead-free piezoelectric element of the second aspect has a relative permittivity ∈m of preferably 7,000 or larger, more preferably 13,000 or larger, at maximum temperature Tm. In this context, the maximum temperature Tm refers to a temperature at which the relative permittivity exhibits the largest value. Also, the lead-free piezoelectric element of the second aspect has a dielectric loss tan δ of preferably 0.2 or smaller. For the lead-free piezoelectric element of the second aspect, the maximum temperature Tm is preferably 130° C. or higher and 400° C. or lower. This renders the lead-free piezoelectric element usable in a practical temperature range and can lower maximum temperature Tm or curie temperature Tc in comparison to BFO, thereby easily increasing a relative permittivity ∈r at room temperature. The relative permittivity according to the second aspect is defined as a value measured at a frequency of 1 MHz, unless otherwise specified. The lead-free piezoelectric element of the second aspect has a remnant polarization Pr of preferably 20 μC/cm 2 or larger.
Next, the lead-free piezoelectric element of the second aspect will be described with reference to the accompanying drawings.
FIG. 15 is a perspective view illustrating one example of the lead-free piezoelectric element of the second aspect. In FIG. 15 , piezoelectric element 10 of the second aspect includes piezoelectric composition 11 and electrode 12 that applies voltage to piezoelectric composition 11 . FIG. 16 is a perspective view illustrating another example of the lead-free piezoelectric element of the second aspect. In FIG. 16 , piezoelectric element 20 of the second aspect includes piezoelectric composition 21 and electrode 22 that applies voltage to piezoelectric composition 21 . The piezoelectric composition described in this Embodiment is used as piezoelectric composition 11 or 21 . Electrode 12 or 22 applies voltage to piezoelectric composition 11 or 21 . Electrode 12 or 22 is not particularly limited by its material, production method, etc. and can be formed by, for example, the sputtering, vapor deposition, or printing of a metal such as gold, silver, platinum, palladium, nickel, copper, or an alloy of various noble metals.
The lead-free piezoelectric element is not particularly limited by its shape and may have any of shapes other than those shown in FIGS. 15 and 16 . For example, a doughnut-like, cylindrical, or prismatic shape can be appropriately adopted depending on the use of the lead-free piezoelectric element.
Embodiment 2-2
Next, a method for producing the lead-free piezoelectric element of the second aspect will be described. The production method given below can conveniently produce the lead-free piezoelectric element described above in Embodiment 2-1.
A first method for producing the lead-free piezoelectric element of the second aspect includes a starting material preparation step, a temperature elevation step, a first heat treatment step, a temperature lowering step, a second heat treatment step, and a cooling step in the order presented to produce a piezoelectric composition contained in the lead-free piezoelectric element.
A second method for producing the lead-free piezoelectric element of the second aspect includes a starting material preparation step, a first temperature elevation step, a first heat treatment step, a first cooling step, a second temperature elevation step, a second heat treatment step, and a second cooling step in the order presented to produce a piezoelectric composition contained in the lead-free piezoelectric element.
The first and second methods for producing the lead-free piezoelectric element of the second aspect can provide a lead-free piezoelectric element having a large spontaneous polarization or remnant polarization, small leak current, and high piezoelectric properties. This is presumably because the conventional piezoelectric composition is produced merely by a starting material preparation step, a temperature elevation step, a heat treatment step, and a cooling step, whereas the piezoelectric composition according to the second aspect is produced by a process involving a first heat treatment step and a second heat treatment step. Hereinafter, this will be described with reference to the accompanying drawings.
FIGS. 17A and 17B schematically illustrate the domain pinning of a lead-free piezoelectric element including a piezoelectric composition containing BiFeO 3 (hereinafter, also referred to as a BFO-based lead-free piezoelectric element) and a state where the domain pinning is avoided. In FIGS. 17A and 17B , defects 33 (including defect pairs) exist in the interiors of domains 32 partitioned by domain walls 31 or in contact with the domain walls.
In the BFO-based lead-free piezoelectric element, as illustrated in FIG. 17A , domains 32 or domain walls 31 are usually pinned by defects 33 such as Bi vacancy, oxygen vacancy, or Fe 2+ . Furthermore, the valence of iron supposed to be Fe 3+ is changed to Fe 2+ due to, for example, oxygen vacancy generated, resulting in deteriorated insulation properties of the piezoelectric composition. The first heat treatment step and the second heat treatment step are important for preventing the pinning and the deterioration of the insulation properties of the piezoelectric composition.
In the first heat treatment step serving mainly as a sintering step, a longer sintering time can increase the particle size of the piezoelectric composition and further improve crystallinity in crystal grains. This probably increases the mobility of the domain walls. While the particle size of the piezoelectric composition is increased, impurities are ejected from the crystal grains. This step therefore helps particularly improve insulation resistance on the low frequency side and is effective for polarization treatment or reduction in dielectric loss tan δ.
The second heat treatment step serving as an annealing step can decrease the amount of defects such as oxygen vacancy or Fe 2+ and can thus reduce defect density. The subsequent cooling step can be started from an annealing temperature lower than the sintering temperature. Defects or defect pairs that cannot be removed completely may be therefore fixed before gathering at domain walls. As a result, as illustrated in FIG. 17B , various defects or defect pairs can be prevented from pinning domains and domain walls. Since the annealing temperature is lower than the sintering temperature, even cooling at a relatively fast rate produces only small temperature difference from room temperature. This can reduce thermal shock and can prevent the piezoelectric composition from being destroyed during the cooling step.
When the piezoelectric composition includes a phase boundary between 2 types of crystal structures, the absence of leak or domain wall pinning can solve the conventional problems associated with reproducibility. As a result, the piezoelectric element can exert its original piezoelectric performance with high reproducibility. This can increase a permittivity at room temperature or a remnant polarization and can achieve a lead-free piezoelectric element having a relative permittivity ∈r of 400 or larger and a dielectric loss tan δ of 0.2 or smaller at 25° C. and having a piezoelectric constant d33* of 250 pm/V or higher determined from an electric field-strain curve.
As described in Embodiment 2-1, the piezoelectric composition contains 3 to 80 mol %, more preferably 30 to 80 mol %, of BiFeO 3 . This is because the BFO-based piezoelectric composition can easily exert its original performance of high piezoelectric properties in the absence of leak or domain wall pinning
As described in Embodiment 2-1, the piezoelectric composition is preferably made of a relaxor material. This is because a peak of permittivity vs. temperature is broad and a permittivity at room temperature is easily improved. Particularly, in the case of an ultrasonic device that is driven at a relatively high frequency on the order of 1 MHz to 100 MHz, the piezoelectric element easily constitutes a 50-ohm signal processing circuit and easily attains impedance matching between a signal generator/transmission line and the piezoelectric element.
Subsequently, each method for producing the lead-free piezoelectric element of the second aspect will be further described with reference to the accompanying drawings. For the sake of convenience, the (Bi 0.5 K 0.5 )TiO 3 —Bi(Mg 0.5 Ti 0.5 )O 3 —BiFeO 3 system will be mainly described. However, the production method according to the second aspect is not particularly limited by this system and can be applied to other systems for use in the lead-free piezoelectric element of the second aspect.
[First Production Method]
FIG. 18 schematically illustrates a first method for producing the lead-free piezoelectric element of the second aspect except for a starting material preparation step. The first method for producing the lead-free piezoelectric element of the second aspect includes a starting material preparation step, a temperature elevation step, a first heat treatment step, a temperature lowering step, a second heat treatment step, and a cooling step in the order presented to produce a piezoelectric composition contained in the lead-free piezoelectric element. Hereinafter, each step will be described.
<Starting Material Preparation Step>
First, oxide, carbonate, bicarbonate, various acid salts, or the like of each element constituting the piezoelectric composition is prepared as a starting material. For example, Bi 2 O 3 , Fe 2 O 3 , TiO 2 , and MgO can be used as oxides. Also, K 2 CO 3 or KHCO 3 can be used as carbonate.
As mentioned above, K 2 CO 3 or KHCO 3 can be used as a potassium source for the piezoelectric composition of the second aspect. Preferably, KHCO 3 is used. This is because KHCO 3 has much smaller hygroscopicity than that of K 2 CO 3 and can therefore reduce weighing errors as a starting material.
Next, a mixture of starting material powders is prepared using necessary amounts of weighed starting materials. The method for preparing the mixture can be any of dry and wet methods. Wet grinding using, for example, a ball mill or a jet mill can be appropriately used. In the case of performing the wet grinding using a ball mill, the starting materials are mixed with a dispersion medium, and this mixture is added to a grinding apparatus. Pure water, any of various alcoholic materials (e.g., methanol and ethanol), any of various organic liquids, or the like can be used as the dispersion medium. A grinding medium such as zirconia balls or alumina balls is further added to the grinding apparatus where mixing and grinding are then carried out until the grain size of the starting materials becomes fine and uniform. Next, the grinding medium such as zirconia balls or alumina balls is removed, and the dispersion medium is removed by use of suction filtration or a dryer. Then, the obtained starting material powders are placed in a container such as a crucible, followed by preliminary firing. The preliminary firing can be carried out at a temperature of, for example, 600 to 1,000° C. This can achieve homogeneous composition of the mixture and improvement in sintered density after sintering. However, the preliminary firing is not necessarily required. Instead, a compact preparation step mentioned below may be carried out using the starting material powders from which the dispersion medium has been removed by drying. On the other hand, the preliminary firing may be performed twice or more in order to improve homogeneity or sintered density.
In the case of performing the preliminary firing, preliminarily fired powders after the preliminary firing are ground again in the same way as in the grinding of the starting material powders using a grinding apparatus. In the grinding step following the preliminary firing, a binder or the like is added thereto at any of initial, intermediate, and final stages, followed by drying again to prepare starting material powders. For example, polyvinyl alcohol (PVA) or polyvinyl butyral (PVB) can be used as the binder.
Next, the obtained mixed powder of organic components and a ceramic is formed into cylindrical pellets of approximately 10 mm in diameter and approximately 1 mm in thickness to approximately 50 mm in diameter and approximately 5 mm in thickness using, for example, a press machine. Finally, the obtained compact is placed in an electric furnace and heated at 500 to 750° C. for a few hours to approximately 20 hours for binder removal treatment to obtain a starting material compact.
The starting material preparation step is described above with reference to the usual solid-phase method. However, the starting material preparation step is not limited by the solid-phase method and may be carried out by, for example, a hydrothermal synthesis method or a method using alkoxide as a starting material.
<Temperature Elevation Step>
Next, as illustrated in FIG. 18 , the obtained starting material compact is placed again in a crucible or the like, and the temperature is elevated to the temperature of the first heat treatment step. The rate of temperature rise is not particularly limited and is usually set to 50 to 1,000° C./hr, though differing depending on the size of the starting material compact, the capacity of a heating apparatus, etc. For the purpose of removing water, for example, the temperature may be kept at 100 to 200° C. for a given time, or the rate of temperature rise may be slowed down. Such cases are also included in the temperature elevation step of the second aspect.
<First Heat Treatment Step>
Next, as illustrated in FIG. 18 , the starting material compact is heat-treated at 800 to 1,150° C. When the piezoelectric composition of interest is a ceramic, the heat treatment time is 2 to 300 hours, more preferably 6 to 200 hours. In the case of obtaining a ceramic as the piezoelectric composition, this first heat treatment step serves as a sintering step for the starting material compact. This heat treatment time can be controlled to thereby control the particle size of the ceramic. As mentioned above, the ceramic obtained as the piezoelectric composition has a particle size of preferably 0.5 to 200 μm, more preferably 1 to 100 μm. This preferred particle size of the piezoelectric composition can be achieved by the heat treatment time (sintering time) set to 6 to 300 hours. The first heat treatment step may be carried out in air or may be carried out in an oxygen atmosphere or reductive atmosphere or in compositionally the same atmosphere (i.e., atmosphere where the compact is covered with preliminarily fired powders having the same composition thereas).
When the piezoelectric composition of interest is a single crystal, the heat treatment temperature is 2 to 3,000 hours, more preferably 6 to 3,000 hours. In the case of obtaining a single crystal as the piezoelectric composition, this first heat treatment step serves as a crystal growth step for the starting material compact.
<Temperature Lowering Step>
As mentioned later, the second heat treatment step serves as an annealing step. As illustrated in FIG. 18 , the temperature lowering step therefore intervenes between the first heat treatment step and the second heat treatment step. The rate of temperature drop is not particularly limited and is usually set to 50 to 1,000° C./hr, though differing depending on the size of the starting material compact, the temperature lowering performance of a heating apparatus, etc.
<Second Heat Treatment Step>
Next, as illustrated in FIG. 18 , the second heat treatment step is carried out for the starting material compact. This second heat treatment step serves as an annealing step. The annealing temperature is set to 300 to 900° C., more preferably 400 to 800° C. The annealing time is set to 5 minutes to 100 hours. This annealing step is carried out in order to remove various defects of the piezoelectric composition. In this context, the temperature of the second heat treatment step is set to be lower than the temperature of the first heat treatment step. This is because a second heat treatment temperature higher than the first heat treatment temperature further promotes sintering or melts the starting material compact. The annealing step may be carried out in air or may be carried out in an oxygen atmosphere, oxidative atmosphere (e.g., oxygen-nitrogen mixed gas atmosphere), or reductive atmosphere or in compositionally the same atmosphere (i.e., atmosphere where the compact is covered with preliminarily fired powders having the same composition thereas). For example, nitrogen gas, argon gas, or nitrogen-hydrogen mixed gas can be used as a reducing gas for the reductive atmosphere.
The annealing step may be carried out as a single round or may be carried out in two or more rounds at different temperatures. Specifically, the annealing step preferably involves heating at a first annealing temperature on the high temperature side, then temporal cooling to room temperature, and re-heating after temperature elevation to a second annealing temperature on the low temperature side. This is because various defects are removed at temperatures that are not the same among the defects. In the case of performing the annealing step in two rounds at different temperatures, the different temperatures are preferably 600 to 900° C. on the high temperature side and 300 to 600° C. on the low temperature side, more preferably 700 to 900° C. on the high temperature side and 400 to 600° C. on the low temperature side.
<Cooling Step>
Finally, as illustrated in FIG. 18 , the compact thus heat-treated is cooled to room temperature. This cooling step is carried out in order to prevent various defects of the piezoelectric composition from gathering at domain walls. The rate of cooling is preferably 0.01 to 200° C./second, more preferably 5 to 100° C./second. A rate of cooling of 200° C./second or slower can be on the order of 1/10 to 1/100 or less of the rate of cooling in, for example, ultrahigh-speed quenching which involves dipping a compact having a temperature of 900° C. in hot water of 70° C. and thus, can avoid destroying the piezoelectric composition.
[Second Production Method]
FIG. 19 schematically illustrates a second method for producing the lead-free piezoelectric element of the second aspect except for a starting material preparation step. The second method for producing the lead-free piezoelectric element of the second aspect includes a starting material preparation step, a first temperature elevation step, a first heat treatment step, a first cooling step, a second temperature elevation step, a second heat treatment step, and a second cooling step in the order presented to produce a piezoelectric composition contained in the lead-free piezoelectric element. Hereinafter, each step will be described.
<Starting Material Preparation Step>
The starting material preparation step in the second production method is carried out in the same way as in the starting material preparation step in the first production method.
<First Temperature Elevation Step>
As illustrated in FIG. 19 , the first temperature elevation step in the second production method is carried out in the same way as in the temperature elevation step in the first production method.
<First Heat Treatment Step>
As illustrated in FIG. 19 , the first heat treatment step in the second production method is carried out in the same way as in the first heat treatment step in the first production method.
<First Cooling Step>
Next, as illustrated in FIG. 19 , the compact thus heat-treated is cooled to room temperature. The first cooling step can be carried out at substantially the same rate of cooling as that in the cooling step in the first production method. Although not shown in FIG. 19 , the step of processing the compact after the first cooling step into a compact having a smaller shape may be additionally carried out. This enables the second heat treatment step (annealing step) mentioned later to be carried out for the compact having a smaller shape and consequently, can reliably prevent the piezoelectric composition from being destroyed by thermal shock in the second cooling step mentioned later. An electrode preparation step may be further carried out after the processing step.
<Second Temperature Elevation Step>
As mentioned later, the second heat treatment step serves as an annealing step. As illustrated in FIG. 19 , the temperature elevation step is therefore carried out after the first cooling step. The rate of temperature rise is not particularly limited and can be set to, for example, 50 to 1,000° C./hr.
<Second Heat Treatment Step>
The second heat treatment step in the second production method serves as an annealing step. As illustrated in FIG. 19 , the second heat treatment step in the second production method is carried out in the same way as in the second heat treatment step in the first production method. The annealing step may be carried out as a single round as in the second heat treatment step in the first production method or may be carried out in two or more rounds at different temperatures as in Example 2-9 mentioned later.
<Second Cooling Step>
As illustrated in FIG. 19 , the second cooling step in the second production method is carried out in the same way as in the cooling step in the first production method.
Embodiment 2-3
Next, the ultrasonic probe of the second aspect will be described. The ultrasonic probe of the second aspect includes the lead-free piezoelectric element described in Embodiment 2-1.
FIG. 20 is a cross-sectional view schematically illustrating the ultrasonic probe of the second aspect. The ultrasonic probe of the second aspect can be produced as follows: first, piezoelectric element 202 is temporarily polarized under desired polarization conditions. General piezoelectric element polarization conditions can be used as the polarization conditions. For example, piezoelectric element 202 is heated to 100 to 150° C. in an oil bath and kept for approximately 5 minutes to approximately 1 hour under conditions of 10 to 80 kV/cm. Then, the temperature of piezoelectric element 202 is lowered to room temperature to complete polarization. Next, piezoelectric element 202 (before cutting) thus completely polarized is fixed, using an electrically conductive adhesive or the like, onto lower lead electrode 206 fixed on back load material 220 . Next, upper lead electrode 204 is also similarly bonded thereto using an electrically conductive adhesive or the like. First matching layer 230 and second matching layer 232 are further bonded and fixed thereonto. Next, in this state, the piezoelectric element is segmented using a dicing apparatus. For example, the piezoelectric element is cut into pitches of 200 to 400 μm in width. Acoustic lens 240 is further bonded thereto. After necessary casing (not shown), ultrasonic probe 200 can be produced.
The ultrasonic probe having the segmented piezoelectric element is described above. Alternatively, a single-plate ultrasonic probe may be used, as a matter of course.
Embodiment 2-4
Next, the diagnostic imaging apparatus of the second aspect will be described. The diagnostic imaging apparatus of the second aspect includes the ultrasonic probe described in Embodiment 2-3.
FIG. 21 is a perspective view schematically illustrating the diagnostic imaging apparatus of the second aspect. In FIG. 21 , ultrasonic diagnostic imaging apparatus 300 includes ultrasonic probe 302 , ultrasonic diagnostic imaging apparatus body 304 , and display 306 . A conventional ultrasonic diagnostic apparatus body may be used as ultrasonic diagnostic imaging apparatus body 304 except for ultrasonic probe 302 . In order to render the properties of ultrasonic diagnostic imaging apparatus body 304 consistent with ultrasonic probe 302 including the lead-free piezoelectric element, the signal processing circuit of ultrasonic diagnostic imaging apparatus body 304 and the electric impedance matching circuit of ultrasonic probe 302 can be adjusted to ones intended for ultrasonic probe 302 . In order to apparently bring the electric impedance of ultrasonic probe 302 closer to the impedance of an ultrasonic probe including a conventional lead-based piezoelectric element, ultrasonic probe 302 may further include a circuit that finely adjusts impedance. Diagnostic imaging apparatus 300 can be used as a diagnostic imaging apparatus for specified diseases, for example, an ultrasonic diagnostic apparatus for intimal thickness measurement, or as an ultrasonic diagnostic imaging apparatus for other uses.
Hereinafter, the second aspect will be described with reference to Examples. However, the second aspect is not limited by Examples below.
Example 2-1
A piezoelectric element was prepared as mentioned below.
<Starting Material Preparation Step>
30 g in total of Bi 2 O 3 , KHCO 3 , TiO 2 , MgO, and Fe 2 O 3 was weighed such that the composition of the resulting piezoelectric composition satisfied z=0.45 (x=0.45 and y=0.1) in compositional formula x(Bi 0.5 K 0.5 )TiO 3 -yBi(Mg 0.5 Ti 0.5 )O 3 -zBiFeO 3 to prepare starting materials. The starting materials used were reagents having a purity of 99.9 to 99.99%. Next, the weighed starting materials were placed in a pot together with ethanol and zirconia balls and ground for 16 hours using a ball mill. Then, the starting materials were dried. The starting material powders were further preliminarily fired at 800° C. for 6 hours. The obtained starting material powders were placed again in a pot together with ethanol and zirconia balls and ground again for 16 hours using a ball mill. Then, PVB was added thereto as a binder, followed by drying. Next, a pressure of approximately 200 to 250 MPa was applied to the obtained starting material powders using a uniaxial press apparatus to prepare pellets of 10 mm in diameter and 1.5 mm in thickness. The obtained pellets were heated at 700° C. for 10 hours for removal of the binder to obtain a starting material compact.
<Temperature Elevation Step>
Next, the temperature of the obtained starting material compact was elevated to 1,000° C. at a rate of temperature rise of 300° C./hr.
<First Heat Treatment Step>
Next, the starting material compact was sintered at 1,000° C. for 2 hours.
<Temperature Lowering Step>
Next, the temperature of the compact thus sintered was lowered to 800° C. at a rate of 300° C./hr.
<Second Heat Treatment Step (Annealing Step)>
Subsequently, the temperature-lowered compact was annealed at 800° C. for 20 hours.
<Cooling Step>
Finally, the compact thus annealed was cooled to room temperature at a rate of cooling of 40 to 100° C./second to obtain a piezoelectric composition.
Next, the obtained piezoelectric composition was processed into a thickness of approximately 0.4 mm by polishing. Then, gold electrodes were formed on both sides of the piezoelectric composition by sputtering to obtain a piezoelectric element. The surface resistance of the electrodes in the prepared piezoelectric element was measured with 2 mm spacing between the terminals and consequently confirmed to be as favorable as a few ohms or less.
Subsequently, the dielectric properties and piezoelectric properties of the prepared piezoelectric element were measured.
First, the relative permittivity and dielectric loss of the prepared piezoelectric element were measured as dielectric properties using an LCR meter (model 6440B) manufactured by Wayne Kerr Electronics. FIG. 22 illustrates the temperature characteristics of relative permittivity of the piezoelectric element. FIG. 23 illustrates the temperature characteristics of dielectric loss of the piezoelectric element. Since dielectric loss (tan δ) becomes large (1 or larger) at a temperature elevated to 500° C. at a low frequency, the relative permittivity and the dielectric loss were evaluated at 1 MHz in this study. As a result, the piezoelectric element had a relative permittivity ∈r of 430 and a dielectric loss tan δ of 0.12 at 25° C. Also, the piezoelectric element had a relative permittivity ∈m of 7,700 and a dielectric loss tan δ of 0.09 at maximum temperature Tm (376° C.).
Next, the electric field-strain properties and electric field-polarization properties of the prepared piezoelectric element were measured as piezoelectric properties by use of a ferroelectric evaluation system “FCE-3” manufactured by TOYO Corp. or a self-made measurement system using a contact-type displacement gauge and an integrator. This measurement of the piezoelectric properties was performed after calibration with the value of commercially available PZT having a known piezoelectric constant d33* and remnant polarization. FIG. 24 illustrates the electric field-strain properties of the piezoelectric element. FIG. 25 illustrates the electric field-polarization properties of the piezoelectric element. The piezoelectric element had a piezoelectric constant d33* of 331 pm/V determined from FIG. 24 and a remnant polarization Pr of 13.6 μC/cm 2 determined from FIG. 25 , and thus exhibited great piezoelectric properties as a lead-free piezoelectric element, though asymmetry was seen in the electric field-strain properties.
The piezoelectric composition in the piezoelectric element was observed under a scanning electron microscope (SEM). As a result, the piezoelectric composition (ceramic) had a particle size of 0.5 to 1.5 μm.
Example 2-2
A piezoelectric element was prepared as mentioned below.
<Starting Material Preparation Step>
A starting material compact was prepared in the same way as in Example 2-1.
<Temperature Elevation Step>
Next, the temperature of the obtained starting material compact was elevated to 1,000° C. at a rate of temperature rise of 100° C./hr.
<First Heat Treatment Step>
Next, the starting material compact was sintered at 1,000° C. for 20 hours.
<Temperature Lowering Step>
Next, the temperature of the compact thus sintered was lowered to 800° C. at a rate of 100° C./hr.
<Second Heat Treatment Step (Annealing Step)>
Subsequently, the temperature-lowered compact was annealed at 800° C. for 20 hours.
<Cooling Step>
Finally, the compact thus annealed was cooled to room temperature at a rate of cooling of 40 to 100° C./second to obtain a piezoelectric composition.
Next, the obtained piezoelectric composition was processed into a thickness of approximately 0.4 mm by polishing. Then, gold electrodes were formed on both sides of the piezoelectric composition by sputtering to obtain a piezoelectric element. The surface resistance of the electrodes in the prepared piezoelectric element was measured with 2 mm spacing between the terminals and consequently confirmed to be as favorable as a few ohms or less.
Subsequently, the dielectric properties and piezoelectric properties of the prepared piezoelectric element were measured in the same way as in Example 2-1. FIG. 26 illustrates the temperature characteristics of relative permittivity of the piezoelectric element. FIG. 27 illustrates the temperature characteristics of dielectric loss of the piezoelectric element. As a result, the piezoelectric element had a relative permittivity ∈r of 491 and a dielectric loss tan δ of 0.11 at 25° C. Also, the piezoelectric element had a relative permittivity ∈m of 13,500 and a dielectric loss tan δ of 0.12 at maximum temperature Tm (371° C.).
FIG. 28 illustrates the electric field-strain properties of the piezoelectric element. FIG. 29 illustrates the electric field-polarization properties of the piezoelectric element. The piezoelectric element had a piezoelectric constant d33* of 378 pm/V determined from FIG. 28 and a remnant polarization Pr of 27 μC/cm 2 determined from FIG. 29 , and thus exhibited great piezoelectric properties as a lead-free piezoelectric element.
The piezoelectric composition in the piezoelectric element was observed under a scanning electron microscope (SEM). As a result, the piezoelectric composition (ceramic) had a particle size of 2 to 5 μm.
In this Example, the longer sintering time than that of Example 2-1 was able to increase both relative permittivity ∈r and remnant polarization Pr compared with those of Example 2-1.
Example 2-3
A piezoelectric element was prepared in the same way as in Example 2-2 except that the sintering time of the first heat treatment step was set to 200 hours. Next, the dielectric properties and piezoelectric properties of the prepared piezoelectric element were measured in the same way as in Example 2-1. As a result, the piezoelectric element had a relative permittivity ∈r of 490 and a dielectric loss tan δ of 0.08 at 25° C., and had a relative permittivity ∈m of 14,000 and a dielectric loss tan δ of 0.12 at maximum temperature Tm (370° C.). Also, the piezoelectric element had a piezoelectric constant d33* of 410 pm/V and a remnant polarization Pr of 27 μC/cm 2 .
The piezoelectric composition in the piezoelectric element was observed under a scanning electron microscope (SEM). As a result, the piezoelectric composition (ceramic) had a particle size of 3 to 10 μm.
Example 2-4
A piezoelectric element was prepared in the same way as in Example 2-2 except that the sintering time of the first heat treatment step was set to 300 hours. Next, the dielectric properties and piezoelectric properties of the prepared piezoelectric element were measured in the same way as in Example 2-1 and were almost similar to the results of Example 2-3.
Comparative Example 2-1
A piezoelectric element was prepared as mentioned below.
<Starting Material Preparation Step>
A starting material compact was prepared in the same way as in Example 2-1.
<Temperature Elevation Step>
Next, the temperature of the obtained starting material compact was elevated to 1,000° C. at a rate of temperature rise of 300° C./hr.
<First Heat Treatment Step>
Subsequently, the starting material compact was sintered at 1,000° C. for 2 hours.
<Temperature Lowering Step>
The temperature lowering step was not carried out.
<Second Heat Treatment Step (Annealing Step)>
The second heat treatment step was not carried out.
<Cooling Step>
Finally, the compact thus sintered was cooled to room temperature at a rate of cooling of 0.055° C./second to obtain a piezoelectric composition.
Next, the obtained piezoelectric composition was processed into a thickness of approximately 0.4 mm by polishing. Then, gold electrodes were formed on both sides of the piezoelectric composition by sputtering to obtain a piezoelectric element.
Subsequently, the dielectric properties and piezoelectric properties of the prepared piezoelectric element were measured in the same way as in Example 2-1. FIG. 30 illustrates the temperature characteristics of relative permittivity of the piezoelectric element. FIG. 31 illustrates the temperature characteristics of dielectric loss of the piezoelectric element. As a result, the piezoelectric element had a relative permittivity ∈r of 440 and a dielectric loss tan δ of 0.14 at 25° C. Also, the piezoelectric element had a relative permittivity ∈m of 3,590 and a dielectric loss tan δ of 0.13 at maximum temperature Tm (305° C.).
FIG. 32 illustrates the electric field-strain properties of the piezoelectric element. FIG. 33 illustrates the electric field-polarization properties of the piezoelectric element. The piezoelectric element had a piezoelectric constant d33* of 84 pm/V determined from FIG. 32 , and its remnant polarization Pr determined from FIG. 33 was not accurately measurable due to leak current.
Example 2-5
A piezoelectric composition was prepared as mentioned below.
<Starting Material Preparation Step>
A starting material compact was prepared in the same way as in Example 2-1 except that the size of the starting material compact was set to 50 mm in diameter and 5 mm in thickness.
<First Temperature Elevation Step>
Next, the temperature of the obtained starting material compact was elevated to 1,000° C. at a rate of temperature rise of 100° C./hr.
<First Heat Treatment Step>
Next, the starting material compact was sintered at 1,000° C. for 20 hours.
<First Cooling Step>
Next, the compact thus sintered was cooled from 1,000° C. to room temperature over 12 hours.
<Processing Step>
Next, the temperature-lowered compact was abrasively cut and processed into a compact of 15 mm in diameter and 3 mm in thickness.
<Second Temperature Elevation Step>
Next, the temperature of the processed compact was elevated to 800° C. over 2 hours and 40 minutes.
<Second Heat Treatment Step (Annealing Step)>
Next, the temperature-elevated compact was annealed at 800° C. for 20 hours.
<Second Cooling Step>
Finally, the compact thus annealed was cooled to room temperature at a rate of cooling of 40 to 100° C./second to obtain a piezoelectric composition.
Next, the obtained piezoelectric composition was processed into a diameter of 13 mm and a thickness of 1 mm by polishing. Then, gold electrodes were formed on both sides of the piezoelectric composition by sputtering to obtain a piezoelectric element.
Next, the dielectric properties and piezoelectric properties of the prepared piezoelectric element were measured in the same way as in Example 2-1. As a result, the piezoelectric element had a relative permittivity ∈r of 460 and a dielectric loss tan δ of 0.11 at 25° C., and had a relative permittivity ∈m of 12,500 and a dielectric loss tan δ of 0.12 at maximum temperature Tm (371° C.). Also, the piezoelectric element had a piezoelectric constant d33* of 360 pm/V and a remnant polarization Pr of 24 μC/cm 2 .
Example 2-6
A piezoelectric composition was prepared as mentioned below.
<Starting Material Preparation Step>
A starting material compact was obtained in the same way as in the starting material preparation step of Example 2-1 except that 30 g in total of Bi 2 O 3 , KHCO 3 , TiO 2 , MgO, and Fe 2 O 3 was weighed such that the composition of the resulting piezoelectric composition satisfied z=0.4 (x=0.5 and y=0.1) in compositional formula x(Bi 0.5 K 0.5 )TiO 3 -yBi(Mg 0.5 Ti 0.5 )O 3 -zBiFeO 3 to prepare starting materials.
<Temperature Elevation Step>
Next, the temperature of the obtained starting material compact was elevated to 1,000° C. at a rate of temperature rise of 300° C./hr.
<First Heat Treatment Step>
Next, the starting material compact was sintered at 1,000° C. for 2 hours.
<Temperature Lowering Step>
Next, the temperature of the compact thus sintered was lowered to 800° C. at a rate of 100° C./hr.
<Second Heat Treatment Step (Annealing Step)>
Subsequently, the temperature-lowered compact was annealed at 800° C. for 20 hours.
<Cooling Step>
Finally, the compact thus annealed was cooled to room temperature at a rate of cooling of 40 to 100° C./second to obtain a piezoelectric composition.
Next, a piezoelectric element was prepared in the same way as in Example 2-1. The piezoelectric constant d33* of the prepared piezoelectric element was measured in the same way as in Example 2-1. In addition, piezoelectric elements were prepared in the same way as above except that: the amount z of BFO (molar ratio) in the compositional formula was changed to 0.1 to 0.85 (in this context, x=0.9−z and y=0.1); the sintering temperature of the first heat treatment step was changed to 900 to 1,065° C. to achieve the largest sintered density; and the rate of cooling in the cooling step was changed to 40 to 100° C./second. The piezoelectric constants d33* of the prepared piezoelectric elements were measured in the same way as in Example 2-1. These results are indicated by mark ● in FIG. 34 .
Example 2-7
A piezoelectric composition was prepared in the same way as in Example 2-6 except that the sintering time of the first heat treatment step was set to 20 hours. Next, a piezoelectric element was prepared in the same way as in Example 2-1. The piezoelectric constant d33* of the prepared piezoelectric element was measured in the same way as in Example 2-1. In addition, piezoelectric elements were prepared in the same way as above except that the amount z of BFO (molar ratio) in the compositional formula shown in the starting material preparation step of Example 2-6 was changed to 0.4 to 0.5 (in this context, x=0.9−z and y=0.1). The piezoelectric constants d33* of the prepared piezoelectric elements were measured in the same way as in Example 2-1. These results are indicated by mark □ in FIG. 34 .
Comparative Example 2-2
A piezoelectric composition was prepared in the same way as in Example 2-6 except that the sintered compact was cooled over 5 hours in the cooling step without the temperature lowering step and the second heat treatment step (annealing step). Next, a piezoelectric element was prepared in the same way as in Example 2-1. The piezoelectric constant d33* of the prepared piezoelectric element was measured in the same way as in Example 2-1. In addition, piezoelectric elements were prepared in the same way as above except that the amount z of BFO (molar ratio) in the compositional formula shown in the starting material preparation step of Example 2-6 was changed to 0.05 to 0.85 (in this context, x=0.9−z and y=0.1). The piezoelectric constants d33* of the prepared piezoelectric elements were measured in the same way as in Example 2-1. These results are indicated by mark ♦ in FIG. 34 .
Comparative Example 2-3
Piezoelectric compositions in which z=0.4 to 0.6 (x=0.9−z and y=0.1) were prepared in the same way as in Comparative Example 2-1 without the temperature lowering step and the second heat treatment step (annealing step). In addition, piezoelectric compositions were prepared in the same way as in Comparative Example 2-1 except that, as in conventional cases, the piezoelectric compositions were annealed at 900° C. for 5 minutes and then dipped in water of 70° C. (the rate of cooling in this procedure was approximately 830° C./second or faster). In this approach, some piezoelectric compositions were destroyed. From among undestroyed piezoelectric compositions, piezoelectric elements were prepared in the same way as in Example 2-1. Next, the piezoelectric constants d33* of the prepared piezoelectric elements were measured in the same way as in Example 2-1. These results are indicated by mark A in FIG. 34 .
As is evident from FIG. 34 , the piezoelectric constants d33* of Examples 2-6 and 2-7 involving the annealing step reached a peak when the amount z of BFO (molar ratio) was 0.45. As is also evident, the piezoelectric constant d33* of Example 2-6 was increased even when the amount z of BFO (molar ratio) was 0.1. The crystal structure of the piezoelectric compositions of Example 2-6 were analyzed by powder X-ray diffraction. As a result, the composition in which z=0.1 was confirmed to be in proximity to a tetragonal-pseudocubic phase boundary. X-ray diffraction results of the piezoelectric compositions prepared separately and results about piezoelectric elements prepared using the piezoelectric compositions demonstrated that a tetragonal-pseudocubic phase boundary exists, for example, in x=0.92, y=0.04, and z=0.04. The composition in which z=0.45 was confirmed to include a rhombohedral-pseudocubic phase boundary.
Next, the influence of an additive on the piezoelectric element of the second aspect will be described.
Example 2-8
A piezoelectric element was prepared as mentioned below.
<Starting Material Preparation Step>
A starting material compact was prepared in the same way as in the starting material preparation step of Example 2-1 except that: the starting materials used were 30 g in total of Bi 2 O 3 , KHCO 3 , TiO 2 , MgO, and Fe 2 O 3 weighed such that the composition of the resulting piezoelectric composition satisfied z=0.45 (x=0.45 and y=0.1) in compositional formula x(Bi 0.5 K 0.5 )TiO 3 -yBi(Mg 0.5 Ti 0.5 )O 3 -zBiFeO 3 ; and 0.1 wt % (0.03 g) of MnCO 3 was further added to this 30 g of the starting materials to prepare starting materials.
<First Temperature Elevation Step>
Next, the temperature of the obtained starting material compact was elevated to 1,000° C. at a rate of temperature rise of 300° C./hr.
<First Heat Treatment Step>
Next, the starting material compact was sintered at 1,000° C. for 20 hours.
<First Cooling Step>
Next, the compact thus sintered was cooled to room temperature at a rate of cooling of 300° C./hr.
<Second Temperature Elevation Step>
Next, the temperature of the cooled compact was elevated to 800° C. at a rate of temperature rise of 300° C./hr.
<Second Heat Treatment Step (Annealing Step)>
Next, the temperature-elevated compact was annealed at 800° C. for 20 hours.
<Second Cooling Step>
Finally, the compact thus annealed was cooled to room temperature at a rate of cooling of 40 to 100° C./second to obtain a piezoelectric composition.
Next, the obtained piezoelectric composition was processed into a thickness of approximately 0.4 mm by polishing and then cut into a size of 4 mm long and 1.5 mm wide. Gold electrodes were formed on both sides of the piezoelectric element by sputtering to obtain a piezoelectric element as illustrated in FIG. 16 .
Subsequently, the dielectric properties and piezoelectric properties of the prepared piezoelectric element were measured in the same way as in Example 2-1. FIG. 35 illustrates the temperature characteristics of relative permittivity of the piezoelectric element. FIG. 36 illustrates the temperature characteristics of dielectric loss of the piezoelectric element. As a result, the piezoelectric element had a relative permittivity ∈r of 483 and a dielectric loss tan δ of 0.12 at 25° C. Also, the piezoelectric element had a relative permittivity ∈m of 12,000 and a dielectric loss tan δ of 0.09 at maximum temperature Tm (367° C.). The piezoelectric element had a piezoelectric constant d33* of 372 pm/V and a remnant polarization Pr of 24 μC/cm 2 , and thus exhibited great piezoelectric properties as a lead-free piezoelectric element. In order to evaluate insulation properties at high temperatures having a great impact on polarization treatment, the dielectric loss tan δ was measured at a temperature of 150° C. and 100 Hz and consequently confirmed to be 0.13, indicating relatively low loss.
Example 2-9
A piezoelectric element was prepared in the same way as in Example 2-8 except that the second heat treatment step and the second cooling step were changed as described below. FIG. 37 schematically illustrates a method for producing the piezoelectric element of this Example except for a starting material preparation step.
<Second Heat Treatment Step (Annealing Step)>
In this Example, the annealing step was carried out in 2 stages (first annealing step and second annealing step) as described below.
(First Annealing Step; which is Indicated as Step 2 -A in FIG. 37 )
The compact after the second temperature elevation step was annealed at 800° C. for 20 hours.
(Cooling Step; which is Indicated as Step 2 -B in FIG. 37 )
Next, the compact after the first annealing step was cooled to room temperature at a rate of cooling of 40 to 100° C./second.
(Temperature Elevation Step; which is Indicated as Step 2 -C in FIG. 37 )
Next, the temperature of the compact thus cooled was elevated to 500° C. at a rate of temperature rise of 250° C./hr.
(Second Annealing Step; which is Indicated as Step 2 -D in FIG. 37 )
Next, the temperature-elevated compact was annealed at 500° C. for 10 minutes.
<Second Cooling Step>
Finally, the compact after the second annealing was cooled to room temperature at a rate of cooling of 200 to 300° C./hr (0.06 to 0.08° C./second) to obtain a piezoelectric composition.
Next, the dielectric properties and piezoelectric properties of the prepared piezoelectric element were measured in the same way as in Example 2-1. FIG. 38 illustrates the temperature characteristics of relative permittivity of the piezoelectric element. FIG. 39 illustrates the temperature characteristics of dielectric loss of the piezoelectric element. As a result, the piezoelectric element had a relative permittivity ∈r of 493 and a dielectric loss tan δ of 0.12 at 25° C. Also, the piezoelectric element had a relative permittivity ∈m of 11,400 and a dielectric loss tan δ of 0.08 at maximum temperature Tm (367° C.). The piezoelectric element had a piezoelectric constant d33* of 370 pm/V and a remnant polarization Pr of 21 μC/cm 2 , and thus exhibited great piezoelectric properties as a lead-free piezoelectric element. In order to evaluate insulation properties at high temperatures having a great impact on polarization treatment, the dielectric loss tan δ was measured at a temperature of 150° C. and 100 Hz and consequently confirmed to be 0.06 which was lower than half the dielectric loss tan δ of Example 2-8, indicating very low loss.
Table 6 shows typical characteristic values of the piezoelectric elements of Examples 2-8 and 2-9.
TABLE 6
Example 2-8
Example 2-9
Piezoelectric constant d33* (pm/V)
372
370
Remnant polarization Pr (μC/cm 2 )
24
21
Relative permittivity ∈m (1 MHz)
12,000
11,400
Dielectric loss tanδ (1 MHz)
0.09
0.08
Dielectric loss tanδ (100 Hz, 150° C.)
0.13
0.06
Although the details are unknown, the results described above demonstrated that the addition of Mn in a trace amount and the 2-stage second heat treatment step (annealing step) are particularly effective for reduction in the loss of the piezoelectric element, which cannot be achieved by simple procedures of Mn addition and sintering.
The influence of an additive on the piezoelectric element of the second aspect is described above with reference to cases using MnCO 3 added in an amount of 0.1 wt %. MnCO 3 added in an amount on the order of 0.05 to 0.3 wt % produces almost similar effects. The Mn additive used in Example 2-8 or 2-9 was MnCO 3 . Likewise, other Mn additives such as MnO, Mn 2 O 3 , Mn 3 O 4 , and MnO 2 are also effective.
Next, the influence of heat treatment in a reductive atmosphere on the piezoelectric element of the second aspect will be described.
Example 2-10
A piezoelectric element was prepared as mentioned below.
<Starting Material Preparation Step>
A starting material compact was prepared in the same way as in the starting material preparation step of Example 2-1 except that: the starting materials used were 30 g in total of Bi 2 O 3 , KHCO 3 , TiO 2 , MgO, and Fe 2 O 3 weighed such that the composition of the resulting piezoelectric composition satisfied z=0.523 (x=0.427 and y=0.05) in compositional formula x(Bi 0.5 K 0.5 )TiO 3 -yBi(Mg 0.5 Ti 0.5 )O 3 -zBiFeO 3 ; and 0.1 wt % (0.03 g) of MnCO 3 was further added to this 30 g of the starting materials to prepare starting materials.
<First Temperature Elevation Step>
Next, the temperature of the obtained starting material compact was elevated to 1,000° C. at a rate of temperature rise of 300° C./hr.
<First Heat Treatment Step>
Next, the starting material compact was sintered at 1,000° C. for 20 hours.
<First Cooling Step>
Next, the compact thus sintered was cooled to room temperature at a rate of cooling of 300° C./hr.
<Second Temperature Elevation Step>
Next, the temperature of the cooled compact was elevated to 800° C. at a rate of temperature rise of 300° C./hr in a nitrogen atmosphere.
<Second Heat Treatment Step (Annealing Step)>
Next, the temperature-elevated compact was annealed at 800° C. for 20 hours in a nitrogen atmosphere.
<Second Cooling Step>
Finally, the compact thus annealed was cooled to room temperature at a rate of cooling of 0.01 to 0.05° C./second in a nitrogen atmosphere to obtain a piezoelectric composition.
Next, the obtained piezoelectric composition was processed into a thickness of approximately 0.4 mm by polishing and then cut into a size of 4 mm long and 1.5 mm wide. Gold electrodes were formed on both sides of the piezoelectric element by sputtering to obtain a piezoelectric element as illustrated in FIG. 16 .
Subsequently, the dielectric properties and piezoelectric properties of the prepared piezoelectric element were measured in the same way as in Example 2-1. As a result, the piezoelectric element had a relative permittivity ∈r of 460 and a dielectric loss tan δ of 0.11 at 25° C. Also, the piezoelectric element had a relative permittivity ∈m of 11,400 and a dielectric loss tan δ of 0.1 at maximum temperature Tm (373° C.). The piezoelectric element had a piezoelectric constant d33* of 293 pm/V and a remnant polarization Pr of 27 μC/cm 2 , and thus exhibited great piezoelectric properties as a lead-free piezoelectric element. As an indicator for leak current having a great impact on polarization treatment, the dielectric loss tan δ was measured at a temperature of 150° C. and 100 Hz and consequently confirmed to be 0.36, indicating relatively low loss.
Example 2-11
A piezoelectric element was prepared in the same way as in Example 2-10 except that the second heat treatment step and the second cooling step were changed as described below.
<Second Heat Treatment Step (Annealing Step)>
In this Example, the annealing step was carried out in 2 stages (first annealing step and second annealing step) as described below.
(First Annealing Step)
The compact after the second temperature elevation step was annealed at 800° C. for 20 hours in a nitrogen atmosphere.
(Cooling Step)
Next, the compact after the first annealing step was cooled to room temperature at a rate of cooling of 0.01 to 0.05° C./second in a nitrogen atmosphere.
(Temperature Elevation Step)
Next, the temperature of the compact thus cooled was elevated to 500° C. at a rate of temperature rise of 200° C./hr in air.
(Second Annealing Step)
Next, the temperature-elevated compact was annealed at 500° C. for 30 minutes in air.
<Second Cooling Step>
Finally, the compact after the second annealing was cooled to room temperature at a rate of cooling of 200 to 300° C./hr (0.06 to 0.08° C./second) to obtain a piezoelectric composition.
Next, the obtained piezoelectric composition was processed into a thickness of approximately 0.4 mm by polishing and then cut into a size of 4 mm long and 1.5 mm wide. Gold electrodes were formed on both sides of the piezoelectric element by sputtering to obtain a piezoelectric element as illustrated in FIG. 16 .
Subsequently, the dielectric properties and piezoelectric properties of the prepared piezoelectric element were measured in the same way as in Example 2-1. As a result, the piezoelectric element had a relative permittivity ∈r of 470 and a dielectric loss tan δ of 0.12 at 25° C. Also, the piezoelectric element had a relative permittivity ∈m of 11,100 and a dielectric loss tan δ of 0.09 at maximum temperature Tm (376° C.). The piezoelectric element had a piezoelectric constant d33* of 309 pm/V and a remnant polarization Pr of 26 μC/cm 2 , and thus exhibited great piezoelectric properties as a lead-free piezoelectric element. As an indicator for leak current having a great impact on polarization treatment, the dielectric loss tan δ was measured at a temperature of 150° C. and 100 Hz and consequently confirmed to be 0.08 which was lower than ¼ of that of Example 2-10, demonstrating that a piezoelectric element advantageous for polarization can be achieved.
The gas used for the reductive atmosphere in this Example was nitrogen gas. Alternatively, argon gas, nitrogen-hydrogen mixed gas, or the like may be used.
From the results described above, the piezoelectric element prepared by use of the production method of the second aspect involving the heat treatment steps shown in FIG. 18, 19 , or 37 can be confirmed to have higher piezoelectric properties or ferroelectric properties than those of a piezoelectric element prepared by a conventional method. Thus, the production method of the second aspect was found very effective for providing a piezoelectric element having high piezoelectric properties or ferroelectric properties with high reproducibility.
As described above, the lead-free piezoelectric element of the second aspect has high piezoelectric properties. Also, the method for producing the lead-free piezoelectric element of the second aspect can conveniently produce, with high reproducibility, a lead-free environment-responsive piezoelectric element containing no lead and having high piezoelectric properties. The lead-free piezoelectric element of the second aspect can be expected to be applied to ultrasonic probes, transducers, sensors, etc. and can be further applied to ultrasonic diagnostic imaging apparatuses.
REFERENCE SIGNS LIST
1 Composition region (excluding segment AE) of the piezoelectric composition of the first aspect
2 More preferred composition region (excluding segment AI) of the piezoelectric composition of the first aspect
3 More preferred composition region (excluding segment JN) of the piezoelectric composition of the first aspect
10 , 20 , 202 Piezoelectric element
11 , 21 Piezoelectric composition
12 , 22 Electrode
31 Domain wall
32 Domain
33 Defect
35 Line representing tetragonal-pseudocubic phase boundary
45 Line representing rhombohedral-pseudocubic phase boundary
200 , 302 Ultrasonic probe
204 Upper lead electrode
206 Lower lead electrode
220 Back load material
230 First matching layer
232 Second matching layer
240 Acoustic lens
300 Ultrasonic diagnostic imaging apparatus
304 Ultrasonic diagnostic imaging apparatus body
306 Display | The present invention is a piezoelectric composition and a piezoelectric element using the piezoelectric composition, the composition being characterized by: having a Perovskite structure represented by general formula ABO3; being represented by composition formula x(Bi0.5K0.5)TiO3-yBi(Mg0.5Ti0.5)O3-zBiFeO3, x+y+z=1 in the composition formula above; and in a triangular coordinate using x, y and z in the composition formula above, having a composition represented by a region which is surrounded by a pentagon ABCDE with apexes of point A (1, 0, 0), point B (0.7, 0.3, 0), point C (0.1, 0.3, 0.6), point D (0.1, 0.1, 0.8) and point E (0.2, 0, 0.8) and which does not include the line segment AE that connects point A (1, 0, 0) and point E (0.2, 0, 0.8). | 2 |
TECHNICAL FIELD OF THE INVENTION
This invention relates to an apparatus for use in a Fourdrinier paper process to continuously stretch separately the ropes employed to drive dryer cans and continuously recombine the stretched ropes to the drive system.
BACKGROUND OF THE INVENTION
In a Fourdrinier paper making process a sheet of fibers is laid on a travelling screen and subjected to drainage and vacuum dewatering and then passed over a series of rotating heated drums (dryer cans) to evaporate the water content to about 5% which is suitable for finishing, and prepared in rolls for sales. The paper sheet is guided through the series of dryer cans by endless ropes that are seated in a groove at one end of the can similar to a pulley. The endless ropes are usually used in combinations of 2 or 3 ropes simultaneously fitting into the one groove around each can. This is for the purpose of providing a means for gripping one edge of the travelling sheet of paper as it passes through the series of dryer cans. As the rope is used, its water content changes, and the rope, usually made of braided fibers of nylon or other fibrous material, stretches and shrinks as it passes through the various stresses of pulling the paper over several dryer cans. It has been a routine processing step to pass the ropes leaving the last can of the series through a rope stretching step so as to remove as much of the strains and length changes in the rope as possible before returning the ropes to the first can in the series.
In the past, the rope stretchers involve pulleys mounted on a travelling support that slides or rolls on a vertical track supported by L-shaped arms attached to a rigid base. Because the pulley over which the rope runs is supported on one side only (by one track and one set of arms) the tension forces on the pulley tend to apply a torque to the pulley and its support, and the torque produces undesirable stresses and strains in the rope and in the rope stretching device.
It is an object of this invention to provide a novel improved rope stretching device. It is another object to provide an improved rope stretching device that has no torque applied to the rope or to the stretching device. Still other objects will become apparent from the more detailed description which follows.
BRIEF SUMMARY OF THE INVENTION
This invention relates to an improvement in the rope stretching apparatus in a Fourdrinier paper making process. The improvement comprises a rigid immovable frame having a plurality of elongated parallel tracks each said track containing a reversing pulley mounted on a carriage movable lengthwise along said track and adapted to engage one said rope and cause its direction of travel to change through 180°; an entrance guide pulley adapted to receive said rope from the last in said series of dryer cans and direct it into said reversing pulley; and an exit pulley adapted to receive said rope from said reversing pulley and direct it to the first of said series of dryer cans; and means to apply an adjustable force to each said carriage which produces tension in said rope travelling between said entrance pulley and said exit pulley.
In specific and preferred embodiments of the invention the ropes are separated and stretched separately and returned to be combined at the upstream end of the dryer can series in an elongated tapering converging arrangement so as to provide a nip therebetween for receipt of one edge of the travelling paper sheet. In another such embodiment impact bumpers are included at the ends of the tracks to absorb any impact damage by the carriages in the event of rope or cable breakage. In still another embodiment the carriage is supported on both sides by a trapezoidally shaped sliding block or by tapered wheels fitting into the concave spaces in the faces of the beams forming the track.
BRIEF DESCRIPTION OF THE DRAWINGS
The novel features believed to be characteristic of this invention are set forth with particularity in the appended claims. The invention itself, however, both as to its organization and method of operation, together with further objects and advantages thereof, may best be understood by reference to the following description taken in connection with the accompanying drawings in which:
FIG. 1 is a schematic flow sheet showing where this invention fits into the paper making process;
FIG. 2 is a schematic illustration of one method for tensioning the restraint cable of the rope stretching apparatus of this invention;
FIG. 3 is a schematic illustration of a second method for tensioning the restraint cable of the rope stretching apparatus of this invention;
FIG. 4 is a top plan view of the support frame and tracks of this invention;
FIG. 5 is a front elevational view of the support frame and tracks of this invention;
FIG. 6 is a cross-sectional view taken at 6--6 of FIG. 4;
FIG. 7 is a cross-sectional view taken at 7--7 of FIG. 4;
FIG. 8 is a top plan view of the travelling carriage of this invention;
FIG. 9 is a side elevational view of the travelling carriage of this invention;
FIG. 10 is a rear elevational view of the travelling carriage of this invention;
FIG. 11 is a partial front elevational view of the travelling carriage of this invention; and
FIG. 12 is an end elevational view of a rope stretching apparatus of the prior art.
DETAILED DESCRIPTION OF THE INVENTION
The features of this invention are best understood by reference to the attached drawings.
In FIG. 1 there is shown the general system of employing the applicant's invention in a Fourdrinier paper making process. After the initial formation of a web of fibers in a Fourdrinier moving screen, the web is dewatered in a press section down to about 50-60% moisture, and then subjected to evaporation in a dryer section where the moisture is reduced to about 5%. The dewatered paper at 63 is fed into a nip 62 which leads the wet paper sheet over a series of heated rolls (called "dryer cans") 20 and eventually leaves the last dryer can 20 of the series at 64 to be finished and wound into rolls for storage and sale. At the same end of each dryer can 20 there is a convex groove or flange of U-shape or V-shape functioning as a guide for a plurality, usually 2 or 3, separate endless rope loops 21 travelling in the direction of arrows 22. An edge of the wet paper sheet is gripped between these loops and thereby guides the paper sheet over each dryer can in the entire series (20-120 cans). After leaving the last dryer can 20 in the series the ropes 21 are returned to the first dryer can 20 in the series, but on the way the ropes 21 are passed through a rope stretching apparatus 23, wherein the plurality of ropes are separated to single ropes, stretched as single ropes, and then recombined as a plurality of ropes forming the nip 62.
In FIG. 12 there is shown a typical apparatus of the prior art for rope stretching two ropes simultaneously. Each stretcher includes a frame or support beam 66 having a strip 67 serving as a track attached to the support beam 66. Wheels 68 are grooved to engage track 67. Wheels 68 are attached to a movable carriage 69 which in turn carries a shaft 70 around which rotates a pulley 71 with rope 72 in the pulley recess. Rope 72 is the same as rope 21 in FIG. 1 coming from and returning to the dryer cans 20 in the series. Each carriage 69 is attached to a restraining cable (not shown) which can be tensioned so as to apply a tension force to rope 72 causing it to be stretched. The principal difficulty with the prior art stretching device is that pulley 71 is supported from one side only and the tension forces applied to rope 72 tend to twist pulley 71 because of its lateral distance from frame 66. This applies stresses and strains to carriage 69, wheels 68, and track 67 which eventually cause damage to these parts and to rope 72.
In the present invention rope stretching apparatus 23 has a separate carriage 25 for each rope in the combined strands 21. Each carriage 25 is supported from both sides so as to eliminate all torque stresses in the apparatus and to allow for proper stretching and cleaning of rope 21. The tension forces on rope 21 are applied by a restraining cable 29 attached to each carriage 25 and directed by pulleys 30 and 31 to a suitable means for tensioning cable 29. One such means is shown in FIG. 2 where weights 33 and gravity apply the force by passing cable 29 over pulleys 32. The force is adjustable by permitting the addition or subtraction of weights 33 to reach any desired force. Another means is shown in FIG. 3 where a cylinder, hydraulic or pneumatic, is employed to push pulley 35 upward against cable 29 which is fastened to hand crank winch 36 for fine adjustment of the tensioning force.
In FIGS. 4-7 there is shown the supporting frame and tracks for the apparatus of this invention. Two tracks are shown as the combination of two horizontal channel beams 52 spaced laterally outwardly from a central I-beam 53. In the spaces between each channel beam 52 and the central I-beam 53 the movable carriage of FIGS. 8-11 travels horizontally and longitudinally. These beams are held together in a parallel relationship by spaced vertical legs 50 and by base plates 49. At the forward end of the supporting frame there are mounted an entrance pulley 27 and an exit pulley 28 to guide each single rope into and away from the stretching zone. Across the forward end of the tracks there is an impact bumper 55 and across the rearward end of the tracks there is an impact bumper 56. These bumpers 55 and 56 may separate for each track or they may be a single bumper across both tracks. Preferably, the bumpers are made in a pillow form and are a rubbery material. They may however be a more complicated structure of shock absorbing components. Bumpers 55 and 56 are needed to catch the carriages 25 should rope 21 or cable 29 break. Cutouts 60 are shown in lateral beams 59 to provide room for the return stretch rope to travel from the carriage (FIGS. 8-11) to exit pulley 28 and thence back to dryer cans 20. Legs 51 are longer than legs 50 so as to provide clearances for bumper 55 and entrance pulleys 27.
In FIGS. 8-11 there are shown the movable carriages which travel in the tracks of the support frame of FIGS. 4-7. Each carriage 25 has a pulley 26 around which rope 21 loops as it travels from entrance pulley 27 to exit pulley 28. Carriage 25 is a four-sided box having a front wall 37, a rear wall 38, and two side walls 39. Pulley is positioned centrally between side walls 39 and is rotatably supported by shaft 41 journaled in a bearing in bearing blocks 40. On each side wall 39 there is mounted a convex guide means that corresponds closely in cross section to the concave space 54 formed by the face of each channel beam 52 and by each side of the I-beam 53. The convex guide means for carriage 25 may be a solid trapezoidally shaped strip 43 or a plurality of tapered rollers 48 (see FIG. 10). The strip 43 and the rollers 48 are preferably made of a low-friction material such as plastic (polyamide, polyfluorocarbon, polyolefin, etc.). If the strip 43 is employed it may be desirable to employ a guide key 44 to mate with a corresponding groove in strip 43 so as to locate strip 43 accurately. Screws 45 and 46 may be used to attach strip 43 and key 44 to carriage 25. An eyebolt 47 is attached to rear wall 38 for attachment of tension cable 29 to carriage 25. A cutout 73 is made in front wall 37 (FIG. 11) to provide room for rope 21 to pass from pulley 42 to exit pulley 28.
Preferably the apparatus of this invention is made of structural metal, e.g., iron, steel, aluminum, or the like, although some components may be plastic or rubber as indicated above.
An advantage of this apparatus over the prior art is that it provides straight aligned forces with no torque applied to the rope pulleys. Another advantage is that the lateral spacing between adjacent carriages 25 may be greater than in the prior art and this permits easier ropes before returning to the dryer cans. Another advantage is that guide pulleys 61A and 61B leading ropes 21A and 21B through nip 62 can be spaced to any location to provide a wider nip as desired. Nip 62 is important when beginning a new length of paper to be dried after a break in the paper sheet or a break in the operation for any reason. A tail of 6-10 inches is usually cut in the paper so that the tail can be led into nip 62 and will pull the entire paper sheet onto the first dryer can in good alignment.
While the invention has been described with respect to certain specific embodiments, it will be appreciated that many modifications and changes may be made by those skilled in the art without departing from the spirit of the invention. It is intended, therefore, by the appended claims to cover all such modifications and changes as fall within the true spirit and scope of the invention. | An apparatus for continuously receiving two or more guide ropes, separately stretching those ropes and returning them to be joined for guiding purposes; the apparatus including a sliding carriage for each rope, a pulley on each carriage, a cable attached to each carriage with adjustable means to apply tension to the cable and thereby to the rope, and pulleys to lead the ropes into and out of the apparatus. | 3 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation-in-part of Application Ser. No. 638,247, filed Dec. 8, 1975, now abandoned for MARBLE MELT FEED SYSTEM.
BACKGROUND OF THE INVENTION
Glass fibers are conventionally formed by the attenuation of molten glass through orifices in a bushing by mechanical means. One of the ways of forming the molten glass above the bushing orifices is to supply marbles of glass having the desired composition to a pre-melter above the bushing orifices. The marbles are heated to a temperature above their melting point and the molten glass is held in the bushing until it is attenuated into fibers. Typical systems for feeding glass marbles directly to the pre-melter are those illustrated in U.S. Pat. Nos. 2,453,864; 2,687,599; 3,875,893; 3,013,096; 3,103,361; 3,049,754; 3,056,846; 3,104,761 and 3,701,642. With the exception of U.S. Pat. No. 2,687,599 and U.S. Pat. No. 3,779,730 which will be more fully discussed below, all of these patents must either vibrate the feed system or force-feed or drop marbles into the system in order to maintain a constant supply of marbles to the pre-melter.
In U.S. Pat. No. 2,687,599 gravity flow of glass marbles from a marble supply to a pre-melter is utilized. The marbles run along a plurality of tubular cylindrical tracks which are slightly in excess of the diameter of the marbles to a mechanism for dropping marbles one by one into the pre-melter.
In U.S. Pat. No. 3,779,730 a single line of marbles flow by gravity from a hopper to a pre-melter. Recognizing the tendency for such a system to become clogged, this patent includes an alarm system for determining clogs and warning the operator of these occurrences.
While the prior art systems may be utilized to feed marbles to a marble melt bushing, these systems do encounter problems. Thus, when an oversized marble gets into these conveyor systems, blockage of the system often results. When any such system is blocked, it becomes necessary to manually remove the oversized blocking marble from the system. Often this removal involves stopping production while the impediment is being removed.
A second problem common to the prior art systems is the fact that glass marbles have a tendency to chip and break. As these chips enter the feed systems of the prior art along with full sized marbles, the flow of marbles may be stopped with the resulting necessity of manually clearing the blockage.
A third problem which occurs, even when only correctly sized glass marbles are employed, is a tendency for the marbles to bridge among themselves in the conveying system. In simpler terms, glass marbles have a tendency to plug up a passage rather than to flow through the passage evenly. This again results in an interruption in flow of the marble in the feed system with the same necessity for manual clearance.
In another system, marbles are gravity fed vertically from hoppers to the pre-melter and bushing. However, realizing that the weight of the marbles on the bushing has an adverse effect on fiber production, the marbles are, in at least one embodiment, fed to a "pre-pre-melter," which melts the marbles and allows only molten glasss to the pre-melter and bushing. Such a system involves extra heating means, precious metal, and, of course, added costs. Typical of such systems are U.S. Pat. No. 3,056,846 and U.S. Pat. No. 3,730,695.
As can be readily seen, the prior art marble feed systems require an almost constant need for supervision to prevent interruptions and to clear blockages that do occur in the marble feed system or require intricately controlled feeds involving complicated apparatus.
The present invention eliminates the necessity for a constant watch over the marble melt feeding of a bushing and allows for the continuous feed of broken and oversized marbles along with the properly sized marbles to a pre-melter. The system is easy to construct and has no moving parts. Other advantages of the present invention will become apparent to those of ordinary skill in the art.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view, partly in section, of the marble feed system of the present invention.
FIG. 2 is a diagrammatic representation of the marble feed system of the present invention.
FIG. 3 is a sectional view through line 3--3 of FIG. 2 illustrating the shape of the chute employed in the system of the present invention at its connection to the marble container.
FIG. 4 is a sectional view through line 4--4 of FIG. 2 illustrative the shape of the chute at its entrance to the marble pre-melter.
FIG. 5 illustrates a typical stop employed to interrupt the flow of marbles through the system when desired.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
As shown in FIG. 1, the chute 12 of the present invention is connected to a supply of marbles such as a container or hopper 11 containing glass marbles 10 and associated with a pre-melter 25 for a glass fiber forming bushing 27.
The chute 12 is shown in its preferred embodiment wherein the top and bottom are formed of metal mesh to dissipate heat rising from the bushing 27 and pre-melter 25 to avoid premature softening of the glass marbles 10 within the chute 12 which might cause blockages. Of course, the entire chute 12 could be formed of metal mesh, if desired. As can be seen from this figure, the connections between the chute 12, the container or hopper 11 and pre-melter 25 are elongated and slot-like in shape.
As illustrated in FIG. 2, the glass marble feed system of the present invention comprises a source of glass marbles such as a container or hopper 11 which contains a supply of glass marbles of a desired glass composition which is to be melted and formed into glass fibers. The container 11 has an elongate slot-like opening 13 at or near its bottom which is directly connected to a chute, generally illustrated at 12. The height of opening 13 and the height of chute 12 at its connection to the opening at 13 must be of such a size that their dimensions are not less than three times the diameter of a properly sized marble for use in the system at their connection between the two. As can be seen in FIG. 3, the chute 12 employed typically has a rectangular cross-section with the height of the rectangular at its connection 13 to the hopper 11 being at least three times the diameter of the marbles employed.
The chute 12 is designed for gravity flow of the marbles from the hopper 11 to a pre-melter 25. The angle of inclination of the main body 19 of the chute 12 above the horizontal is thus critical. The angle must be sufficient to allow gravity flow of the marbles 10 from the container 11 to the pre-melter 25 but slight enough to prohibit disruption of the bushing due to the weight of the marbles 10 in the chute 12. It has been found that if the angle of inclination of the main body 19 of the chute 12 is less than about 10° from the horizontal, pure gravity flow is not obtained. Conversely, if the angle of inclination exceeds about 30° , the weight of the marbles upon the molten glass in the bushing 27 and pre-melter 25 adversely affects the operation of the bushing 27. Between about 10° and 30° successful operation of the marble feed system results. Especially good results have been obtained at an angle of inclination of 15° from the horizontal.
To accomplish this result, the chute 12 is designed having a main body 19 which is maintained between the critical angles. The main body 19 may be directly connected to the container or hopper 11 at one end or a connecting member 17 may be provided. The connection member 17 is especially desirable when angles of the walls of the container or hopper 11 are such that their angle from the horizontal exceeds the critical angle for the main body 19. The connection member 17 can thus be angled from between 10° to 90° from the horizontal at its connection to the container or hopper 11 without affecting the operation of the chute 12. The connection member 17 is then shaped to provide an angle within the critical angles at its connection to the main body 19.
A second connecting member 21 is provided to associate the main body 19 of the chute 12 with the pre-melter 25. The connecting member 21 is shaped, similarly to the connecting member 17, to connect to the main body 19 of the chute at its critical angle and to the pre-melter 25, which is fed vertically.
The container or hopper 11, the connection member 17, the main body 19 and the connection member 21 are attached to each other by means such as flanges 16. The connection member 21 is not directly attached to the pre-melter 25, but is mounted within an opening at the top of the pre-melter 25.
The majority of the weight of the marbles is absorbed by the main body 19 of the chute 12. This allows vertical feeding of the pre-melter 25 by pure gravity flow without adversely affecting production of the bushing 27.
The length of the chute 12 is not critical, but the design affords an opportunity for a compact system. For example, the horizontal distance between the center point 15 of the container or hopper 11 and the center point 31 of the pre-melter 25 can be, for example, as little as 24 inches (60.96 centimeters).
The entrance of the pre-melter 25 is also elongate and slot-like in shape. Its width, and the height of the chute 12 at its entrance to the pre-melter 25 is not less than 2 times the dimension of the glass marbles 10 to be melted. FIG. 4 illustrates the elongate slot-like shape of the chute 12 at this point 23 and its difference in height than at the opening to the container or hopper 11 as shown in FIG. 3.
The reduction in height of the chute 12 from three times the dimension of the marbles at its connection with the marble source 11 to two times the dimension of the glass marbles at its entrance to the pre-melter 25 can be accomplished by several means. Preferably, there is a gradual taper in height near the opening to the pre-melter in the connecting member 21. Optionally, this taper could be along the complete length of the chute 12. Alternatively, there could be one or more step reductions in the height of the chute 12 along its length.
The elongate slot-like shape of the entrance to the pre-melter 25 serves another function. As relatively cold marbles 10 enter the pre-melter 25, a cold spot develops at that point. With the prior art cylindrical feed tubes, marbles 10 enter only at the mouths of the cylinders, thus forming one or more isolated cold spots. With the present system, marble feed is continuous across the length of the pre-melter 25, thus leading to a more even temperature distribution across the pre-melter 25.
In the preferred embodiment of the present invention, the chute 12 is formed of metal mesh. The use of such material lowers the weight of the chute 12 considerably. Even more important, the metal mesh allows heat from the pre-melter 25 to rise out of the chute 12. This prevents the temperature within the chute 12 from reaching a point where the marbles within the chute 12 might soften, stick to the chute surface and possibly block the system.
While the system of the present invention is designed for continuous operation, it is sometimes necessary to shut down the operation for maintenance and the like. To cut off the marble feed to the pre-melter 25 without the necessity of emptying the container or hopper 11, a marble stop 29 is provided at any desired point along the chute 12. As can be seen in FIG. 4, the stop 29 is constructed of prongs or fingers 35 connected by a bar 37 to a handle 39. The prongs 35 are spaced such that the glass marbles cannnot fit between the prongs. The prongs 35 are manually fed through the metal mesh to close off the chute 12 from further marble feed. The bar 37 rests on the metal and holds the prongs 35 in place. When operation of the system is to resume, the operator need only pull the stop 29 out of the chute 12 with handle 39. This stop can be formed of a single piece or can be formed of a number of smaller units that can be located adjacent each other.
As has been previously stated, the dimensions of the chute 12 are critical to proper marble feed. Typically, glass marbles have diameters of approximately 0.748 to 0.9843 inch (19 to 25 millimeters). In order to accomodate the larger marbles, and maintain a width of at least three times the diameters of the marbles, the chute 12 should be at least about 3.0 inches (7.62 centimeters) in height at its point of connection 13 to the container or hopper 11. To maintain the width of the opening 23 to the pre-melter 25 at two times the diameter of the marbles at its entrance to the pre-melter 25, the chute 12 should be at least about 2.0 inches (5.08 centimeters) in height. These dimensions can, of course be varied according to the size of the glass marbles employed, as long as the required relationships are maintained.
EXAMPLE
A K37 bushing 27 was connected to a glass marble pre-melter 25. This bushing produces glass fiber strand having 400 filaments. The pre-melter 25 had an opening at its top of 21/2 inches by 13 inches (6.35 by 33.02 centimeters). Fitted inside of the pre-melter 25 was one rectangular end 23 of a marble chute 12 according to the present invention having a length of 12 inches (30.48 centimeters) and a height of 2 inches (5.08 centimeters) at its end 23. The difference in length and width between the two lengths were compensated for with metal strips to seal the unit. This chute 12 was then widened to dimensions of 3 inches (7.62 centimeters) by 12 inches (30.48 centimeters). The chute was located at an angle of 15 degrees above the horizontal along its straight main body section 19 and was connected at its opposing end 13 to the bottom of a hopper 11 containing glass marbles 10. The opening at the bottom of the hopper 11 was also a rectangle having dimensions of 3 inches by 12 inches (7.62 by 30.48 centimeters). The glass marbles 10 employed had an average diameter of approximately 0.748 inches (19 millimeters).
Glass marbles 10 were then allowed to flow through the system. The pre-melter 25 was operated at a temperature of 2,390° F. (1,310° C.) and the bushing 27 at a temperature of 2,107° F. (1,152.8° C). Glass fibers were pulled from the bushing at a rate of 42.9 pounds per hour of glass. This operation was continued for 336 hours without any interruption in marble flow occurring.
The system operated freely with no stoppage resulting from either oversized marbles, broken marbles, or bridging of marbles.
As can be seen from the above example, the marble feed system of the present invention allows continuous operation of a marble melt glass fiber bushing without the necessity for constant supervision and stoppage resulting from blockages of the glass marble feed system.
While the foregoing description of the invention has been made with reference to specific embodiments, it is not intended that the invention be limited except insofar as in the appended claims. | A marble feed system is disclosed for feeding glass marbles into a marble melt glass fiber forming bushing. The system comprises a storage container or hopper, a marble pre-melter, a glass fiber forming bushing, and a chute connecting the container or hopper to the pre-melter. The chute is specifically designed to prevent blockages of glass marbles due to bridging, oversized marbles and broken marbles during feeding. The novel design enables pure gravity flow of glass marbles without the need for external vibration of the feed system or other means of force feeding the marbles through the system. | 2 |
BACKGROUND
For many years various cutting bits (or tools) have been used to impinge the earth strata (e.g., coal formations, rock formations, road surfaces, and the like) so as to perform various mining, boring, and road planing operations. It is typical that these tools wear during operation so that at some point in time the tool reaches the end of its useful life which necessitates replacement thereof in the field.
Tools which impinge the earth strata include rotatable cutting bits (e.g., point attack mine tools, construction tools, and the like) which include a hard insert at the axially forward end. These rotatable cutting bits are rotatably mounted within the bore of a holder (or block) and held therein by a retainer.
In many applications, a plurality of holders (with a cutting bit in each holder) mount to a driven member (e.g., a drum or wheel) which is driven under the influence of a driver (e.g., a motor). One example of such an arrangement is a road planing drum laced with road planing tools. It can be appreciated that, using present techniques, it is time-consuming for the operator to change an entire drum of cutting bits. It thus would be desirable to provide a cutting bit assembly that provides a secure connection between the cutting bit and the holder yet permits the relatively easy connection or removal of the cutting bit to the holder.
Heretofore, some styles of the retainer have been discarded along with the used cutting bit. In order to reduce the overall operating costs of the cutting bit, it would be desirable to provide a cutting bit assembly in which the operator is able to reuse the retainer.
Tools which impinge the earth strata further include a roof bit with a hard insert at the axially forward end (i.e., impingement end) thereof wherein the roof bit non-rotatably connects, either directly or through a chuck or other type of connector, to a driver member. Driving the driver member causes the roof bit to be driven, which typically is in a rotary fashion. In order to secure the driver member to the roof bit, it is important that there be a secure connection between the roof bit and the driver member.
In the past, a steel retainer pin having a shank and a serrated head has been used to secure a roof bit to a chuck (or coupling). The roof bit body contains a hole which registers with a hole in the chuck. The shank of the retainer pin passes through the hole in the roof bit and into the hole in the chuck. The retainer pin is forced into the hole in the roof bit so that the serrated head engages the periphery of the roof bit body that defines the hole so as to secure the roof bit to the chuck. Another retention arrangement (or retainer) which has been used comprises a chuck with a hole that contains a spring-biased pin which engages a corresponding hole in the roof bit body when the roof bit is positioned on the chuck so that the hole in the roof bit comes into registration with the pin so as to secure the roof bit to the chuck.
Although each one of the above retention arrangements has functioned in an adequate fashion, there remain some drawbacks therewith. Both retention arrangements have been difficult to remove. Both retention arrangements have experienced breakage during either mounting of the roof bit on the chuck or the removal of the roof bit from the chuck. In the case of the serrated steel retainer pin, it is necessary to shear the retainer pin to remove the roof bit from the chuck. This destroys the retainer pin and leaves the serrated head in the hole in the roof bit body. This part of the retainer pin must then be removed from the roof bit body when the roof bit body is recycled.
In view of these drawbacks with the past retention arrangements, it would be desirable to provide a cutting bit assembly, especially one for a roof bit assembly, which would permit the easy removal of the roof bit, and would not experience breakage during either the mounting or removal of the roof bit from the chuck.
SUMMARY
In one form thereof, the invention is a cutting bit assembly which comprises a driven member and a cutting bit detachably connected to the driven member by a retainer. The retainer includes a magnetic pin that removably engages at least one of the cutting bit and the driven member.
BRIEF DESCRIPTION OF THE DRAWINGS
The following is a brief description of the drawings which form a part of this patent application:
FIG. 1 is an isometric view of a specific embodiment of a roof bit assembly which has been exploded along its longitudinal axis;
FIG. 2 is a cross-sectional view of the roof bit assembly of FIG. 1 with the components in an assembled condition;
FIG. 3 is a side view of an embodiment of a rotatable cutting bit held in a holder with a portion of the support and the retention clip shown in cross-section;
FIG. 4 is a rear end view of the embodiment of FIG. 3 with a portion of the structure shown in cross-section;
FIG. 5 is a side view of another embodiment of a rotatable cutting bit held in a holder with a portion of the support (or block) and retention pin shown in cross-section; and
FIG. 6 is a rear view of the embodiment of FIG. 5 wherein a portion of the cutting bit, the block, and the retention pin are shown in cross-section.
DETAILED DESCRIPTION
Referring to the drawings, FIGS. 1 and 2 illustrate a specific embodiment of a roof bit assembly generally designated as 20. Roof bit assembly 20 includes a cutting bit (or roof bit) 22 which has an axially forward end 24 and an axially rearward end 26. There is a single cutting insert 28 at the axially forward end 24 of the cutting bit 22. The cutting insert 28 is of the style shown and described in issued U.S. Pat. No. 5,172,775, to Sheirer et al., for a Rotary Drill Bit Assembly (assigned to the assignee of the present patent application), which is hereby incorporated by reference herein. Cutting bit 22 contains a cavity 30 therein which has an opening 32 at the rearward end 26 of the cutting bit 22. Cutting bit 22 further includes a bit wall 34 which contains a passage 36 that passes completely therethrough so as to communicate with the cavity 30.
Roof bit assembly 20 further includes a chuck 40 which has an axially forward end 42 and an axially rearward end 44. A generally cylindrical passage 46 passes through the entire length of the chuck 40. The chuck 40 has an enlarged diameter portion 48 which separates the chuck 40 into an axially forward portion 50 and an axially rearward portion 52. The chuck 40 contains a generally cylindrical blind recess (or hole) 54 in the exterior surface of the axially forward portion 50 thereof. The chuck 40 further contains a generally cylindrical blind recess (or hole) 56 in the exterior surface of the axially rearward portion 52 thereof.
Roof bit assembly 20 also includes a drill rod 60 which has an axially forward end 62 and an axially rearward end (not illustrated). Drill rod 60 presents a bore 64 which has an opening at the axially forward end thereof. The drill rod 60 also contains a hole 65, which as will become apparent registers with blind recess 56 upon assembly, adjacent to the axially forward end 62. The drill rod 60 operatively connects to a driver 66 and a pressurized source of coolant 68. Some aspects of the roof bit assembly (especially the chuck and drill rod) are exemplified and described in issued U.S. Pat. No. 5,400,861, to Sheirer, for a Rotatable Cutting Bit Assembly (assigned to the assignee of the present patent application), which is hereby incorporated by reference herein. While not illustrated herein, the cutting inserts described in U.S. Pat. No. 5,400,861 are suitable for use in conjunction with the present invention.
A magnetic pin 70 passes through passage 36 and into blind recess (or hole) 54 so as to connect the cutting bit 22 to the chuck 40. Another magnetic pin 72 passes through hole 65 in the drill rod 60 and into blind recess 56 so as to connect the chuck 40 to the drill rod 60.
The cutting bit 22, the chuck 40, and the drill rod 60 are each made from a ferromagnetic steel. Exemplary grades (AISI) of steel for these components include 15B35 steel for the cutting bit, 4140 steel for the chuck, and 4130 steel for the drill rod. Thus, there is a magnetic attraction between the magnetic pin 70 and the cutting bit 22 and the chuck 40 when in close physical contact. There is also a magnetic attraction between the magnetic pin 72 and the chuck 40 and the drill rod 60 when in close physical contact. The magnetic strength of the magnetic pin 70, i.e., the magnetic attraction between the magnetic pin 70 and the cutting bit 22 and chuck 40, is sufficiently great so that the magnetic pin 70 remains in place to securely connect the cutting bit 22 to the chuck 40 during the operation of the roof bit. The magnetic strength of the magnetic pin 72, i.e., the magnetic attraction between the magnetic pin 72 and the chuck 40 and the drill rod 60, is sufficiently great so that the magnetic pin 72 remains in place to securely connect the chuck 40 and the drill rod 60 during the operation of the roof bit.
It should be appreciated that while the specific embodiment depicts the use of two magnetic pins (70, 72), applicants do not intend to limit the invention to the use of two magnetic pins. Applicants contemplate that only one magnetic pin may be used wherein that pin secures together either the cutting bit 22 and the chuck 40 or the chuck 40 and the drill rod 60.
When it is time to replace the cutting bit 22, the operator can take a magnet, which has an attractive magnetic strength with respect to the magnetic pin 70 that is greater than the magnetic attraction between the magnetic pin and the cutting bit 22 and chuck 40, and position the magnet near the magnetic pin 70 so as to remove the magnetic pin 70 from the passage 36 and the recess 54. The operator could also use a puller or some type of gripper (or pliers) to grip or pull the magnetic pin out of engagement with the roof bit and the chuck. The magnetic pin could have a head or some other structure which would facilitate the operator to obtain a firm grip on the pin.
Once the pin has been removed from engagement with the cutting bit and the chuck, the cutting bit can be removed from the chuck and a new cutting bit 22 can then be positioned on the chuck 40. The magnetic pin 70 is then passed through the passage 36 and into the recess 54 of the chuck so as to securely connect the new cutting bit 22 to the chuck 40. The magnetic pin 70 may be reused in conjunction with the new cutting bit.
The same type of action can be taken with respect to the removal or insertion of the magnetic pin 72 that disconnects, or secures together, the chuck 40 and the drill rod 60. In other words, magnetic pin 72 can be magnetically or physically removed from engagement with the chuck 40 and the drill rod 60 so as to disconnect the same magnetic pin 72 can be physically inserted through hole 65 into engagement with blind recess 56 in the chuck 40 so as to secure the same together.
There are a number of advantages present through the use of the magnetic pins (70, 72). The magnetic pins are easy to insert and remove which is in contrast to earlier retention arrangements. The magnetic pins do not break during the assembly or disassembly of the cutting bit from the chuck, or the chuck from the drill rod, as has been the case in the past. The magnetic pins are reusable and a portion is not left in the roof bit body (as with the serrated type retainer) making the roof bit bodies easier to recycle.
A roof bit, which was made of 15B35 steel, was secured to a chuck, which was made of 4140 steel, via a magnetic pin (such as is shown in FIGS. 1 and 2, except that there was only one magnetic pin to secure the roof bit to the chuck) for testing. The roof bit had a one inch diameter and except for the passage, was structurally similar to a Kennametal KCV4-1 inch style of roof bit. The magnetic pin was a 1/4 inch diameter by 1/4 inch long cylinder of a neodymium iron boron magnet sold under the trademark Duracore by Nortronics Company, Inc., of Minneapolis, Minn. The roof bit-chuck connection was tested at a rotational speed of about 1100 revolution per minute (rpm) without the magnetic pin being thrown out under the influence of centrifugal force. The typical rotational speed for the operation of a roof bit is about 600 rpm. Thus, the magnetic pin has sufficient magnetic attraction so as to resist the centrifugal forces acting thereon during rotation. The magnetic strength of the magnetic pin (70, 72) can be selected depending upon the strength required for the specific application. In this regard, a ferric iron magnet may be suitable for many applications.
Referring to FIGS. 3 and 4, there is shown an embodiment of the invention in which there is a rotatable cutting bit 80 with a hard insert 82 at the axially forward end 84 thereof and an annular groove 86 near the axially rearward end 88 thereof. The cutting bit 80 further includes a head portion 90 and a shank 92.
A holder 94 (or block) contains a bore 96 which has an opening at each of the forward face 102 and the rearward face 104 of the holder 94. Holder 94 contains a cylindrical recess 106 in the rearward face 104 thereof. An integral boss 108 extends out from the holder 94 so as to be proximate to recess 106. Boss 108 includes an arcuate indention 110 in the bottom surface thereof. The holder 94 is mounted (typically as by welding) to a rotatable drum 111 such as, for example, a road planing drum or a coal mining drum.
The holder 94 rotatably retains the cutting bit 80 in the bore 96 thereof by means of a generally U-shaped retention clip 112. Clip 112 has a body portion 114 with a pair of arms 116, 118 that depend therefrom. Retention clip 112 has an interior surface which comprises an arcuate portion 115 and a pair of straight portions 117 and 119 which correspond to arms 116 and 118, respectively. Retention clip 112 has a top surface 121.
When the groove 86 of the cutting bit 80 receives the retention clip 112, the arms (116, 118) extend through the groove 86, and because the spacing between straight portions 117 and 119 of the retention clip 112 is slightly larger than the diameter of the groove 86, the arms 116, 118 do not expand when the retention clip 112 is first received in the groove 86. The curvature of the arcuate portion 115 is about equal to the curvature of the groove 86 so that the arcuate portion 115 of the interior surface of the retention clip 112 is in physical contact with the surface of the groove 86 when the retention clip 112 is received in the groove 86.
Once the retention clip 112 is received within the recess 86 and in the position depicted in FIG. 4, the operator passes a cylindrical magnetic pin 122 into the recess 106 so as to engage the arcuate indention 110 of the boss 108 and physically contact the top surface 121 of the retention clip 112. The boss 108, which is an integral part of the holder 94, is made from the ferromagnetic steel (e.g., AISI 8740 steel) that comprises the holder 94. Thus, there is a magnetic attraction between the magnetic pin 122 and the boss 108 when in close physical contact. The magnetic attraction between the magnetic pin 122 and the boss 108 provides for the secure retention of the magnetic pin 122 during the operation of the cutting bit-holder arrangement. The magnetic pin 122 retains the retention clip 112 in position, the retention clip 112, in turn, rotatably retains the cutting bit 80 within the bore 96 of the holder 94.
It should be appreciated that the magnetic pin 122 does not have to be made from a magnetic material. One exemplary non-magnetic material for the retention pin 122 is plastic.
When there is a need to replace the cutting bit 80, the operator removes the magnetic pin 122 from recess 106 so that the pin 122 is out of engagement with the holder 94 and the retention clip 112. This can be done by physically removing the magnetic pin 122 using pliers or another type of gripper. The operator could also place a magnet near the magnetic pin 122 so as to draw it out of engagement with the holder 94 and the retention clip 112. For the magnet to draw the magnetic pin out of engagement, the magnetic attraction between the magnet and the magnetic pin must be greater than the magnetic attraction that maintains the magnetic pin in position.
Once the magnetic pin 122 is removed from recess 106, i.e., disengaged from the holder and the retention clip, the retention clip 112 may then be removed from the groove 86 and the cutting bit 80 removed from the bore 96 of the holder 94. A new cutting bit 80 may then be positioned within the bore 96 of the holder 94, the retention clip 112 positioned so as to engage the groove 86, and the magnetic pin 122 repositioned in the recess 106 so as to engage the holder 94 and the retention pin 112 thereby providing for the secure rotatable retention of the cutting bit 80 in the holder 94. It should be appreciated that the magnetic pin may be reused in conjunction with the new cutting bit.
Referring to FIGS. 5 and 6, there is shown a rotatable cutting bit 130 which has an axially forward end 132 and an axially rearward end 134. Cutting bit 130 has a head portion 136 and a shank portion 138. The shank portion 138 contains an annular groove 140 between the shoulder 142 and the rearward end 134 of the cutting bit 130. A hard insert 144 is at the axially forward end 132 of the cutting bit 130.
A support (or block) 146 has a longitudinal bore 148 therein, and a transverse bore 149 which passes through a portion of the central bore 148. The transverse bore 149 includes a reduced diameter portion 151 and an enlarged diameter portion 153 with a shoulder 154 at the juncture thereof. As shown in FIG. 5, the longitudinal axis of the bore 148 is generally coaxial with the central longitudinal axis of the cutting bit 130. The central axis of the transverse bore 149 is generally perpendicular to the central longitudinal axis of the longitudinal bore 148. Transverse bore 149 opens to each side surface 150, 152 of the support 146. Support 146 is connected (such as by welding or the like) to a rotatable drum 157.
A cylindrical pin 156 is received within the transverse bore 149. Cylindrical pin 156 has an elongate body 158 and a protrusion 160 which extends from one end of the body 158. The diameter of the protrusion 160 is less than the diameter of the elongate body 158. The cylindrical pin 156 further includes a magnet 162 with a central aperture 164. The protrusion 160 passes through the aperture 164 so that there is a clearance fit therebetween. The magnetic attraction between the body 158 and the magnet 162 retains the magnet 162 on the body 158. However, the magnet 162 could be affixed to the protrusion 160 by epoxy or the like.
The cylindrical pin 156 engages the groove 140 on the shank of the cutting bit and rotatably retains the cutting bit 130 within the bore 148 of the holder 146. The cylindrical pin 156 is positioned in the enlarged diameter portion 153 of the transverse bore 149 in such a fashion that the magnet 162 abuts against the shoulder 154. The support 146 is made of a ferromagnetic steel so that there is a magnetic attraction between the magnet 162 and the support 146. The magnetic attraction between the magnet 162 (of the cylindrical pin 156) and the holder 146 is great enough to retain the cylindrical pin 156 within the transverse bore 149 during operation. The cylindrical pin 156 rotatably retains the cutting bit 130 within the bore 148 of the holder 146 during the operation of the cutting bit-holder assembly.
When it becomes necessary to replace the cutting bit 130, the operator may place a magnet in or near the enlarged diameter portion 153 of the transverse bore 149 and draws the cylindrical pin 156 out of the transverse bore 149. For the magnet to draw the cylindrical pin out of engagement, the magnetic attraction between the magnet and the cylindrical pin must be greater than the magnetic attraction that maintains the cylindrical pin in position. In the alternative, a pin or rod placed in the reduced diameter portion 151 of the transverse bore 149 may be used to push or punch the cylindrical pin 156 out of the transverse bore 149 via the enlarged diameter portion 153.
Once the cylindrical pin 156 has been removed from the transverse bore 149, the cutting bit 130 may then be removed from the longitudinal bore 148 of the holder 146. A new cutting bit 130 may be inserted into the bore 148 of the holder 146 and the cylindrical pin 156 reinserted into the transverse bore 149 so as to engage the groove 140 in the shank 138 of the cutting bit 130. The cutting bit 130 is now rotatably retained within the longitudinal bore 148 of the block 146. The cylindrical pin 156 may be reused in conjunction with the new cutting bit 130.
The patents and other documents identified herein are hereby incorporated by reference herein.
Other embodiments of the invention will be apparent to those skilled in the art from a consideration of the specification or practice of the invention disclosed herein. It is intended that the specification and examples be considered as illustrative only, with the true scope and spirit of the invention being indicated by the following claims. | A cutting bit assembly which includes a driven member and a cutting bit detachably connected to the driven member by a retainer. The retainer includes a magnetic pin that removably engages at least one of the cutting bit and the driven member. | 4 |
CROSS-REFERENCE
This application claims priority to and is a continuation of U.S. patent application Ser. No. 14/949,710, filed Nov. 23, 2015, which is a continuation of U.S. patent application Ser. No. 14/742,663, filed Jun. 17, 2015, which is a continuation of U.S. patent application Ser. No. 14/184,047, filed Feb. 19, 2014, which is a continuation of U.S. patent application Ser. No. 13/588,966, filed Aug. 17, 2012, which is a continuation of U.S. patent application Ser. No. 11/328,970, filed Jan. 9, 2006, which claims the benefit under 35 U.S.C. §119(e) of U.S. Provisional Patent Application No. 60/643,056, filed Jan. 10, 2005, the full disclosures of which are incorporated herein by reference.
FIELD OF THE INVENTION
The present invention relates to ophthalmic surgical procedures and systems.
BACKGROUND OF THE INVENTION
Cataract extraction is one of the most commonly performed surgical procedures in the world with estimates of 2.5 million cases being performed annually in the United States and 9.1 million cases worldwide. This is expected to increase to approximately 13.3 million cases by 2006 globally. This market is composed of various segments including intraocular lenses for implantation, viscoelastic polymers to facilitate surgical maneuvers, disposable instrumentation including ultrasonic phacoemulsification tips, tubing, and various knives and forceps. Modern cataract surgery is typically performed using a technique termed phacoemulsification in which an ultrasonic tip with an associated water stream for cooling purposes is used to sculpt the relatively hard nucleus of the lens after performance of an opening in the anterior lens capsule termed anterior capsulotomy or more recently capsulorhexis. Following these steps as well as removal of residual softer lens cortex by aspiration methods without fragmentation, a synthetic foldable intraocular lens (IOL's) inserted into the eye through a small incision. This technique is associated with a very high rate of anatomic and visual success exceeding 95% in most cases and with rapid visual rehabilitation.
One of the earliest and most critical steps in the procedure is the performance of capsulorhexis. This step evolved from an earlier technique termed can-opener capsulotomy in which a sharp needle was used to perforate the anterior lens capsule in a circular fashion followed by the removal of a circular fragment of lens capsule typically in the range of 5-8 mm in diameter. This facilitated the next step of nuclear sculpting by phacoemulsification. Due to a variety of complications associated with the initial can-opener technique, attempts were made by leading experts in the field to develop a better technique for removal of the anterior lens capsule preceding the emulsification step. These were pioneered by Neuhann, and Gimbel and highlighted in a publication in 1991 (Gimbel, Neuhann, Development Advantages and Methods of the Continuous Curvilinear Capsulorhexis. Journal of Cataract and Refractive Surgery 1991; 17:110-111, incorporated herein by reference). The concept of the capsulorhexis is to provide a smooth continuous circular opening through which not only the phacoemulsification of the nucleus can be performed safely and easily, but also for easy insertion of the intraocular lens. It provides both a clear central access for insertion, a permanent aperture for transmission of the image to the retina by the patient, and also a support of the IOL inside the remaining capsule that would limit the potential for dislocation.
Using the older technique of can-opener capsulotomy, or even with the continuous capsulorhexis, problems may develop related to inability of the surgeon to adequately visualize the capsule due to lack of red reflex, to grasp it with sufficient security, to tear a smooth circular opening of the appropriate size without radial rips and extensions or technical difficulties related to maintenance of the anterior chamber depth after initial opening, small size of the pupil, or the absence of a red reflex due to the lens opacity. Some of the problems with visualization have been minimized through the use of dyes such as methylene blue or indocyanine green. Additional complications arise in patients with weak zonules (typically older patients) and very young children that have very soft and elastic capsules, which are very difficult to mechanically rupture.
Finally, during the intraoperative surgical procedure, and subsequent to the step of anterior continuous curvilinear capsulorhexis, which typically ranges from 5-7 mm in diameter, and prior to IOL insertion the steps of hydrodis section, hydrodilineation and phaco emulsification occur. These are intended to identify and soften the nucleus for the purposes of removal from the eye. These are the longest and thought to be the most dangerous step in the procedure due to the use of pulses of ultrasound that may lead to inadvertent ruptures of the posterior lens capsule, posterior dislocation of lens fragments, and potential damage anteriorly to the corneal endothelium and/or iris and other delicate intraocular structures. The central nucleus of the lens, which undergoes the most opacification and thereby the most visual impairment, is structurally the hardest and requires special techniques. A variety of surgical maneuvers employing ultrasonic fragmentation and also requiring considerable technical dexterity on the part of the surgeon have evolved, including sculpting of the lens, the so-called “divide and conquer technique” and a whole host of similarly creatively named techniques, such as phaco chop, etc. These are all subject to the usual complications associated with delicate intraocular maneuvers (Gimbel. Chapter 15: Principles of Nuclear PhacoEmulsification. In Cataract Surgery Techniques Complications and Management. 2 nd ed. Edited by Steinert et al. 2004: 153-181, incorporated herein by reference.).
Following cataract surgery one of the principal sources of visual morbidity is the slow development of opacities in the posterior lens capsule, which is generally left intact during cataract surgery as a method of support for the lens, to provide good centration of the IOL, and also as a means of preventing subluxation posteriorly into the vitreous cavity. It has been estimated that the complication of posterior lens capsule opacification occurs in approximately 28-50% of patients (Steinert and Richter. Chapter 44. In Cataract Surgery Techniques Complications and Management. 2 nd ed. Edited by Steinert et al. 2004: pg. 531-544 and incorporated herein by reference). As a result of this problem, which is thought to occur as a result of epithelial and fibrous metaplasia along the posterior lens capsule centrally from small islands of residual epithelial cells left in place near the equator of the lens, techniques have been developed initially using surgical dissection, and more recently the neodymium YAG laser to make openings centrally in a non-invasive fashion. However, most of these techniques can still be considered relatively primitive requiring a high degree of manual dexterity on the part of the surgeon and the creation of a series of high energy pulses in the range of 1 to 10 mJ manually marked out on the posterior lens capsule, taking great pains to avoid damage to the intraocular lens. The course nature of the resulting opening is illustrated clearly in FIG. 44-10, pg. 537 of Steinert and Richter, Chapter 44 of In Cataract Surgery Techniques Complications and Management. 2 nd ed (see complete cite above).
What is needed are ophthalmic methods, techniques and apparatus to advance the standard of care of cataract and other ophthalmic pathologies.
SUMMARY OF THE INVENTION
The techniques and system disclosed herein provide many advantages. Specifically, rapid and precise openings in the lens capsule and fragmentation of the lens nucleus and cortex is enabled using 3-dimensional patterned laser cutting. The duration of the procedure and the risk associated with opening the capsule and fragmentation of the hard nucleus are reduce, while increasing precision of the procedure. The removal of a lens dissected into small segments is performed using a patterned laser scanning and just a thin aspiration needle. The removal of a lens dissected into small segments is performed using patterned laser scanning and using a ultrasonic emulsifier with a conventional phacoemulsification technique or a technique modified to recognize that a segmented lens will likely be more easily removed (i.e., requiring less surgical precision or dexterity) and/or at least with marked reduction in ultrasonic emulsification power, precision and/or duration. There are surgical approaches that enable the formation of very small and geometrically precise opening(s) in precise locations on the lens capsule, where the openings in the lens capsule would be very difficult if not impossible to form using conventional, purely manual techniques. The openings enable greater precision or modifications to conventional ophthalmic procedures as well as enable new procedures. For example, the techniques described herein may be used to facilitate anterior and/or posterior lens removal, implantation of injectable or small foldable IOLs as well as injection of compounds or structures suited to the formation of accommodating IOLs.
Another procedure enabled by the techniques described herein provides for the controlled formation of a hemi-circular or curvilinear flap in the anterior lens surface. Contrast to conventional procedures which require a complete circle or nearly complete circular cut. Openings formed using conventional, manual capsulorhexis techniques rely primarily on the mechanical shearing properties of lens capsule tissue and uncontrollable tears of the lens capsule to form openings. These conventional techniques are confined to the central lens portion or to areas accessible using mechanical cutting instruments and to varying limited degrees utilize precise anatomical measurements during the formation of the tears. In contrast, the controllable, patterned laser techniques described herein may be used to create a semi-circular capsular flap in virtually any position on the anterior lens surface and in virtually any shape. They may be able to seal spontaneously or with an autologous or synthetic tissue glue or other method. Moreover, the controllable, patterned laser techniques described herein also have available and/or utilize precise lens capsule size, measurement and other dimensional information that allows the flap or opening formation while minimizing impact on surrounding tissue. The flap is not limited only to semi-circular but may be any shape that is conducive to follow on procedures such as, for example, injection or formation of complex or advanced IOL devices or so called injectable polymeric or fixed accommodating IOLs.
The techniques disclosed herein may be used during cataract surgery to remove all or a part of the anterior capsule, and may be used in situations where the posterior capsule may need to be removed intraoperatively, for example, in special circumstances such as in children, or when there is a dense posterior capsular opacity which can not be removed by suction after the nucleus has been removed. In the first, second and third years after cataract surgery, secondary opacification of the posterior lens capsule is common and is benefited by a posterior capsulotomy which may be performed or improved utilizing aspects of the techniques disclosed herein.
Because of the precision and atraumatic nature of incisions formed using the techniques herein, it is believed that new meaning is brought to minimally invasive ophthalmic surgery and lens incisions that may be self healing.
In one aspect, a method of making an incision in eye tissue includes generating a beam of light, focusing the beam at a first focal point located at a first depth in the eye tissue, scanning the beam in a pattern on the eye while focused at the first depth, focusing the beam at a second focal point located at a second depth in the eye tissue different than the first depth, and scanning the beam in the pattern on the eye while focused at the second depth.
In another aspect, a method of making an incision in eye tissue includes generating a beam of light, and passing the beam through a multi-focal length optical element so that a first portion of the beam is focused at a first focal point located at a first depth in the eye tissue and a second portion of the beam is focused at a second focal point located at a second depth in the eye tissue different than first depth.
In yet another aspect, a method of making an incision in eye tissue includes generating a beam of light having at least a first pulse of light and a second pulse of light, and focusing the first and second pulses of light consecutively into the eye tissue, wherein the first pulse creates a plasma at a first depth within the eye tissue, and wherein the second pulse arrives before the plasma disappears and is absorbed by the plasma to extend the plasma in the eye tissue along the beam.
In yet one more aspect, a method of making an incision in eye tissue includes generating a beam of light, and focusing the light into the eye tissue to create an elongated column of focused light within the eye tissue, wherein the focusing includes subjecting the light to at least one of a non-spherical lens, a highly focused lens with spherical aberrations, a curved mirror, a cylindrical lens, an adaptive optical element, a prism, and a diffractive optical element.
In another aspect, a method of removing a lens and debris from an eye includes generating a beam of light, focusing the light into the eye to fragment the lens into pieces, removing the pieces of lens, and then focusing the light into the eye to ablate debris in the eye.
In one more aspect, a method of removing a lens from a lens capsule in an eye includes generating a beam of light, focusing the light into the eye to form incisions in the lens capsule, inserting an ultrasonic probe through the incision and into the lens capsule to break the lens into pieces, removing the lens pieces from the lens capsule, rinsing the lens capsule to remove endothermial cells therefrom, and inserting at least one of a synthetic. foldable intraocular lens or an optically transparent gel into the lens capsule.
In another aspect, an ophthalmic surgical system for treating eye tissue includes a light source for generating a beam of light, a delivery system for focusing the beam onto the eye tissue, a controller for controlling the light source and the delivery system such that the light beam is focused at multiple focal points in the eye tissue at multiple depths within the eye tissue.
In yet another aspect, an ophthalmic surgical system for treating eye tissue includes a light source for generating a beam of light having at least a first pulse of light and a second pulse of light, a delivery system for focusing the beam onto the eye tissue, a controller for controlling the light source and the delivery system such that the first and second pulses of light are consecutively focused onto the eye tissue, wherein the first pulse creates a plasma at a first depth within the eye tissue, and wherein the second pulse is arrives before the plasma disappears and absorbed by the plasma to extend the plasma in the eye tissue along the beam.
In one more aspect, an ophthalmic surgical system for treating eye tissue includes a light source for generating a beam of light, a delivery system for focusing the beam onto the eye tissue, the delivery system including at least one of a non-spherical lens, a highly focused lens with spherical aberrations, a curved mirror, a cylindrical lens, an adaptive optical element, a prism, and a diffractive optical element, and a controller for controlling the light source and the delivery system such that an elongated column of focused light within the eye tissue is created.
Other objects and features of the present invention will become apparent by a review of the specification, claims and appended figures.
INCORPORATION BY REFERENCE
All publications, patents, and patent applications mentioned in this specification are herein incorporated by reference to the same extent as if each individual publication, patent, or patent application was specifically and individually indicated to be incorporated by reference.
BRIEF DESCRIPTION OF THE DRAWINGS
The novel features of the invention are set forth with particularity in the appended claims. A better understanding of the features and advantages of the present invention will be obtained by reference to the following detailed description that sets forth illustrative embodiments, in which the principles of the invention are utilized, and the accompanying drawings of which:
FIG. 1 is a plan diagram of a system that projects or scans an optical beam into a patient's eye.
FIG. 2 is a diagram of the anterior chamber of the eye and the laser beam producing plasma at the focal point on the lens capsule.
FIG. 3 is a planar view of the iris and lens with a circular pattern for the anterior capsulotomy (capsulorexis).
FIG. 4 is a diagram of the line pattern applied across the lens for OCT measurement of the axial profile of the anterior chamber.
FIG. 5 is a diagram of the anterior chamber of the eye and the 3-dimensional laser pattern applied across the lens capsule.
FIG. 6 is an axially-elongated plasma column produced in the focal zone by sequential application of a burst of pulses (1, 2, and 3) with a delay shorter than the plasma life time.
FIGS. 7A-7B are multi-segmented lenses for focusing the laser beam into 3 points along the same axis.
FIGS. 7C-7D are multi-segmented lenses with co-axial and off-axial segments having focal points along the same axis but different focal distances F1, F2, F3.
FIG. 8 is an axial array of fibers (1, 2, 3) focused with a set of lenses into multiple points (1, 2, 3) and thus producing plasma at different depths inside the tissue (1, 2, 3).
FIG. 9A and FIG. 9B are diagrams illustrating examples of the patterns that can be applied for nucleus segmentation.
FIG. 10A-C is a planar view of some of the combined patterns for segmented capsulotomy and phaco-fragmentation.
FIG. 11 is a plan diagram of one system embodiment that projects or scans an optical beam into a patient's eye.
FIG. 12 is a plan diagram of another system embodiment that projects or scans an optical beam into a patient's eye.
FIG. 13 is a plan diagram of yet another system embodiment that projects or scans an optical beam into a patient's eye.
FIG. 14 is a flow diagram showing the steps utilized in a “track and treat” approach to material removal.
FIG. 15 is a flow diagram showing the steps utilized in a “track and treat” approach to material removal that employs user input.
FIG. 16 is a perspective view of a transverse focal zone created by an anamorphic optical scheme.
FIGS. 17A-17C are perspective views of an anamorphic telescope configuration for constructing an inverted Keplerian telescope.
FIG. 18 is a side view of prisms used to extend the beam along a single meridian.
FIG. 19 is a top view illustrating the position and motion of a transverse focal volume on the eye lens.
FIG. 20 illustrates fragmentation patterns of an ocular lens produced by one embodiment of the present invention.
FIG. 21 illustrates circular incisions of an ocular lens produced by one embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The present invention can be implemented by a system that projects or scans an optical beam into a patient's eye 1 , such as the system shown in FIG. 1 . The system includes a light source 10 (e.g. laser, laser diode, etc.), which may be controlled by control electronics 12 , via an input and output device 14 , to create optical beam 11 (either cw or pulsed). Control electronics 12 may be a computer, microcontroller, etc. Scanning may be achieved by using one or more movable optical elements (e.g. lenses, gratings, or as shown in FIG. 1 a mirror(s) 16 ) which also may be controlled by control electronics 12 , via input and output device 14 . Mirror 16 may be tilted to deviate the optical beam 11 as shown in FIG. 1 , and direct beam 11 towards the patient's eye 1 . An optional ophthalmic lens 18 can be used to focus the optical beam 11 into the patient's eye 1 . The positioning and character of optical beam 11 and/or the scan pattern it forms on the eye may be further controlled by use of an input device 20 such as a joystick, or any other appropriate user input device.
Techniques herein include utilizing a light source 10 such as a surgical laser configured to provide one or more of the following parameters:
1) pulse energy up to 1 μJ repetition rate up to 1 MHz, pulse duration <1 ps
2) pulse energy up to 10 μJ rep. rate up to 100 kHz, pulse duration <1 ps.
3) Pulse energy up to 1000 μJ, rep rate up to 1 kHz, pulse duration <3 ps.
Additionally, the laser may use wavelengths in a variety of ranges including in the near-infrared range: 800-1100 nm. In one aspect, near-infrared wavelengths are selected because tissue absorption and scattering is reduced. Additionally, a laser can be configured to provide low energy ultrashort pulses of near-infrared radiation with pulse durations below 10 ps or below 1 ps, alone or in combination with pulse energy not exceeding 100 μJ, at high repetition rate including rates above 1 kHz, and above 10 kHz.
Short pulsed laser light focused into eye tissue 2 will produce dielectric breakdown at the focal point, rupturing the tissue 2 in the vicinity of the photo-induced plasma (see FIG. 2 ). The diameter d of the focal point is given by d=λF/D b , where F is the focal length of the last focusing element, D b is the beam diameter on the last lens, and λ is the wavelength. For a focal length F=160 mm, beam diameter on the last lens D b =10 mm, and wavelength λ=1.04 um, the focal spot diameter will be d≈λ/(2·NA)≈λF/D b =15 where the numerical aperture of the focusing optics, NA≈D b /(2F).
To provide for continuous cutting, the laser spots should not be separated by more than a width of the crater produced by the laser pulse in tissue. Assuming the rupture zone being R=15 μm (at low energies ionization might occur in the center of the laser spot and not expand to the full spot size), and assuming the maximal diameter of the capsulotomy circle being D c =8 mm, the number of required pulses will be: N=πD c /R=1675 to provide a circular cut line 22 around the circumference of the eye lens 3 as illustrated in FIG. 3 . For smaller diameters ranging from 5-7 mm, the required number of pulses would be less. If the rupture zone were larger (e.g. 50 μm), the number of pulses would drop to N=503.
To produce an accurate circular cut, these pulses should be delivered to tissue over a short eye fixation time. Assuming the fixation time t=0.2 s, laser repetition rate should be: r=N/t=8.4 kHz. If the fixation time were longer, e.g. 0.5 s, the required rep. rate could be reduced to 3.4 kHz. With a rupture zone of 50 μm the rep. rate could further drop to 1 kHz.
Threshold radiant exposure of the dielectric breakdown with 4 ns pulses is about Φ=100 J/cm 2 . With a focal spot diameter being d=15 μm, the threshold pulse energy will be E th Φ*πd 2 /4=176 μJ. For stable and reproducible operation, pulse energy should exceed the threshold by at least a factor of 2, so pulse energy of the target should be E=352 μJ. The creation of a cavitation bubble might take up to 10% of the pulse energy, i.e. E b =35 μJ. This corresponds to a bubble diameter
d
b
=
6
E
b
π
P
a
3
=
48
µm
.
The energy level can be adjusted to avoid damage to the corneal endothelium. As such, the threshold energy of the dielectric breakdown could be minimized by reducing the pulse duration, for example, in the range of approximately 0.1-1 ps. Threshold radiant exposure, Φ, for dielectric breakdown for 100 fs is about Φ=2 J/cm 2 ; for 1 ps it is Φ=2.5 J/cm 2 . Using the above pulse durations, and a focal spot diameter d=15 the threshold pulse energies will be E th =Φ*πd 2 /4=3.5 and 4.4 μJ for 100 fs and 1 ps pulses, respectively. The pulse energy could instead be selected to be a multiple of the threshold energy, for example, at least a factor of 2. If a factor of 2 is used, the pulse energies on the target would be E th =7 and 9 μJ, respectively. These are only two examples. Other pulse energy duration times, focal spot sizes and threshold energy levels are possible and are within the scope of the present invention.
A high repetition rate and low pulse energy can be utilized for tighter focusing of the laser beam. In one specific example, a focal distance of F=50 mm is used while the beam diameter remains D b =10 mm, to provide focusing into a spot of about 4 μm in diameter. Aspherical optics can also be utilized. An 8 mm diameter opening can be completed in a time of 0.2 s using a repetition rate of about 32 kHz.
The laser 10 and controller 12 can be set to locate the surface of the capsule and ensure that the beam will be focused on the lens capsule at all points of the desired opening. Imaging modalities and techniques described herein, such as for example, Optical Coherence Tomography (OCT) or ultrasound, may be used to determine the location and measure the thickness of the lens and lens capsule to provide greater precision to the laser focusing methods, including 2D and 3D patterning. Laser focusing may also be accomplished using one or more methods including direct observation of an aiming beam, Optical Coherence Tomography (OCT), ultrasound, or other known ophthalmic or medical imaging modalities and combinations thereof.
As shown in FIG. 4 , OCT imaging of the anterior chamber can be performed along a simple linear scan 24 across the lens using the same laser and/or the same scanner used to produce the patterns for cutting. This scan will provide information about the axial location of the anterior and posterior lens capsule, the boundaries of the cataract nucleus, as well as the depth of the anterior chamber. This information may then be loaded into the laser 3-D scanning system, and used to program and control the subsequent laser assisted surgical procedure. The information may be used to determine a wide variety of parameters related to the procedure such as, for example, the upper and lower axial limits of the focal planes for cutting the lens capsule and segmentation of the lens cortex and nucleus, the thickness of the lens capsule among others. The imaging data may be averaged across a 3-line pattern as shown in FIG. 9 .
An example of the results of such a system on an actual human crystalline lens is shown in FIG. 20 . A beam of 10 μJ, 1 ps pulses delivered at a pulse repetition rate of 50 kHz from a laser operating at a wavelength of 1045 nm was focused at NA=0.05 and scanned from the bottom up in a pattern of 4 circles in 8 axial steps. This produced the fragmentation pattern in the ocular lens shown in FIG. 20 . FIG. 21 shows in detail the resultant circular incisions, which measured ˜10 μm in diameter, and ˜100 μm in length.
FIG. 2 illustrates an exemplary illustration of the delineation available using the techniques described herein to anatomically define the lens. As can be seen in FIG. 2 , the capsule boundaries and thickness, the cortex, epinucleus and nucleus are determinable. It is believed that OCT imaging may be used to define the boundaries of the nucleus, cortex and other structures in the lens including, for example, the thickness of the lens capsule including all or a portion of the anterior or posterior capsule. In the most general sense, one aspect of the present invention is the use of ocular imaging data obtained as described herein as an input into a laser scanning and/or pattern treatment algorithm or technique that is used to as a guide in the application of laser energy in novel laser assisted ophthalmic procedures. In fact, the imaging and treatment can be performed using the same laser and the same scanner. While described for use with lasers, other energy modalities may also be utilized.
It is to be appreciated that plasma formation occurs at the waist of the beam. The axial extent of the cutting zone is determined by the half-length L of the laser beam waist, which can be expressed as: L˜λ/(4·NA 2 )=dF/D b . Thus the lower the NA of the focusing optics, the longer waist of the focused beam, and thus a longer fragmentation zone can be produced. For F=160 mm, beam diameter on the last lens D b =10 mm, and focal spot diameter d=15 the laser beam waist half-length L would be 240 μm.
With reference to FIG. 5 , a three dimensional application of laser energy 26 can be applied across the capsule along the pattern produced by the laser-induced dielectric breakdown in a number of ways such as, for example:
1) Producing several circular or other pattern scans consecutively at different depths with a step equal to the axial length of the rupture zone. Thus, the depth of the focal point (waist) in the tissue is stepped up or down with each consecutive scan. The laser pulses are sequentially applied to the same lateral pattern at different depths of tissue using, for example, axial scanning of the focusing elements or adjusting the optical power of the focusing element while, optionally, simultaneously or sequentially scanning the lateral pattern. The adverse result of laser beam scattering on bubbles, cracks and/or tissue fragments prior to reaching the focal point can be avoided by first producing the pattern/focusing on the maximal required depth in tissue and then, in later passes, focusing on more shallow tissue spaces. Not only does this “bottom up” treatment technique reduce unwanted beam attenuation in tissue above the target tissue layer, but it also helps protect tissue underneath the target tissue layer. By scattering the laser radiation transmitted beyond the focal point on gas bubbles, cracks and/or tissue fragments which were produced by the previous scans, these defects help protect the underlying retina. Similarly, when segmenting a lens, the laser can be focused on the most posterior portion of the lens and then moved more anteriorly as the procedure continues.
2) Producing axially-elongated rupture zones at fixed points by:
a) Using a sequence of 2-3 pulses in each spot separated by a few ps. Each pulse will be absorbed by the plasma 28 produced by the previous pulse and thus will extend the plasma 28 upwards along the beam as illustrated in FIG. 6A . In this approach, the laser energy should be 2 or 3 times higher, i.e. 20-30 μJ. Delay between the consecutive pulses should be longer than the plasma formation time (on the order of 0.1 ps) but not exceed the plasma recombination time (on the order of nanoseconds)
b) Producing an axial sequence of pulses with slightly different focusing points using multiple co-axial beams with different pre-focusing or multifocal optical elements. This can be achieved by using multi-focal optical elements (lenses, mirrors, diffractive optics, etc.). For example, a multi-segmented lens 30 can be used to focus the beam into multiple points (e.g. three separate points) along the same axis, using for example co-axial (see FIGS. 7A-7C ) or off-coaxial (see FIG. 7D ) segments to produce varying focal lengths (e.g. F 1 , F 2 , F 3 ). The multi-focal element 30 can be co-axial, or off-axis-segmented, or diffractive. Co-axial elements may have more axially-symmetric focal points, but will have different sizes due to the differences in beam diameters in each segment. Off-axial elements might have less symmetric focal points but all the elements can produce the foci of the same sizes.
c) Producing an elongated focusing column (as opposed to just a discrete number of focal points) using: (1) non-spherical (aspherical) optics, or (2) utilizing spherical aberrations in a lens with a high F number, or (3) diffractive optical element (hologram).
d) Producing an elongated zone of ionization using multiple optical fibers. For example, an array of optical fibers 32 of different lengths can be imaged with a set of lenses 34 into multiple focal points at different depths inside the tissue as shown in FIG. 8 .
Patterns of Scanning:
For anterior and posterior capsulotomy, the scanning patterns can be circular and spiral, with a vertical step similar to the length of the rupture zone. For segmentation of the eye lens 3 , the patterns can be linear, planar, radial, radial segments, circular, spiral, curvilinear and combinations thereof including patterning in two and/or three dimensions. Scans can be continuous straight or curved lines, or one or more overlapping or spaced apart spots and/or line segments. Several scan patterns 36 are illustrated in FIGS. 9A and 9B , and combinations of scan patterns 38 are illustrated in FIGS. 10A-10C . Beam scanning with the multifocal focusing and/or patterning systems is particularly advantageous to successful lens segmentation since the lens thickness is much larger than the length of the beam waist axial. In addition, these and other 2D and 3D patterns may be used in combination with OCT to obtain additional imaging, anatomical structure or make-up (i.e., tissue density) or other dimensional information about the eye including but not limited to the lens, the cornea, the retina and as well as other portions of the eye.
The exemplary patterns allow for dissection of the lens cortex and nucleus into fragments of such dimensions that they can be removed simply with an aspiration needle, and can be used alone to perform capsulotomy. Alternatively, the laser patterning may be used to pre-fragment or segment the nucleus for later conventional ultrasonic phacoemulsification. In this case however, the conventional phacoemulsification would be less than a typical phacoemulsification performed in the absence of the inventive segmenting techniques because the lens has been segmented. As such, the phacoemulsification procedure would likely require less ultrasonic energy to be applied to the eye, allowing for a shortened procedure or requiring less surgical dexterity.
Complications due to the eye movements during surgery can be reduced or eliminated by performing the patterned laser cutting very rapidly (e.g. within a time period that is less than the natural eye fixation time). Depending on the laser power and repetition rate, the patterned cutting can be completed between 5 and 0.5 seconds (or even less), using a laser repetition rate exceeding 1 kHz.
The techniques described herein may be used to perform new ophthalmic procedures or improve existing procedures, including anterior and posterior capsulotomy, lens fragmentation and softening, dissection of tissue in the posterior pole (floaters, membranes, retina), as well as incisions in other areas of the eye such as, but not limited to, the sclera and iris.
Damage to an IOL during posterior capsulotomy can be reduced or minimized by advantageously utilizing a laser pattern initially focused beyond the posterior pole and then gradually moved anteriorly under visual control by the surgeon alone or in combination with imaging data acquired using the techniques described herein.
For proper alignment of the treatment beam pattern, an alignment beam and/or pattern can be first projected onto the target tissue with visible light (indicating where the treatment pattern will be projected. This allows the surgeon to adjust the size, location and shape of the treatment pattern. Thereafter, the treatment pattern can be rapidly applied to the target tissue using an automated 3 dimensional pattern generator (in the control electronics 12 ) by a short pulsed cutting laser having high repetition rate.
In addition, and in particular for capsulotomy and nuclear fragmentation, an automated method employing an imaging modality can be used, such as for example, electro-optical, OCT, acoustic, ultrasound or other measurement, to first ascertain the maximum and minimum depths of cutting as well as the size and optical density of the cataract nucleus. Such techniques allow the surgeon account for individual differences in lens thickness and hardness, and help determine the optimal cutting contours in patients. The system for measuring dimensions of the anterior chamber using OCT along a line, and/or pattern (2D or 3D or others as described herein) can be integrally the same as the scanning system used to control the laser during the procedure. As such, the data including, for example, the upper and lower boundaries of cutting, as well as the size and location of the nucleus, can be loaded into the scanning system to automatically determine the parameters of the cutting (i.e., segmenting or fracturing) pattern. Additionally, automatic measurement (using an optical, electro-optical, acoustic, or OCT device, or some combination of the above) of the absolute and relative positions and/or dimensions of a structure in the eye (e.g. the anterior and posterior lens capsules, intervening nucleus and lens cortex) for precise cutting, segmenting or fracturing only the desired tissues (e.g. lens nucleus, tissue containing cataracts, etc.) while minimizing or avoiding damage to the surrounding tissue can be made for current and/or future surgical procedures. Additionally, the same ultrashort pulsed laser can be used for imaging at a low pulse energy, and then for surgery at a high pulse energy.
The use of an imaging device to guide the treatment beam may be achieved many ways, such as those mentioned above as well as additional examples explained next (which all function to characterize tissue, and continue processing it until a target is removed). For example, in FIG. 11 , a laser source LS and (optional) aiming beam source AIM have outputs that are combined using mirror DM 1 (e.g. dichroic mirror). In this configuration, laser source LS may be used for both therapeutics and diagnostics. This is accomplished by means of mirror M 1 which serves to provide both reference input R and sample input S to an OCT Interferometer by splitting the light beam B (centerlines shown) from laser source LS. Because of the inherent sensitivity of OCT Interferometers, mirror M 1 may be made to reflect only a small portion of the delivered light. Alternatively, a scheme employing polarization sensitive pickoff mirrors may be used in conjunction with a quarter wave plate (not shown) to increase the overall optical efficiency of the system. Lens L 1 may be a single element or a group of elements used to adjust the ultimate size or location along the z-axis of the beam B disposed to the target at point P. When used in conjunction with scanning in the X & Y axes, this configuration enables 3-dimensional scanning and/or variable spot diameters (i.e. by moving the focal point of the light along the z-axis).
In this example, transverse (XY) scanning is achieved by using a pair of orthogonal galvanometric mirrors G 1 & G 2 which may provide 2-dimensional random access scanning of the target. It should be noted that scanning may be achieved in a variety of ways, such as moving mirror M 2 , spinning polygons, translating lenses or curved mirrors, spinning wedges, etc. and that the use of galvanometric scanners does not limit the scope of the overall design. After leaving the scanner, light encounters lens L 2 which serves to focus the light onto the target at point P inside the patient's eye EYE. An optional ophthalmic lens OL may be used to help focus the light. Ophthalmic lens OL may be a contact lens and further serve to dampen any motion of eye EYE, allowing for more stable treatment. Lens L 2 may be made to move along the z-axis in coordination with the rest of the optical system to provide for 3-dimensional scanning, both for therapy and diagnosis. In the configuration shown, lens L 2 ideally is moved along with the scanner G 1 & G 2 to maintain telecentricity. With that in mind, one may move the entire optical assembly to adjust the depth along the z-axis. If used with ophthalmic lens OL, the working distance may be precisely held. A device such as the Thorlabs EAS504 precision stepper motor can be used to provide both the length of travel as well as the requisite accuracy and precision to reliably image and treat at clinically meaningful resolutions. As shown it creates a telecentric scan, but need not be limited to such a design.
Mirror M 2 serves to direct the light onto the target, and may be used in a variety of ways. Mirror M 2 could be a dichroic element that the user looks through in order to visualize the target directly or using a camera, or may be made as small as possible to provide an opportunity for the user to view around it, perhaps with a binocular microscope. If a dichroic element is used, it may be made to be photopically neutral to avoid hindering the user's view. An apparatus for visualizing the target tissue is shown schematically as element V, and is preferably a camera with an optional light source for creating an image of the target tissue. The optional aiming beam AIM may then provide the user with a view of the disposition of the treatment beam, or the location of the identified targets. To display the target only, AIM may be pulsed on when the scanner has positioned it over an area deemed to be a target. The output of visualization apparatus V may be brought back to the system via the input/output device IO and displayed on a screen, such as a graphical user interface GUI. In this example, the entire system is controlled by the controller CPU, and data moved through input/output device IO. Graphical user interface GUI may be used to process user input, and display the images gathered by both visualization apparatus V and the OCT interferometer. There are many possibilities for the configuration of the OCT interferometer, including time and frequency domain approaches, single and dual beam methods, etc, as described in U.S. Pat. Nos. 5,748,898; 5,748,352; 5,459,570; 6,111,645; and 6,053,613 (which are incorporated herein by reference.
Information about the lateral and axial extent of the cataract and localization of the boundaries of the lens capsule will then be used for determination of the optimal scanning pattern, focusing scheme, and laser parameters for the fragmentation procedure. Much if not all of this information can be obtained from visualization of the target tissue. For example, the axial extent of the fragmentation zone of a single pulse should not exceed the distance between (a) the cataract and the posterior capsule, and (b) the anterior capsule and the corneal endothelium. In the cases of a shallow anterior chamber and/or a large cataract, a shorter fragmentation zone should be selected, and thus more scanning planes will be required. Conversely, for a deep anterior chamber and/or a larger separation between the cataract and the posterior capsule a longer fragmentation zone can be used, and thus less planes of scanning will be required. For this purpose an appropriate focusing element will be selected from an available set. Selection of the optical element will determine the width of the fragmentation zone, which in turn will determine the spacing between the consecutive pulses. This, in turn, will determine the ratio between the scanning rate and repetition rate of the laser pulses. In addition, the shape of the cataract will determine the boundaries of the fragmentation zone and thus the optimal pattern of the scanner including the axial and lateral extent of the fragmentation zone, the ultimate shape of the scan, number of planes of scanning, etc.
FIG. 12 shows an alternate embodiment in which the imaging and treatment sources are different. A dichroic mirror DM 2 has been added to the configuration of FIG. 11 to combine the imaging and treatment light, and mirror M 1 has been replaced by beam splitter BS which is highly transmissive at the treatment wavelength, but efficiently separates the light from the imaging source SLD for use in the OCT Interferometer. Imaging source SLD may be a superluminescent diode having a spectral output that is nominally 50 nm wide, and centered on or around 835 nm, such as the SuperLum SLD-37. Such a light source is well matched to the clinical application, and sufficiently spectrally distinct from the treatment source, thus allowing for elements DM and BS to be reliably fabricated without the necessarily complicated and expensive optical coatings that would be required if the imaging and treatment sources were closer in wavelength.
FIG. 13 shows an alternate embodiment incorporating a confocal microscope CM for use as an imaging system. In this configuration, mirror M 1 reflects a portion of the backscattered light from beam B into lens L 3 . Lens L 3 serves to focus this light through aperture A (serving as a spatial filter) and ultimately onto detector D. As such, aperture A and point P are optically conjugate, and the signal received by detector D is quite specific when aperture A is made small enough to reject substantially the entire background signal. This signal may thus be used for imaging, as is known in the art. Furthermore, a fluorophore may be introduced into the target to allow for specific marking of either target or healthy tissue. In this approach, the ultrafast laser may be used to pump the absorption band of the fluorophore via a multiphoton process or an alternate source (not shown) could be used in a manner similar to that of FIG. 12 .
FIG. 14 is a flowchart outlining the steps utilized in a “track and treat” approach to material removal. First an image is created by scanning from point to point, and potential targets identified. When the treatment beam is disposed over a target, the system can transmit the treatment beam, and begin therapy. The system may move constantly treating as it goes, or dwell in a specific location until the target is fully treated before moving to the next point.
The system operation of FIG. 14 could be modified to incorporate user input. As shown in FIG. 15 , a complete image is displayed to the user, allowing them to identify the target(s). Once identified, the system can register subsequent images, thus tracking the user defined target(s). Such a registration scheme may be implemented in many different ways, such as by use of the well known and computationally efficient Sobel or Canny edge detection schemes. Alternatively, one or more readily discernable marks may be made in the target tissue using the treatment laser to create a fiduciary reference without patient risk (since the target tissue is destined for removal).
In contrast to conventional laser techniques, the above techniques provide (a) application of laser energy in a pattern, (b) a high repetition rate so as to complete the pattern within the natural eye fixation time, (c) application of sub-ps pulses to reduce the threshold energy, and (d) the ability to integrate imaging and treatment for an automated procedure.
Laser Delivery System
The laser delivery system in FIG. 1 can be varied in several ways. For example, the laser source could be provided onto a surgical microscope, and the microscope's optics used by the surgeon to apply the laser light, perhaps through the use of a provided console. Alternately, the laser and delivery system would be separate from the surgical microscope and would have an optical system for aligning the aiming beam for cutting. Such a system could swing into position using an articulating arm attached to a console containing the laser at the beginning of the surgery, and then swing away allowing the surgical microscope to swing into position.
The pattern to be applied can be selected from a collection of patterns in the control electronics 12 , produced by the visible aiming beam, then aligned by the surgeon onto the target tissue, and the pattern parameters (including for example, size, number of planar or axial elements, etc.) adjusted as necessary for the size of the surgical field of the particular patient (level of pupil dilation, size of the eye, etc.). Thereafter, the system calculates the number of pulses that should be applied based on the size of the pattern. When the pattern calculations are complete, the laser treatment may be initiated by the user (i.e., press a pedal) for a rapid application of the pattern with a surgical laser.
The laser system can automatically calculate the number of pulses required for producing a certain pattern based on the actual lateral size of the pattern selected by surgeon. This can be performed with the understanding that the rupture zone by the single pulse is fixed (determined by the pulse energy and configuration of the focusing optics), so the number of pulses required for cutting a certain segment is determined as the length of that segment divided by the width of the rupture zone by each pulse. The scanning rate can be linked to the repetition rate of the laser to provide a pulse spacing on tissue determined by the desired distance. The axial step of the scanning pattern will be determined by the length of the rupture zone, which is set by the pulse energy and the configuration of the focusing optics.
Fixation Considerations
The methods and systems described herein can be used alone or in combination with an aplanatic lens (as described in, for example, the U.S. Pat. No. 6,254,595, incorporated herein by reference) or other device to configure the shape of the cornea to assist in the laser methods described herein. A ring, forceps or other securing means may be used to fixate the eye when the procedure exceeds the normal fixation time of the eye. Regardless whether an eye fixation device is used, patterning and segmenting methods described herein may be further subdivided into periods of a duration that may be performed within the natural eye fixation time.
Another potential complication associated with a dense cutting pattern of the lens cortex is the duration of treatment: If a volume of 6×6×4 mm=144 mm 3 of lens is segmented, it will require N=722,000 pulses. If delivered at 50 kHz, it will take 15 seconds, and if delivered at 10 kHz it will take 72 seconds. This is much longer than the natural eye fixation time, and it might require some fixation means for the eye. Thus, only the hardened nucleus may be chosen to be segmented to ease its removal. Determination of its boundaries with the OCT diagnostics will help to minimize the size of the segmented zone and thus the number of pulses, the level of cumulative heating, and the treatment time. If the segmentation component of the procedure duration exceeds the natural fixation time, then the eye may be stabilized using a conventional eye fixation device.
Thermal Considerations
In cases where very dense patterns of cutting are needed or desired, excess accumulation of heat in the lens may damage the surrounding tissue. To estimate the maximal heating, assume that the bulk of the lens is cut into cubic pieces of 1 mm in size. If tissue is dissected with E 1 =10 uJ pulses fragmenting a volume of 15 um in diameter and 200 um in length per pulse, then pulses will be applied each 15 um. Thus a 1×1 mm plane will require 66×66=4356 pulses. The 2 side walls will require 2×66×5=660 pulses, thus total N=5016 pulses will be required per cubic mm of tissue. Since all the laser energy deposited during cutting will eventually be transformed into heat, the temperature elevation will be DT=(E 1 *N)/pcV=50.16 mJ/(4.19 mJ/K)=12 K. This will lead to maximal temperature T=37+12° C.=49° C. This heat will dissipate in about one minute due to heat diffusion. Since peripheral areas of the lens will not be segmented (to avoid damage to the lens capsule) the average temperature at the boundaries of the lens will actually be lower. For example, if only half of the lens volume is fragmented, the average temperature elevation at the boundaries of the lens will not exceed 6° C. (T=43° C.) and on the retina will not exceed 0.1 C. Such temperature elevation can be well tolerated by the cells and tissues. However, much higher temperatures might be dangerous and should be avoided.
To reduce heating, a pattern of the same width but larger axial length can be formed, so these pieces can still be removed by suction through a needle. For example, if the lens is cut into pieces of 1×1×4 mm in size, a total of N=6996 pulses will be required per 4 cubic mm of tissue. The temperature elevation will be DT=(E 1 *N)/pcV=69.96 mJ/(4.19 mJ/K)/4=1.04 K. Such temperature elevation can be well tolerated by the cells and tissues.
An alternative solution to thermal limitations can be the reduction of the total energy required for segmentation by tighter focusing of the laser beam. In this regime a higher repetition rate and low pulse energy may be used. For example, a focal distance of F=50 mm and a beam diameter of D b =10 mm would allow for focusing into a spot of about 4 μm in diameter. In this specific example, repetition rate of about 32 kHz provides an 8 mm diameter circle in about 0.2 s.
To avoid retinal damage due to explosive vaporization of melanosomes following absorption of the short laser pulse the laser radiant exposure on the RPE should not exceed 100 mJ/cm 2 . Thus NA of the focusing optics should be adjusted such that laser radiant exposure on the retina will not exceed this safety limit. With a pulse energy of 10 μJ, the spot size on retina should be larger than 0.1 mm in diameter, and with a 1 mJ pulse it should not be smaller than 1 mm. Assuming a distance of 20 mm between lens and retina, these values correspond to minimum numerical apertures of 0.0025 and 0.025, respectively.
To avoid thermal damage to the retina due to heat accumulation during the lens fragmentation the laser irradiance on the retina should not exceed the thermal safety limit for near-IR radiation—on the order of 0.6 W/cm 2 . With a retinal zone of about 10 mm in diameter (8 mm pattern size on a lens+1 mm on the edges due to divergence) it corresponds to total power of 0.5 W on the retina.
Transverse Focal Volume
It is also possible to create a transverse focal volume 50 instead of an axial focal volume described above. An anamorphic optical scheme may used to produce a focal zone 39 that is a “line” rather than a single point, as is typical with spherically symmetric elements (see FIG. 16 ). As is standard in the field of optical design, the term “anamorphic” is meant herein to describe any system which has different equivalent focal lengths in each meridian. It should be noted that any focal point has a discrete depth of field. However, for tightly focused beams, such as those required to achieve the electric field strength sufficient to disrupt biological material with ultrashort pulses (defined as t pulse <10 ps), the depth of focus is proportionally short.
Such a 1-dimensional focus may be created using cylindrical lenses, and/or mirrors. An adaptive optic may also be used, such as a MEMS mirror or a phased array. When using a phased array, however, careful attention should be paid to the chromatic effects of such a diffractive device. FIGS. 17A-17C illustrate an anamorphic telescope configuration, where cylindrical optics 40 a/b and spherical lens 42 are used to construct an inverted Keplerian telescope along a single meridian (see FIG. 17A ) thus providing an elongated focal volume transverse to the optical axis (see FIG. 17C ). Compound lenses may be used to allow the beam's final dimensions to be adjustable.
FIG. 18 shows the use of a pair of prisms 46 a/b to extend the beam along a single meridian, shown as CA. In this example, CA is reduced rather than enlarged to create a linear focal volume.
The focus may also be scanned to ultimately produce patterns. To effect axial changes, the final lens may be made to move along the system's z-axis to translate the focus into the tissue. Likewise, the final lens may be compound, and made to be adjustable. The 1-dimensional focus may also be rotated, thus allowing it to be aligned to produce a variety of patterns, such as those shown in FIGS. 9 and 10 . Rotation may be achieved by rotating the cylindrical element itself. Of course, more than a single element may be used. The focus may also be rotated by using an additional element, such as a Dove prism (not shown). If an adaptive optic is used, rotation may be achieved by rewriting the device, thus streamlining the system design by eliminating a moving part.
The use of a transverse line focus allows one to dissect a cataractous lens by ablating from the posterior to the anterior portion of the lens, thus planing it. Furthermore, the linear focus may also be used to quickly open the lens capsule, readying it for extraction. It may also be used for any other ocular incision, such as the conjunctiva, etc. (see FIG. 19 ).
Cataract Removal Using a Track and Treat Approach
A “track and treat” approach is one that integrates the imaging and treatment aspect of optical eye surgery, for providing an automated approach to removal of debris such as cataractous and cellular material prior to the insertion of an IOL. An ultrafast laser is used to fragment the lens into pieces small enough to be removed using an irrigating/aspirating probe of minimal size without necessarily rupturing the lens capsule. An approach such as this that uses tiny, self-sealing incisions may be used to provide a capsule for filling with a gel or elastomeric IOL. Unlike traditional hard IOLS that require large incisions, a gel or liquid may be used to fill the entire capsule, thus making better use of the body's own accommodative processes. As such, this approach not only addresses cataract, but presbyopia as well.
Alternately, the lens capsule can remain intact, where bilateral incisions are made for aspirating tips, irrigating tips, and ultrasound tips for removing the bulk of the lens. Thereafter, the complete contents of the bag/capsule can be successfully rinsed/washed, which will expel the debris that can lead to secondary cataracts. Then, with the lens capsule intact, a minimal incision is made for either a foldable IOL or optically transparent gel injected through incision to fill the bag/capsule. The gel would act like the natural lens with a larger accommodating range.
It is to be understood that the present invention is not limited to the embodiment(s) described above and illustrated herein, but encompasses any and all variations falling within the scope of the appended claims. For example, materials, processes and numerical examples described above are exemplary only, and should not be deemed to limit the claims. Multi-segmented lens 30 can be used to focus the beam simultaneously at multiple points not axially overlapping (i.e. focusing the beam at multiple foci located at different lateral locations on the target tissue). Further, as is apparent from the claims and specification, not all method steps need be performed in the exact order illustrated or claimed, but rather in any order that accomplishes the goals of the surgical procedure.
DETAILED DESCRIPTION OF THE INVENTION
While preferred embodiments of the present invention have been shown and described herein, it will be obvious to those skilled in the art that such embodiments are provided by way of example only. Numerous variations, changes, and substitutions will now occur to those skilled in the art without departing from the invention. It should be understood that various alternatives to the embodiments of the invention described herein may be employed in practicing the invention. It is intended that the following claims define the scope of the invention and that methods and structures within the scope of these claims and their equivalents be covered thereby. | A system for ophthalmic surgery on an eye includes: a pulsed laser which produces a treatment beam; an OCT imaging assembly capable of creating a continuous depth profile of the eye; an optical scanning system configured to position a focal zone of the treatment beam to a targeted location in three dimensions in one or more floaters in the posterior pole. The system also includes one or more controllers programmed to automatically scan tissues of the patient's eye with the imaging assembly; identify one or more boundaries of the one or more floaters based at least in part on the image data; iii. identify one or more treatment regions based upon the boundaries; and operate the optical scanning system with the pulsed laser to produce a treatment beam directed in a pattern based on the one or more treatment regions. | 0 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a looper driving system in an embroidery machine of the chain stitch type having a plurality of loopers for embroidering a multicolored pattern on a single piece of cloth.
2. Description of the Prior Art
Embroidery machines having a plurality of loopers for embroidering a cloth in a multicolored pattern using a plurality of threads of different color, are known from the prior art. A known embroidery machine of this type has employed a disk-like table which includes a plurality of loopers mounted thereto in a planetary fashion, the rotation of the table being controlled to displace any desired one of the loopers to the location where the machine needle passes through a cloth to be embroidered. While this prior art machine has generally been successful in perfoming its intended function, it has disadvantageously included a complicated mechanism for positioning any desired one of loopers at the needle location and/or for imparting a rotational movement to the looper at the needle location.
SUMMARY OF THE INVENTION
It is, accordingly, an object of the present invention to provide an improved looper driving system in an embroidery machine which is simple in construction.
It is another object of the present invention to provide such looper driving system which may precisely control the rotation of loopers in an embroidery machine.
According to the present invention, there is provided in an embroidery machine of the chain stitch type having a looper support frame, a reciprocable needle, and a plurality of loopers for embroidering a cloth in a multicolored pattern, a looper driving system comprising a looper case mounted to the looper support frame, the looper case being adapted to support the loopers therein in aligned relation and for rotation about their axes and to move in the direction of alignment of the loopers for selectively positioning one of the loopers at the location where the needle passes the cloth; a transmission shaft rotatable about its axis and axially movably mounted to the looper support frame in parallel relation thereto; a first means for converting both the axial and rotational movements of the transmission shaft into a single rotational movement of one of the loopers selectively moved to the needle location; and a second means for rotating the selected one of loopers when the looper is moved to the needle location from a position away from the needle location.
The present invention will become more fully apparent from the claims and description as it proceeds in connection with the drawings.
BRIEF EXPLANATION OF THE DRAWINGS
FIG. 1 is a front view showing the several parts of a looper driving system in accordance with the invention;
FIG. 2 is a sectional view taken along the line II--II of FIG. 1;
FIG. 3 is a plan view of the embroidery machine shown in FIG. 1; and
FIG. 4 is a schematic plan view showing the driving mechanism of the transmission shaft.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to the drawings and FIGS. 1 to 3 in particular, shown therein and generally designated by the reference numeral 1 is a looper support frame of an embroidery machine. As shown therein, the looper support frame 1 is disposed generally below a throat plate 2 on which is spread a portion of a cloth surrounding the location N where a machine needle (not shown) passes through the cloth. A looper case 3 is horizontally movably disposed in front of the looper support frame 1. Specifically, the looper case 3 is longitudinally slidable through an upper and a lower slider 3a secured thereto which slidably hold a longitudinally extending rail 4 mounted to the front end of the looper support frame 1. The looper case 3 is operatively connected to a cam or other suitable driving mechanism (not shown) which is controlled for rotation in response to thread changeover signals produced from a control unit (not shown) of the embroidery machine.
The looper case 3 includes a plurality of vertically extending loopers 5 (six loopers shown in the drawings) rotatably supported therewithin and arranged in series in equidistant parallel relation for forming an embroidery pattern on a single piece of cloth in association with the needle. Each of the loopers 5 has a spur gear 5a formed thereon adjacent the upper end thereof. As the looper case 3 moves, all of the loopers 5 are horizontally moved in unison, and as this occurs, one of the loopers 5 selected by a thread changeover signal is transferred to the location N where the needle passes through the cloth.
A horizontally extending transmission shaft 6 is rotatably and axially movably supported on the looper support frame 1. Specifically, as shown in FIG. 4, the transmission shaft 6 is operatively connected to a drive shaft 19 which in turn is operatively connected through pulleys 12 and 13 to a control motor 11 driven in accordance with a cloth transfer signal produced from the control unit. Thus, the transmission shaft 6 is driven for rotation both in forward and reverse directions so as to direct a desired one of the loopers 5 at the needle location N in one direction of movement of the cloth which is intermittently fed in a horizontal plane from the needle in accordance with a pattern to be embroidered. Additionally, a drive motor 14 is provided and is connected through pulleys 15 and 16 to a cam 17 with a cam groove 17a engageable with a follower 18 now to be described. This follower is idly but axially non-movably mounted on the drive shaft 19 and adapted to engage the cam groove 17a of the cam 17. Thus, as the cam 17 is rotated by the drive motor 14, the drive shaft 19 and hence the transmission shaft 6 are axially moved.
The transmission shaft 6 includes a driving gear 7 in the form of a worm which is operable to convert the axial and the rotational movements of the transmission shaft 6 to a single rotational movement of an intermediate gear 8 which will be explained below.
Rotatably supported by the looper support frame 1 adjacent the looper 5 at the needle location N is an intermediate gear 8 which operatively connects the transmission shaft 6 with the looper 5 at the needle location N. The intermediate gear 8 includes a spur gear-shaped, upper gear portion 8a which is engageable with the spur gear 5a of the looper 5 and a worm wheel-shaped, lower gear portion 8b which is engageable with the worm 7 formed on the drive shaft 6. Thus, the axial and rotational movements of the transmission shaft 6 is converted to a single rotational movement through the meshing engagement of the lower gear portion 8b of the intermediate gear 8 with the worm 7. This rotational movement of the intermediate gear 8 is transmitted to the looper 5 at the needle location N through the gear portion 8a, thereby orienting the looper 5 in the direction of movement of the cloth and at the same time rotating it for forming a stitch.
As best shown in FIG. 3, a pair of racks 9 are mounted to the looper support frame 1 adjacent the opposite sides of the intermediate gear 8 and adapted to mesh the gear 5a of the loopers 5 transferred from the needle location N. The racks 9 extend along a path of movement 10 of the loopers 5 and arranged in spaced relation to provide a space for accommodating the front end of the upper gear portion 8a of the intermediate gear 8. The tooth pitch of the respective racks 9 are determined on the basis of the pitch circle and tooth number of the gear portion 8a of the intermediate gear 8 and of the arrangement pitch of the loopers 5. Thus, the meshing condition may be unitized when the spur gear 5a of the looper 5 removes from the respective rack 9 into meshing engagement with the upper gear portion 8a of the intermediate gear 8, so that the orientation of each of the loopers 5 may be unitized when it is moved from its inoperative position to the needle location N under the thread changeover signal.
In the sewing machine thus constructed, when it is desired to displace any desired one of the loopers 5 to the needle location N, the looper case 3 is moved until the selected looper 5 meshes with the gear portion 8b of the intermediate gear 8. As this occurs, the intermediate gear 8 is rotated a composite rotational angle in response to the axial and rotational movements of the worm 7 on the transmission shaft 6, that is a rotational angle in which the rotational angle of the worm 7 which varies with the direction of feed of the cloth is added to or substracted from the fixed rotational angle representative of the axial movement of the worm 7. Thus, the rotation of the selected looper 5 may be controlled in accordance with the direction of feed of the cloth.
What has been described is a very simple and effective system for driving loopers in an embroidery machine. The system is effective to transmit a composite movement to the looper 5 at the needle location which consists of a first rotational movement to conform to the direction of movement of the cloth and a second rotational movement to form a stitch.
A feature of the system is that it can precisely transmit such a composite movement to the looper 5 at the needle location.
Another feature of the system is that it can be made simple in construction to transmit such a composite movement to the looper 5.
Still another feature of the system is that it can check improper rotational movements of the loopers 5 during thread changeover; as has been mentioned, each of the loopers 5 in its inoperative position is rotated by meshing engagement with the rack 9, and during thread changeover, any selected looper 5 may be transferred precisely and yet smoothly to the needle location N in the same posture at all times so that the driving condition of the selected looper 5 is uniform at the needle location N.
While the invention has been described with reference to a preferred embodiment thereof, it is to be understood that modifications or variations may be easily made without departing from the spirit of this invention which is defined by the appended claims. | A looper driving system in an embroidery machine of the chain stitch type having a looper support frame, a reciprocable needle, and a plurality of loopers for embroidering a cloth in a multicolored pattern. A transmission shaft rotatable about its axis is axially movably mounted to the looper support frame in parallel relation thereto. Gears convert both the axial and rotational movements of the transmission shaft into a single rotational movement of one of the loopers selectively moved to the needle location. Racks and gears rotate the selected one of loopers when the looper is moved to the needle location from a position away from the needle location. | 3 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The invention relates to electronic data processing systems implemented in semiconductor integrated circuits and, more particularly, to integrated logic circuits employing MOS technology.
[0003] 2. Description of the Related Art
[0004] Despite great effort expended to reduce the size and increase the speed of integrated circuit devices, the performance of such devices remains limited in certain aspects.
[0005] One well known technology used in the fabrication of integrated circuits is static complementary metal oxide semiconductor technology (CMOS). Static CMOS represents an advantageous design approach because it is stable between clock transitions. Accordingly, designing systems using static CMOS technology is relatively easy.
[0006] There are, however, important limitations associated with static CMOS logic circuits. One constraint of static CMOS is that each input must drive two transistors. A static CMOS design connects an output node to VDD through PMOS transistors, and the same output node to Ground through NMOS transistors. Every logic input connects to the gate of an NMOS transistor and to the gate of a PMOS transistor, switching one off as the other is switched on. In this way, the output node is switched between approximately ground potential and approximately VDD.
[0007] The result is highly deterministic, but each transistor contributes a capacitive load. Consequently, each input sees the capacitance of two gates as a load. It follows that the inputs of a static CMOS gate possess a larger RC time constant than would an input connected to a single comparable transistor gate. The result is that static CMOS is not as fast in operation as alternative technologies that require an input to drive only a single transistor.
[0008] In addition to its operating speed consequences, the presence of a second transistor for each gate means that static CMOS requires a relatively large amount of chip real estate. Also, static CMOS circuits require a relatively large number of interconnections, and thus wiring is more complex and requires additional layers of metalization.
[0009] Furthermore, static CMOS tends to exhibit relatively high transient power dissipation during switching. The reason for this is apparent from the structure of static CMOS logic, in which a PMOS transistor is operatively connected between a VDD rail and an output node. An NMOS transistor is operatively connected between the same output node and ground. In steady-state operation, one or the other of the NMOS and PMOS transistors is in a nonconductive state, while the other is conductive. Current through the conductive transistor is generally very small, since the typical output is loaded only with the leakage current flowing into the gates of other NMOS transistors.
[0010] During switching, however, the situation is different. Each NMOS and PMOS transistor must pass through a linear region during the time when it is switching between on and off states. Accordingly, since the NMOS and PMOS transistors of static CMOS are arranged to switch simultaneously, there is a period of time during which both are in linear operation. During this period, current flows directly from VDD through the PMOS transistor to the output node and from the output node through the NMOS transistor to ground. The product of this current and the voltage drop across the two transistors (VDD) constitutes transient power dissipation. Although brief, this transient is fairly large. The result is significant power dissipation, in those transistors, during switching.
[0011] Moreover, because PMOS transistor hole mobility is about three times lower than the mobility of electrons in an NMOS transistor of comparable size, CMOS switching transients are highly asymmetrical. The charge transient of the capacitive load in a static CMOS circuit takes far longer than the discharge transient of the same load. To compensate for this asymmetry, PMOS devices are often fabricated with increased area as compared NMOS devices in the same circuit. While this tends to improve the symmetry of switching transients, it incurs costs measured in additional stray capacitance, a larger RC time constant, and increased area requirements.
[0012] It is accordingly clear that, despite its benefits, static CMOS has several significant drawbacks. As a result, several alternative technologies to static CMOS have been developed. These include Monotonic CMOS, Pseudo-NMOS Static Logic, and Zipper Logic. Each of these has certain advantages, but also disadvantages.
[0013] Monotonic CMOS circuitry avoids some of the problems of traditional CMOS by limiting the set of allowed transitions so as to take advantage of the faster portions of the asymmetric CMOS switching transients. In Monotonic CMOS circuitry, the large charge-up time through the PMOS devices is effectively hidden by pre-charging the output node to VDD pursuant to a clock signal. When the clock signal is in a pre-charge state, a PMOS pre-charge transistor, receiving the clock signal at its gate, forms a conductive path between VDD and an output node of a Monotonic CMOS circuit. In this way the capacitance of the output node is pre-charged to VDD. When the clock transitions to an evaluation state, the pre-charge transistor is non-conductive, and a combination of PMOS and NMOS transistors, configured otherwise like static CMOS, controls the state of the output node. In like fashion, Monotonic CMOS may also include circuits that pre-charge an output node low. Accordingly, the outputs of a circuit are pre-charged high (for a pull-down gate) or low (for a pull-up gate), depending on the design of the circuit. Note that, during an evaluation period following the pre-charge period the gates behave monotonically; that is, the output state of the circuit either remains unchanged, or transitions in a single direction. For example the only possible output transitions for a pull-down monotonic gate are 1 to 1, or 1 to 0. This contrasts with regular static CMOS in which four transitions are possible; 0 to 0, 1 to 1, 0 to 1, or 1 to 0.
[0014] The pull-up and pull-down gates of conventional monotonic static CMOS are cascaded in alternating sequence. By appropriate logic optimization, a circuit can be developed that reduces operating time and power consumption. Each logic input, however, still drives two transistor gates. Thus Monotonic CMOS requires fairly large amounts of chip real estate and provides only a limited improvement over static CMOS in operating speed.
[0015] A further conventional approach is to prepare circuits using static pseudo-NMOS technology. Pseudo-NMOS technology differs from CMOS in that each input drives only a single transistor gate. This is achieved by using a PNMOS device as a load. This technology also has certain disadvantages, however. In particular, although wiring complexity is significantly reduced, in comparison to the above noted technologies, static DC power consumption is increased.
[0016] A further conventional approach to improving switching speed and gate loading is the use of zipper-CMOS logic circuits. In zipper-CMOS, sequentially alternating circuit portions of NMOS and CMOS employ clocked precharging portions of complementary technology. In zipper CMOS, logic evaluation networks of NMOS transistors connect output nodes to ground, whereas logic evaluation networks of PMOS transistors connect output nodes to VDD.
[0017] Although each of the foregoing technologies has desirable aspects, and is advantageously applied in certain circumstances, there exists a need for a family of logic circuits which achieves high speed and low power dissipation within reduced spatial confines.
SUMMARY OF THE INVENTION
[0018] The present invention mitigates problems associated with the prior art and provides an advantageous alternative technology.
[0019] In a first aspect, the invention provides monotonic dynamic-static pseudo-NMOS logic circuits. Each of these circuits include a plurality of circuit portions, of which at least one is a dynamic pseudo-NMOS portion and one is a static pseudo-NMOS portion. The portions each include power and ground connections, a clock input node, at least one logical input node, and at least one output node. An output node of a dynamic portion is connected to a logical input node of a static portion. In some embodiments further portions are connected in alternating series, an output node of one portion connected to an input node of a following portion; static portions and dynamic portions alternating in turn.
[0020] At least one clock node of each portion is connected to either a clock signal, or its complement. Generally, the clock is a free running periodic clock adapted to define a series of consecutive time periods; one being a pre-charge period, the next being an evaluation period, the next being a pre-charge period, and so on. Each dynamic circuit portion includes at least one pre-charge transistor connected between VDD and the output node, and at least one evaluation transistor. In like fashion, each static circuit portion includes at least one pre-charge transistor, and at least one evaluation transistor. The pre-charge transistor of the static circuit portion, however, is connected between the output node and ground. In addition, each static circuit portion includes a pull-up transistor connected between the output node and a source of supply (VDD).
[0021] In a one exemplary embodiment all of the evaluation transistors are NMOS transistors. Each logical input connects to the gate of a single NMOS evaluation transistor. The inputs thus see limited capacitive load, and the subject logic family can respond rapidly to input signals.
[0022] Evaluation transistors switchably connect the output node of a circuit portion to ground. They may do so in series, the parallel, or in combination thereof, according to the logical function to be implemented.
[0023] In each dynamic circuit portion of an exemplary embodiment, a PMOS pre-charge transistor switchably connects a power connection to the output node. The PMOS pre-charge transistor receives the clock signal at its gate, whereby the PMOS pre-charge transistor is controlled to be conductive during a pre-charge period. In a static circuit portion, an NMOS pre-charge transistor recieves a clock signal at its gate, and is conductive during a pre-charge period. The NMOS pre-charge transistor switchably connects a ground connection to the output node of the static circuit portion. Accordingly, the clock signal acts to control the pre-charge transistors so as to pre-charge static portion output nodes toward ground and dynamic portion outpout nodes toward VDD during a pre-charge period.
[0024] In a static circuit portion of an exemplary embodiment, the PMOS pull-up transistor is conductive during an evaluation period. During a subsequent evaluation period, the output node of a dynamic portion is either pulled to ground if its evaluation transistors are conductive, or floats with its pre-charged voltage applied to the input of a subsequent portion if its evaluation transistors are non-conductive. During such an evaluation period, the output node of a static portion is either pulled high by the PMOS pull-up transistor, or remains at ground, depending on the conductive state of its evaluation transistors. The conductivity of the pre-charge transistors, of course, depend on the input signals applied to their gates.
[0025] In another aspect, the invention includes a method of evaluating electronic logic using the apparatus heretofore described.
[0026] In a further aspect, the invention includes a method that includes having first and second circuit portions that are connected together. The first circuit portion is a dynamic pseudo-NMOS circuit including a logical input and a first output node. The second circuit portion is a static pseudo-NMOS circuit including a plurality of logical inputs and a second output node. Normally, the output of the first node is connected to one of the logical inputs of the second circuit portion. The method includes receiving a periodic clock signal at a gate of a transistor switch that is part of the dynamic pseudo-NMOS circuit. The periodic clock signal divides operating time into alternating pre-charge and evaluation periods. Each transition between periods is marked by a transition in the level of the clock signal, either from low to high or high to low.
[0027] The embodiments of the invention shown within use NMOS devices for evaluation rather than PMOS devices. This contrasts with zipper-CMOS which employs NMOS and PMOS transistors respectively in alternating logic evaluation stages. Since, as described above, PMOS devices operate more slowly than NMOS devices, the technology presented here offers faster switching speeds at the expense of some additional DC power dissipation.
[0028] In a further advantage over conventional technology, it is noted that monotonic dynamic-static pseudo-NMOS logic uses fewer devices, less area, and less wiring to implement a particular logic function than the comparable function implemented with a combination of Domino logic and static CMOS, as currently known in the art.
[0029] The devices of the invention can be optimally sized to quickly discharge charged nodes, and quickly charge discharged nodes.
[0030] These and other advantages and features of the invention will become more readily apparent from the following detailed description of the invention which is provided in connection with the accompanying drawings
BRIEF DESCRIPTION OF THE DRAWINGS
[0031] [0031]FIG. 1 illustrates a dynamic circuit portion of a Monotonic Dynamic-Static Pseudo-NMOS circuit constructed in one exemplary embodiment;
[0032] [0032]FIG. 2 illustrates a static circuit portion of a Monotonic Dynamic-Static Pseudo-NMOS circuit constructed in one exemplary embodiment;
[0033] [0033]FIG. 3 illustrates the relationship between dynamic and static circuit portions in the exemplary embodiment; and
[0034] [0034]FIG. 4 illustrates the relative timing relationship of a clock signal, its complement, and pre-charge and evaluation periods;
[0035] [0035]FIG. 5 illustrates, in block diagram form, a system employing Monotonic Dynamic-Static Pseudo-NMOS circuitry.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0036] The present invention will be described as set forth in the exemplary embodiments illustrated in FIGS. 1 - 4 . Other embodiments may be utilized and structural or logical changes may be made without departing from the spirit or scope of the present invention. Like items are referred to by like reference numerals.
[0037] In accordance with the present invention, FIG. 1 shows a dynamic monotonic pseudo-NMOS circuit 100 . The circuit includes a logic evaluation network 120 and a pre-charge portion 130 . In the example shown, the logic evaluation network includes two NMOS evaluation transistors 140 , 150 arranged in an AND configuration. The gates 160 , 170 of the NMOS transistors 140 , 150 of the evaluation network are operatively connected to, or serve as, respective inputs 180 , 190 to, the evaluation network 120 . The pre-charge portion 130 includes a PMOS transistor 200 with a gate 210 . The gate 210 is operatively connected to a source of a clock signal 215 . The pre-charge transistor 200 is operatively connected between a source voltage supply at a power node 220 , and an output node 230 of the dynamic monotonic pseudo-NMOS circuit 100 . Also connected to the output node 230 of the dynamic circuit is the drain terminal 240 of one of the evaluation portion NMOS transistors 140 . In the particular embodiment shown, the two NMOS evaluation transistors 140 , 150 are connected in series, thereby effecting an AND function. As is known in the art, other logical functions could be readily implemented. The source 250 of the second evaluation transistor 150 is operatively connected to an electrical ground 260 as shown. In the illustration, the capacitance of the output node, including trace capacitance and junction capacitance, is expressly represented as a capacitor 270 electrically connected between the output node 230 and ground 260 .
[0038] [0038]FIG. 2 shows a static monotonic pseudo-NMOS circuit 400 . Like the dynamic circuit 100 , the static circuit 400 includes an evaluation network 420 , and a pre-charge portion 430 . In the example shown, the evaluation network includes two NMOS transistors 440 , 450 arranged in an AND configuration. The gates 460 , 470 of the NMOS transistors 440 , 450 of the evaluation network 420 are operatively connected to, or serve as, respective inputs 480 , 490 to, the evaluation network 420 . The pre-charge portion 430 includes a PMOS pull-up transistor 500 with a gate 510 . The gate 510 is operatively connected to a source of a complemented clock signal 515 . The pull-up transistor 500 is operatively connected at its source to a source voltage supply at a power node 220 , and at its drain to an output node 530 of the static monotonic pseudo-NMOS circuit 400 . Also connected to the output node 530 of the static circuit are the drain of an NMOS pre-charge transistor 535 , and a drain terminal 540 of one of the evaluation network NMOS transistors 440 . In the particular embodiment shown, the two NMOS evaluation transistors 440 , 450 are connected in series, thereby effecting an AND function. As is known to in the art, other functions could readily be implemented. The source 550 of the second evaluation transistor is operatively connected to an electrical ground 260 as shown. Similarly, the source of the pre-charge NMOS transistor 535 is also connected to ground 260 . The gate 537 of the pre-charge NMOS transistor 535 is operatively connected to a source of a complemented clock signal ({overscore (CLK)}) 515 . As in the case of the dynamic circuit, the capacitance of the output node 530 , including trace capacitance and junction capacitance, is expressly represented as a capacitor 570 electrically connected between the output node 530 and ground 260 .
[0039] As shown in FIG. 3, the output node 230 of a dynamic circuit portion is connected to an input node 490 of a static circuit portion. In the exemplary embodiment shown, the resulting logical function is a NAND function with two inputs 180 , 190 . Additional circuit portions maybe connected to form arbitrary logical functions. As shown, for example, an additional circuit portion 700 may be connected at an input 790 to the output node 530 of the static monotonic pseudo-NMOS circuit 400 .
[0040] In operation, the output nodes 230 , 530 of a dynamic 100 and static 400 circuit portions are pre-charged during a pre-charge period. The output node 230 of the dynamic portion 100 is pre-charged to a non-ground potential (VDD) 220 , and the output node 530 of the static portion 400 is pre-charged to a ground potential 260 . Thereafter, in response to a signal (or concurrent signals) at the various clock inputs at 210 , 510 , 537 , the pre-charge transistors, 200 and 535 respectively, are made nonconductive. Charge stored in the capacitance 270 of the output node 230 is then either discharged to ground, or maintained, depending on the conduction state of the evaluation transistors 140 , 150 of the evaluation network 120 . The resulting electrical potential at output node 230 is applied to the input node 490 of the static circuit portion 400 . This represents the evaluation period, as opposed to the pre-charge period. During evaluation period, pre-charge portion NMOS transistor 535 is nonconductive, and pre-charge PMOS transistor 500 is conductive. Accordingly, output node 530 is continuously supplied with power from the VDD node by means of transistor 500 . As a result output node 530 assumes a non-ground or ground electrical potential (neglecting evaluation transistor resistance) depending on the state of the evaluation network 420 transistors 440 , 450 . The state is maintained for the finite duration of the evaluation period, after which, with a further transition of clock signals 215 , 515 , the system reenters pre-charge state. As is apparent, the system cycles periodically through pre-charge and evaluation periods according to the state of the clock signals 215 , 515 .
[0041] [0041]FIG. 4 shows this timing relationship in graphical form. Both clock signal 1000 , and complemented clock signal 1010 are shown. As is readily apparent, the signals transition substantially simultaneously, and pass through pre-charge 1030 and evaluation 1040 periods in periodic fashion.
[0042] The action of the monotonic dynamic-static pseudo-NMOS gate is thus apparent. During a first pre-charge time period, the output node of each dynamic portion is charged to VDD, and the output node of each static portion is discharged to ground potential. Then, with a clock transition, the circuit enters an evaluation period. The PMOS pre-charge transistor disconnects the output node of the dynamic portion from VDD. Logical inputs are applied to the gates of the NMOS evaluation transistors of the dynamic portion, and the evaluation transistors either leave the output node of the dynamic portion floating at VDD, or connect it to ground, depending on the state of the logical inputs. The static portion combines the state of the output node of the dynamic portion with other inputs applied to its evaluation transistors. These evaluation transistors similarly connect or disconnect the output node of the static circuit to ground. In the meantime, during the evaluation period, a pull-up transistor provides power to the output node of the static circuit portion.
[0043] The arrangement described displays many desirable characteristics. Each logical input to the circuit drives only a single NMOS transistor gate. The capacitive load per input is thus substantially smaller than that for a static CMOS circuit implementing equivalent logic. Because the capacitive input load is small, charging currents are likewise small, and power dissipation and switching times are minimized. Switching times are further minimized by the absence of PMOS transistors, with their relatively low majority carrier mobilities, in the logic evaluation networks of the circuit. Finally, by precharging output nodes and assuring monotonic behavior, the asymmetric switching transients of static CMOS logic are avoided, and overall evaluation time is improved.
[0044] Monotonic dynamic-static pseudo-NMOS logic, as heretofore described, may thus be used with appropriate optimization to implement arbitrary logic functions with low signal delay and low power consumption. Monotonic Dynamic-Static Pseudo-NMOS logic may be applied in a wide variety of electronic systems. For example, as shown in FIG. 5, a computer system 1100 incorporating the CPU 1110 , a floppy disk drive 1120 , a CD-ROM drive 1130 , I/O devices 1140 , and RAM 1150 and ROM 1160 memory offers many opportunities to benefit from the application of this technology. Logic circuits within the CPU 1110 , or within the controllers found in the floppy disk drive 1120 and CD-ROM drive over 1130 respectively could be prepared employing Monotonic Dynamic-Static Pseudo-NMOS logic. The subject logic family is particularly applicable to fabrication of random access memory 1150 because it provides high-speed operation. Likewise, I/O devices 1140 would benefit from application of the technology.
[0045] While preferred embodiments of the invention have been described and illustrated above, it should be understood that these are exemplary of the invention and are not to be considered as limiting. Additions, deletions, substitutions, and other modifications can be made without departing from the spirit or scope of the present invention. Accordingly, the invention is not to be considered as limited by the foregoing description but is only limited by the scope of the appended claims. | A method and apparatus for evaluating logical inputs electronically using electronic logic circuits in monotonic dynamic-static pseudo-NMOS configurations. The apparatus includes alternating dynamic and static circuit portions adapted to transition monotonically in response to a common clock (or complemented clock) signal. The circuit portions include pseudo-NMOS configured switching circuits implementing logical functions. | 7 |
BACKGROUND
[0001] This application relates to tissue manipulation instruments, and more particularly to instruments for implantation of graft tissue into a bone hole.
[0002] In certain surgical procedures, such as tenodesis, a graft tissue is attached to a bone. For instance, in tenodesis a biceps tendon is detached from its attachment to the glenoid and is reattached to the humerus. In one popular method of reattachment a bone tunnel is created on the humerus and the detached tendon is pushed into the tunnel and then held in place via an interference bone screw implanted into the tunnel. Positioning the tendon in the tunnel can be tricky.
[0003] In one method, the graft tissue is externalized from the patient and whip stitched to make a stiff construct at the termination of the tissue. The stiff construct may be pushed directly into tunnel using graspers or the like. A length of suture at the distal portion of the whip stitch may be used to pull the graft tissue into the tunnel. It is desirable in many cases, however, to perform the entire operation with the graft tissue internalized within the patient. Thus, producing the whip stitch is difficult for the surgeon.
[0004] In another method, the graft tissue is folded near the location of tunnel and pushed into the tunnel at the fold. When using instrumentation of prior art, the graft tissue has a natural tendency to compress against the instrument. Should the frictional contact between the graft tissue and instrument be greater than the frictional contact between the graft tissue and tunnel, it is likely that the tissue will move from its desired position as the instrument is retracted from the tunnel.
SUMMARY OF THE INVENTION
[0005] The present invention overcomes these and other limitations of the prior art in a simple and elegant design.
[0006] An instrument according to the present invention provides for implanting a graft into a bone hole. The instrument comprises an elongated handle having a forked distal termination having a first tine and a second tine defining a space therebetween. A flexible member spans the space between the first tine and the second tine so that the graft can be received within the space against the flexible member and thereby manipulated into the bone hole.
[0007] Preferably, the first tine comprises an open ended first notch at its distal end, the flexible member being received within the first notch. Preferably, the flexible member having a first section between the first tine and second tine, and a second section extending from the first notch proximally along the handle where it preferably, is releasably attached to the handle so that a user can release the flexible member from the handle to relax tension in the flexible member. Preferably, the second tine comprises an open ended second notch with the flexible member being received in both the first notch and second notch and spanning the space therebetween.
[0008] In one aspect of the invention, one or both of the first tine and second tine are flexible, with the space between the first tine and second tine being adjustable by tension on the flexible member.
[0009] In one aspect of the invention, the handle is cannulated having a longitudinal cannulation opening to the space between the first tine and second tine. In one aspect of the invention, a guide wire is provided which is passable through the cannulation and which is adapted to be fixed into the bone hole whereby the instrument can be passed down to the bone hole over the guide wire.
[0010] Preferably, the first tine and second tine are curved about a central longitudinal axis of the instrument to accommodate to the bone hole.
[0011] Preferably, the instrument is provided sterile and packaged in a bacteria proof package.
[0012] A method according to the present invention provides for implanting a graft into a bone hole. The method comprises the steps of: positioning the graft between a first tine and a second tine at a distal end of a shaft of a surgical instrument and against a flexible member spanning a space defined between the first tine and second tine; manipulating the first and second tines with the graft therebetween into a bone tunnel; pushing the graft via the flexible member into the bone tunnel; and releasing tension in the flexible member to allow its movement relative to at least one of the first tine and second tine and removing the first and second tines from the bone tunnel, leaving the graft positioned therein.
[0013] Preferably, the graft is folded upon itself over the flexible member.
[0014] In one aspect of the invention, the flexible member is received in an open distally facing notch on the first tine. In one aspect of the invention, the step of releasing tension on the flexible member includes allowing it to fall outwardly of an open distally facing notch on the first tine.
[0015] In one aspect of the invention, at least one of the first tine and second tines are flexible a distance between them is controlled via tension on the flexible member.
[0016] In an aspect of the invention, the first tine and second tines are directed toward the bone tunnel by passing a guide wire leading from the bone tunnel through a cannulation through the shaft. After the graft has been positioned in the bone tunnel an anchor can be passed into the tunnel to fix the graft therein, preferably by passing the anchor over the guide wire.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] FIG. 1 is a side elevation view of a graft implantation tool according to the present invention;
[0018] FIG. 2 is a side elevation view of a graft anchor for use with the tool of FIG. 1 ;
[0019] FIG. 3 is a side elevation view of the tool of FIG. 1 shown adjacent a bone tunnel and a graft ready for implantation into the tunnel;
[0020] FIG. 4 is a side elevation view of the tool of FIG. 1 shown initially capturing the graft and entering the tunnel;
[0021] FIG. 5 is a side elevation view of the tool of FIG. 1 shown fully inserted into the tunnel;
[0022] FIG. 6 is a side elevation view of the tool of FIG. 1 shown retracting from the tunnel leaving the graft in the tunnel;
[0023] FIG. 7 is a side elevation view of the tool of FIG. 1 oriented to show the graft entering the tunnel from the rear of this view and an anchor being implanted into the tunnel;
[0024] FIG. 8 is a side elevation view of the tunnel and graft of FIG. 7 oriented to show the graft entering the tunnel from the left side and illustrating a completed implantation of the graft;
[0025] FIG. 9 is a side elevation view of an alternative embodiment of a graft implantation tool according to the present invention showing flexible tines in a relaxed state;
[0026] FIG. 10 is a side elevation view of the tool of FIG. 9 showing the tines in a collapsed state;
[0027] FIG. 11A is a side elevation view of a tine of FIG. 1 showing a suture capture notch;
[0028] FIG. 11B is a side elevation view of a tine of an alternative embodiment of a graft implantation tool according to the present invention showing a suture capture hole;
[0029] FIG. 11C is a side elevation view of a tine of an alternative embodiment of a graft implantation tool according to the present invention showing an elongated suture capture hole; and
[0030] FIG. 11D is a side elevation view of a tine of an alternative embodiment of a graft implantation tool according to the present invention showing an alternative suture capture notch.
DETAILED DESCRIPTION
[0031] FIG. 1 depicts a graft implantation tool 10 according to the present invention. It comprises an elongated cannulated shaft 12 with a forked distal end 14 . The distal end 14 comprises a first tine 16 and second tine 18 defining a space 20 therebetween. Each of the tines 16 and 18 has a distal terminal end 22 with a distal terminal notch 24 . A length of suture 26 or other flexible material with suitable tensile strength spans the space 20 between the notches 24 . It has a first end 28 affixed to the shaft 12 where the second tine 18 meets the shaft 12 . From there it extends down along an exterior surface 30 of the second tine 18 enters the second tine notch 24 , spans the space 20 , enters the first tine notch 24 and then extends up the shaft 14 where it is secured in a suture retainer 32 , which is shown for illustrative purposes as a simple cleat but any suitable retention can be employed as will be appreciated by those of skill in the art.
[0032] A cannulation 34 extends axially through the shaft 12 and opens into the space 20 between the tines 16 and 18 . The cannulation 34 is wide enough to pass an interference anchor 36 (see FIG. 2 ). The tines 16 and 18 are curved on their exterior surfaces 30 and interior surfaces 38 to fit snugly into a bone tunnel (not shown in FIG. 1 ) and to pass the anchor 36 . One or both of the tines 16 and 18 can be flexible with their spacing being controlled by tension in the suture 26 spanning the space 20 . In such event their relaxed position is preferably slightly spread from parallel as they extend distally. This allows a more open presentation to allow easier loading of a graft (not shown in FIG. 1 ) into the space 20 .
[0033] Turning also now to FIG. 2 , the anchor 36 comprises an elongated body 40 having exterior threads 42 , a narrow distal tip 44 , a proximal tool recess 46 , such as for receipt of a hex driver, and an axial cannulation 47 for passage of a guide wire (not shown in FIGS. 1 and 2 ). Other configurations can be employed as will be appreciated by those of skill in the art. One suitable anchor is the MILAGRO interference screw available from DePuy Mitek, Inc. of Raynham, Mass.
[0034] The tool 10 can be fabricated from any biocompatible materials or combinations thereof providing adequate strength for constructing the cannulated shaft 12 and having adequate elastic properties to provide the flexibility of one or both tines 16 , 18 to accommodate variations in the distance across the space 20 . Metallic materials that can be used to manufacture the instrument of the present invention include stainless steel, titanium, alloys of nickel and titanium, or other biocompatible metallic materials. It can also be formed of polyethylene, polypropylene, PEEK, or other biocompatible non-absorbable polymers.
[0035] Turning also to FIGS. 3 to 6 , use of the tool 10 will now be described. FIG. 3 shows a biceps tendon 48 which has been removed from its placement on the glenoid (not shown) and is placed adjacent to a bone tunnel 50 which has been prepared in a humerus bone 52 . A guide wire 54 extends from the tunnel 50 . Options for creation of the bone tunnel 50 and placement of the guide wire 54 will be apparent to those of skill in the art. The tool 10 has been passed down over the guide wire 54 and is positioned adjacent to the tunnel 50 . The tendon 48 is positioned over the tunnel 50 with the suture 26 orthogonal to the tendon 48 . As the tines 16 and 18 are pressed into the tunnel 50 ( FIG. 4 ) the tendon 48 is received between the tines 16 and 18 and caught upon the suture 26 causing the tendon 48 to fold upon itself. The tendon 48 is then pressed down into the bottom of the tunnel 50 as illustrated in FIG. 5 . At this time the suture 26 is released from the suture retainer 32 releasing tension in the suture 26 and allowing removal of the tines 16 and 18 without the suture hanging up on the tendon 48 and affecting its implantation in the tunnel 50 as illustrated in FIG. 6 . The anchor 36 can then be implanted, preferably over the guide wire 54 employing techniques as may be known or become known to those of skill in the art. For instance, FIG. 7 shows the anchor 36 being passed down a cannula 51 via a cannulated driver 53 and being threaded into the tunnel 50 to trap the tendon 48 therein. FIG. 8 illustrates the completed repair.
[0036] FIGS. 9 and 10 illustrate an alternative embodiment of a graft implantation tool 56 according to the present invention. It has flexible first and second tines 58 and 60 , respectively, and a suture 62 passing from the second tine 60 through a distal notch 64 therein across a space 66 between the tines 58 and 60 , through a distal notch 64 in the first tine 58 . Under slack tension in the suture 62 distal ends 68 of the tines 58 and 60 spread open allowing easy entry of a graft 66 into the space 66 . Tension on the suture 62 causes the tines 58 and 60 to collapse inwardly toward each other grasping the graft 66 . The narrowing of the tine spacing may also ease its entry into a bone tunnel.
[0037] Although shown with tines 16 and 18 which are axially aligned with the shaft 12 they could be angled with respect to the shaft 12 . Also the shaft could be curved. Various depths of the notches 24 into the tines 16 and 18 may be employed for positioning the graft tendon 48 at different axial positions along the tines 16 and 18 . The tension on the suture 26 can also affect such placement with a bit of slack in it between the notches 24 allowing the suture 26 to bow proximally as the tendon 48 is engaged. Turning also now to FIGS. 11 A to H, the axial notch 24 as disclosed in FIG. 1 and FIG. 11A is preferred in the first tine 16 for easy release of the suture 26 from the tendon 48 after its implantation without the suture 26 catching on tendon 48 or the tine 16 . Other designs may enhance temporary holding of the suture 26 so that it does not fall out of place. For instance a closed circular hole 70 , elongated hole 72 or elongated notch 74 with a capture leg 76 or notch 80 and more aggressive capture leg 82 may be substituted especially in the second tine 18 . A notch 84 having an expanded capture leg 86 and a restriction 88 leading into the capture leg 86 allows suture to slip in easily but not slip back out. A notch 89 with a restriction 90 provides some measure of capture but still allows the suture to be extracted from the notch 89 if desired. A notch 92 can be provided with a tortuous path such as in inward spiral 94 . These designs limit suture 26 from falling out of the notch inadvertently yet still allow free sliding of the suture 26 therethrough so that it will not catch on the tendon 48 as the tines 16 and 18 are removed from the tunnel 50 .
[0038] The invention has been described with reference to the preferred embodiments. Obviously, modifications and alterations will occur to others upon reading and understanding the preceding detailed description. It is intended that the invention be construed as including all such modifications and alterations insofar as they come within the scope of the appended claims or the equivalents thereof. | An instrument for placing a graft into a bone tunnel comprises an elongated shaft having a forked distal end comprising a pair of tines. A suture spans a space defined between the tines whereby the graft may be positioned between the tines and against the suture so as to be manipulated into the bone tunnel. The tendon folds about the suture, the suture having a releasable tension such that the instrument can be removed from the bone, leaving the tendon behind without the tendon hanging up on the suture. | 0 |
BACKGROUND OF THE INVENTION
The invention concerns a clasp with plug especially suited to being applied to gold or fashion jewellery such as for instance bracelets, necklaces, chains and similar.
As is known one type of clasp that is frequently applied to items of gold and fashion jewellery is often called a “plug clasp”.
This basically comprises a female element provided with first means of attaching to a first end of one of said items, which has a hole that receives a plug belonging to a male element provided with second means of attaching to the second end of the same item.
The firm yet detachable coupling of the plug of the male element within the corresponding hole in the female element, is achieved by one or more extending members that are made to flex by elastic devices and are provided with means of locking suited to connecting with corresponding means of striking belonging to the female element.
Known plug clasps of the type described above, in comparison to other known kinds of clasp, have the advantage of offering greater reliability against accidental opening. What's more they can be made in any shape whatsoever suited to being integrated with the shape of the item they are applied to.
These clasps do nevertheless have a limitation in that the extending members and the elastic devices they work with, are all enclosed within the plug of the male element and consequently the plug cannot be produced in sizes smaller than a given minimum limit governed by the coexistence inside of the extending members and the elastic devices.
As a result, known types of plug clasp cannot be used on any items, such as necklaces or bracelets, which are somewhat small in cross-section since this would ruin the overall aesthetic appearance of these items.
To overcome these limitations and inconveniences, the depositee of this invention has registered under the same name the Italian patent for industrial invention having deposit number V196A000064 which describes an improved type of plug clasp that against equivalent, known types of plug clasp has markedly smaller cross-sectional dimensions.
To be more precise the clasp comprises a female element and a male element provided with a plug that can be fastened in a corresponding hole in the female element.
The male element contains a flexibly extending member externally operated by an actuator end, provided with means of locking that connect with corresponding means of striking belonging to the female element when the plug is fastened in the hole of the female element.
The extending member is basically L-shaped and sits in a cavity made in the body of the male element, which ends with a well that holds the shaped end of the extending member.
A pivot point is thereby created that allows the extending member to rotate when the user presses it from the outside on the actuator end.
A spring inserted in the body of the male element, having one end connected to the male element and its opposite end restrained within a hole made in the extending member, provides the latter with a flexing movement.
Together with its flexing function, the spring also performs the function of travel stop that limits the movement of the extending member while it rocks to open or close the clasp. The clasp described above has however some limitations and inconveniences.
A first inconvenience is the difficulty found when producing the well that holds the end of the extending member in the body of the male element.
Another inconvenience is the need to produce the hole in the extending member that holds the end of the elastic device. Last but not least an inconvenience is the lack of a genuine travel stop that allows to limit the rocking of the extending member inside the seat that holds it.
SUMMARY OF THE INVENTION
This invention intends to overcome these limitations and inconveniences.
In particular a first scope of the invention is to produce a plug clasp that is simpler to produce than the clasp under the aforementioned patent.
Another scope is that the clasp of the invention should also have a greater precision in its operation. Last but not least a scope is that the clasp invention be easier to assemble than similar, equivalent clasps.
Said scopes are achieved by producing a clasp for gold and/or fashion jewellery items such as bracelets, necklaces and similar that in accordance with the main claim comprises:
at least one female element and at least one male element fastened by means of attaching each to its respective end of one of said adornments;
a plug belonging to the body of said at least one male element, suited to being fastened in a corresponding hole in said at least one female element;
an extending member basically shaped in the form of an L that comprises a first part fitted in a first seat made lengthways in said plug and a second part fitted in a second seat made in the body of said male element and provided with means of locking suited to snapping onto corresponding means of striking belonging to said female element when said plug is fastened in said hole;
a shaped end belonging to said second part and protruding from the body of said at least one male element that acts as the actuator piece for the user to operate;
at least one elastic device inserted between said extending member and the body of said male element, and wherein the end of said first part of said extending member has a fork created by two arms spread apart that meet to create a seat suited to being closed across a fixed pin set crossways through said first seat of said plug, the latter being provided with an opening for introducing a tool suited to closing said arms rotating around said fixed pin.
According to a preferred form of execution, the second part of said extending member consists of a flat sheet metal body whose end is shaped to provide the fork.
The fork is created by two arms spreading apart in a V-shape that meet to create a basically ringed sectioned seat that will couple around the outside of a pin, which also has a basically ringed cross-section.
When the fork's arms are closed by bending, achieved for instance by pliers that are introduced through the opening made in the end of the plug, the extending member remains coupled rotating around the plug.
The elastic devices consist of a coil spring restrained between the second part of the extending member and the body of the male element.
The body of the male element also has a slot from which protrudes an adjustable striking element suited to limiting the movement of the extending member inside said plug.
An advantage obtained from the clasp is that it is easier to produce since the plug does not have blind spots.
Another advantage is that the particular forked construction of the end of the extending member and the way by which it is coupled rotating around the pin, allows greater precision in the clasp's operation.
BRIEF DESCRIPTION OF THE DRAWINGS
An additional advantage is that the existence of an adjustable travel stop contributes towards improving the clasp's operation. Said scopes and advantages shall be better explained during the description of a preferred form of execution of the invention that is given as a guideline but not a limitation with reference to the attache diagrams, where:
FIG. 1 shows the clasp invention in a blow-up isometric illustration;
FIG 2 shows the detail of a part of the clasp illustrated in FIG. 1;
FIG. 3 shows a longitudinal section of the clasp in FIG. 1, assembled and with the plug being inserted in the female element;
FIG. 4 shows a cross-section of the clasp in FIG. 3 made along line III—III
FIG. 5 shows the clasp in FIG. 3 while the plug is being inserted in the female element;
FIG. 6 illustrates the clasp in FIG. 3 assembled;
FlG. 7 illustrates a part of a variant in execution of the clasp invention;
FIG. 8 illustrates another view of the variant in execution in FIG. 7;
FIGS. 9 and 10 illustrate different conditions of the variant in execution illustrated in FIG. 7 .
DESCRIPTION OF THE INVENTION
As can be seen in FIG. 1 the clasp invention, generally indicated by 1 , comprises:
a female element, generally indicated by 2 , whose body 3 is attached by first means of attaching (not illustrated) to a first end of an adornment, for instance a bracelet or a necklace (not illustrated);
a male element, generally indicated by 5 , whose body 6 is attached by second means of attaching (not illustrated) to a second end of the same adornment.
The male element 5 also comprises a basically cylindrically shaped plug 7 , coaxial to its body 6 , provided with a cavity 8 , made partly in the plug 7 and partly in the body 6 , suited to receiving an extending member, generally indicated by 9 , made flexing by inserting one or more springs 10 .
To be more precise it can be seen, also in FIGS. 3, 4 , 5 and 6 , that the aforesaid cavity 8 comprises a first seat 71 made in the plug 7 suited to holding a first part 91 of the extending member 9 and a second seat 72 made in the body 6 of the male element 5 , suited to holding a second part 92 of the same extending member 9 .
The two parts 91 , 92 , are basically perpendicular to one another so that the extending member 9 is given a basically L-shaped structure.
Under the invention the end of said first part 91 of said extending member 9 has a fork 191 created by two arms 191 a , 191 b spread apart that meet to create a seat 191 c suited to being closed across a fixed pin 171 set crossways through said first seat 71 of said plug 7 .
In particular the plug 7 consists of a hollow cylindrical section with a longitudinal slot 7 a , designed for introducing a tool suited to closing said arms 191 a , 191 b rotating around said fixed pin 171 .
Preferably but not necessarily the first part 91 of the extending member 9 consists of a flat sheet metal body while the second part 92 consists of a basically cylindrically shaped body.
At the end of the flat sheet metal body, which represents the first part 91 , a fork 191 has been made that is basically V-shaped with its arms 191 a , 191 b set spreading apart from the seat 191 c that links them together.
The seat 191 c has a basically ringed section suited to coupling around the outer surface of the pin 171 that also has a ringed cross-section.
The spring 10 that allows the flexing movement of the extending member 9 , is a coil type spring which, as can be seen in detail in FIGS. 2, 3 and 4 , has a first end 10 a that is held in a corresponding recess 92 a made in the second part 92 of the extending member 9 and a second end 10 b that is held in a second recess 6 a made in the body 6 of the male element 5 .
The spring is kept in place within the respective recesses by lug elements 92 b , 6 b that fit into corresponding ends 10 a , 10 b of the spring.
The extending member 9 also has means of locking consisting of a tine 94 that connects against corresponding means of striking that consists of a ringed recess 21 , that can be seen in detail in FIG. 3, which belongs to a sheath 22 inserted in the body 3 of the female element 2 and provided with a hole 23 that receives the plug 7 to fasten it to the female element 2 .
It can also be seen that one end of the second part 92 of the extending member 9 has an actuator end 93 that juts out of the body 6 of the male element 5 and on its opposite end a buckling attachment 92 c with a lip 92 d that is set in to face a slot 6 c made in the body 6 when the extending member 9 is fitted in the cavity 8 .
The body 6 , as can be seen in FIG. 1, has a through going hole 6 d that allows a tool, for instance an awl, to be introduced to bend the attachment 92 c in order to adjust the entry of the lip 92 d in the slot 6 c.
In this way, as can be seen in FIG. 3, the end 92 d becomes the travel stop that limits the flexing rotation of the extending member 9 around the pin 171 in the cavity 8 and also prevents them from coming apart.
In practise to attach the male element 5 to the extending member 9 , the latter has to be inserted in the cavity 8 and using a tool, for example needle-nose pliers, through the longitudinal slot 7 a of the plug 7 , the ends 191 a , 191 b of fork 191 can be accessed to be bent and closed rotating around the pin 171 , obtaining the coupling as shown in FIG. 3 .
Then the spring 10 is inserted between the extending member 9 and the body 6 of the male element 5 and using a tool, for instance an awl, which is introduced through hole 6 d , the attachment 92 c is bent setting it at an angle as can be seen in FIG. 5 so that the lip 92 d is set inside the slot 6 c where it acts as travel stop as can be seen in FIG. 6 .
In this way the extending member 9 remains locked onto the male element 5 , with the possibility of flexing outwards by a distance checked by the lip 92 d in the slot 6 c.
To join the element making up the clasp, the plug 7 of the male element 5 is inserted in the hole 23 of the female element 2 as can be seen in FIG. 3 and then, by applying an longitudinal pressure 100 as illustrated in FIG. 5, the tine 94 is pushed against the rim of the sheath 22 . This compresses the spring 10 and lowers the extending member 9 in direction 110 .
If the axial pressure 100 is continued the tine 94 enters the ringed recess 21 and the extending member 9 returns to its initial position by the elastic recoil of the spring 10 .
As a result the layout illustrated in FIG. 6 is obtained where the male element 5 and the female element 2 are fastened together.
To open the clasp it is sufficient to press on the actuator end 93 of the extending member 9 with a pressure 120 directed downwards, as can be seen in FIG. 6, until the elastic force of the spring 10 is overcome and release the tine 94 from the ringed recess 21 .
Then by pulling outwards the elements are separated.
It should be noted that the elasticity of the extending member 9 allows the male element 5 to be fastened onto the female element 2 simply by pushing both towards each other without the need to press on the actuator end 93 of the extending member 9 , thereby facilitating the process of fastening the two elements.
A variant in execution of the clasp invention is illustrated in FIGS. 7 to 10 where it can be seen that it differs from the previous form of execution by the existence inside the body 6 of the male element 5 of a sloping face 95 set beneath the lip 92 d of the buckling attachment 92 c , in line with the lug element 6 b that restrains the spring 10 .
As can be seen in FIG. 7, when the extending member 9 is in its idle position and in other words pushed upwards and set at an angle by the action of the spring 10 , the lip 92 d of the buckling attachment 92 c is set against the sloping face 95 .
If the user pushes the extending member 9 downwards by applying a pressure S on the actuator end 93 , the action of the lip 92 d against the sloping face 95 makes the buckling attachment 92 c flex, bending in the direction of rotation indicated by arrow 97 in FIG. 9 thereby making the lip 92 d enter the slot 6 c.
If the downward pressure on the extending member 9 continues, the buckling attachment 92 c continues to bend until the final set-up illustrated in FIG. 10 where it reaches its bent limit and therefore total entry of the lip 92 d in the slot 6 c.
In this variant in execution the side hole 6 d is no longer necessary for introducing a tool to bend the buckling attachment 92 c since this is bent automatically the first time the extending member 9 is actuated.
In this way in addition to avoiding the need to make a hole in the male element 5 , the need to bend the attachment 92 c during assembly is also eliminated.
It is quite understandable that the clasp invention in both the forms of execution that have been illustrated is easy to produce since the extending member 9 , and in particular its first part 91 and the fork 191 together with the tine 94 , can be produced by simple die-cutting processes.
Even the use of a tubular section to produce the plug 7 simplifies the manufacturing process.
What's more even the assembly operations are simplified and the clasp offers reliable operation given the existence of travel stops.
It is clear that during actual production, the elements that make up the clasp may change in shape and obviously also in dimension, which may be of any form or size.
These variants and any others that may be applied to the clasp under this invention, since they fall under the claims given below, shall all be held covered by this patent. | A clasp ( 1 ) for bracelets, necklaces and similar items has a female element and a male element fastened together by a plug belonging to the male element that fastens in a corresponding hole in the female element by a locking belong to an extending member. The extending member has a protruding actuator end and a first part held in a first seat of the plug, which has a fork at its end created by two arms spread apart that meet to create a seat that encloses across a fixed pin set crossways through the first seat of the plug. The plug has an opening to introduce a tool suited to closing the arms rotating around the fixed pin. | 8 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to nuclear magnetic resonance tomographs and, more particularly, to a nuclear magnetic resonance tomograph allowing to reproducibly calibrate the strength of the high-frequency magnetic field irradiated on a measuring space irrespective of the filling factor.
While the present invention is described herein with reference to a particular embodiment for a particular application, it is understood that the invention is not limited thereto. Those of ordinary skill in the art will recognize additional embodiments and applications within the scope thereof.
2. Description of the Related Art
Methods for calibrating the amplitude of a rf current of a nuclear magnetic resonance imaging apparatus are described in published international patent applications WO-A-88/09928 and WO-A-88/09929. In these prior art methods, rf test pulses are directed upon the object under test, usually a human body, and the resonance signals received are then evaluated. By selecting the pulse shape and pulse sequence of the nuclear resonance excitation pulses in a convenient manner, it is possible in this case to determine the amplitude of the rf excitation in absolute values, by evaluation of the measuring signals.
published European patent application EP-A-0 238 139 describes an image-generating nuclear magnetic resonance method where the pulse angle, i.e. the duration of the rf excitation pulses, is determined again by directing a predetermined pulse sequence upon an object under test and evaluating the measuring signals received as a response thereto.
Published European patent application EP-A-0 152 069 describes an imaging nuclear magnetic resonance apparatus where standardized reference samples are arranged in the direct neighborhood of the object under test within the measuring space. Scaling of the measuring signals received from the test objects is effected by comparing the measuring signals received from the reference samples with the measuring signals received from the object under test, i.e. a human body.
Moreover, a probe head for use in NMR tomography has been known from published German patent application DE-A-35 22 401. This probe head has substantially the form of a hollow cylinder whose outer surface and end faces are closed for rf currents and whose cylindrical inner surface is subdivided into conductive and non-conductive axial strips. Inside the known probe head a substantially homogeneous magnetic rf field is produced which has a direction perpendicular to the probe head axis.
As is generally known, an object under test, for example a portion of a human body or an entire human body, for performing nuclear magnetic resonance imaging is introduced into a measuring space which is surrounded by a conventional rf coil and also by a magnet system and, further, by gradient coils establishing constant magnetic fields having a predetermined gradient of magnetic field strength. The object under test is exposed to a constant magnetic field of high homogeneity and, further, to a rf magnetic field directed at a right angle relative to the constant magnetic field.
Whenever, in the scope of this invention, reference is made hereinafter to a "rf coil" of a "high-frequency coil", this term is to be understood as describing any high-frequency system capable of generating a high-frequency magnetic field of sufficient homogeneity and field strength in a larger three-dimensional space. Such coils may take the for of, for example, saddle coils, Helmholtz coils, line resonators, strip resonators or the like. For the purposes of the present invention, a hollow cylindrical high-frequency resonator of the type described by the afore-mentioned published German patent application DE-A-35 22 401 is particularly preferred, although the invention is by no means limited to such a probe head arrangement.
As is generally known, nuclear resonance signals are generated in nuclear magnetic resonance tomography by using pulsed high-frequency signals having a frequency proportional to the field strength of the constant magnetic field where the proportionality is given by the gyromagnetic factor of the particular nucleus under investigation.
By exciting the nuclear spins with pulsed high-frequency magnetic fields, the spin magnetization is caused to flip by a given angle relative to the direction of the constant magnetic field. This so-called flip angle is defined by the pulse area, so that the flip angle may be adjusted by adjusting the pulse length and/or the pulse amplitude.
In order to generate measuring signals of maximum intensity, i.e. optimum nuclear magnetic resonance excitation, it is customary to apply pulses having a flip angle of 90° or 180° in order to either flip the magnetization into a radial plane or transfer it into a state of anti-magnetization, with inverse sign.
When adjusting the nuclear magnetic resonance tomograph, one, therefore, seeks to adjust the flip angle with the greatest possible accuracy to the value of 90° or 180° in order to achieve the greatest possible signal yield.
Now, the determination of the pulse length does not create too big a technical problem because suitable time controls and gate circuits are available enabling the pulse duration to be adjusted with sufficient precision and at reasonable expense.
On the other hand, however, it has been mentioned before that the flip angle depends not only on the pulse length, but also on the pulse amplitude so that the latter, i.e. the amplitude of the rf magnetic field effective at the measuring space, must be adjusted as well.
Now, the amplitude of the magnetic high-frequency field is not simply proportional to the amplitude of the high-frequency excitation current within the coil. Rather, the amplitude of the magnetic high-frequency field additionally depends on the degree of loading of the high-frequency resonant circuit. If, for example, one and the same high-frequency coil is to be used for examining a very little or very thin patient on the one hand and a large or very fat patient on the other hand, then the so-called filling factor will change due to the fact that the patient's tissue leads to both dielectric losses and magnetic losses as a result of eddy currents generated the patient. In addition, the loading of the high-frequency resonance circuit may vary when the very little or thin patient, or the respective part of a patient's body does not take up the whole space within the coil and when the position of the test object in the coil is not exactly defined.
In all these cases, absolutely undefined conditions are encountered regarding the interdependence of the effective high-frequency magnetic field and the high-frequency excitation current so that it is by no means possible to achieve calibrated conditions with regard to the high-frequency fields strength by adjusting the excitation current.
It must be additionally taken into account that many countries have enacted legislations prescribing limits for the maximum permissible exposure of the human body to high-frequency radiation. In the U.S., for example, the competent FDA has promulgated standards defining a threshold value of 0.4 W of effective high-frequency power per kilogram of weight of the patient's body within the sample space.
It is, therefore, necessary not only for signal-maximizing purposes, but also in the interest of a patient's safety, to calibrate, i.e. to adjust in a reproducible manner, the effective high-frequency field strength, i.e. the amplitude of the high-frequency magnetic field.
With conventional nuclear magnetic resonance tomographs, this is achieved by initially carrying out NMR measurements with an arbitrarily adjusted amplitude of magnetic high-frequency field, with the sample space loaded, i.e. with the patient in place in the tomograph. The tomograph operator then observes the free induction decay (FID) signal on a CRT screen varying in response to the amplitude of the high-frequency magnetic field which is conventionally adjusted manually. The operator then tries--by trial and error, i.e. by varying the amplitude arbitrarily--to find the point where the FID signal reaches its maximum because a further increase of the amplitude (always related to a constant pulse length) would lead to the flip angle of, for example, 90° being exceeded, and then the signal amplitude would drop again as soon as the flip angle exceeds 90°.
This conventional empirical method is, however, subject to a number of drawbacks:
First, this adjustment procedure is extremely time consuming as several scans have to be observed if a reliable assessment of the FID signal is to be made so that one has to wait 5 to 10 seconds, for example, per test measurement. In practice, this has the effect that at the end of this waiting period the user may have forgotten the measuring value previously adjusted; or else an impatient operator of the tomograph may not wait for the full period, but decide to repeat the measurements in quicker sequence, in which case numerous errors may slip in, for example due to dynamic effects of nuclear magnetic resonants.
In addition, considerable errors may result when the maximum of the FID signal to be found is not clearly defined. If, for example, a 180° is to be determined via the maximum of the echo signal, then a corresponding maximum echo signal will be encountered also at 540°, i.e. generally at a flip angle equal to 2n-1 times the desired flip angle. Consequently, it may well happen that the operator of a tomograph adjusts a 540° pulse instead of a 180° pulse without becoming aware of his error. However, a 540° pulse, as compared with a 180° pulse means that the high-frequency magnetic field strength is exceeded by a factor of 3.
Erroneous adjustments of the type mentioned before are well possible in practice because the high-frequency power output of NMR tomographs has to be rated such that both very small objects under tests (small children) and very large objects under test (fat adult patients) may be examined. While in the first mentioned case, for example, a high-frequency power of 100 W would be sufficient, a high-frequency power of 2000 W may be required in the second mentioned case. Given this power reserve, there is, however, the risk that when examining a small test object a high high-frequency power and, thus, a flip angle of a higher order, with the correspondingly high and possibly even dangerous high-frequency power is set by an unexperienced or careless operator.
Now, it is an object of the present invention to improve a nuclear magnetic resonance tomograph such that the high frequency field strength can be standardized or calibrated, even for a low-frequency power, without the necessity to carry out nuclear resonance measurements, so that any damage to the patients can be definitely excluded.
SUMMARY OF THE INVENTION
The shortcomings illustrated by the related art are addressed by the nuclear magnetic resonance tomograph of this invention. The advantageous operation of the present invention is afforded by provision of
a magnet surrounding a measuring space for receiving an object under test;
a coil for generating a high-frequency magnetic field within said measuring space;
a transmitter for generating a high-frequency current, said transmitter comprising means for adjusting an amplitude of said current;
connection means for interconnecting said transmitter and said coil;
high-frequency magnetic field sensor means arranged at a predetermined calibration location outside said measuring space for measuring said high-frequency magnetic field at said predetermined calibration location; and
control means connected with an input thereof to said sensor means and with an output thereof to said means for adjusting to set said high-frequency current amplitude in dependency of said measured high-frequency magnetic field.
In particular, the control means shall comprise:
first means for setting a first high-frequency current of a predetermined first amplitude value;
second means for receiving a first sensor signal from said sensor means corresponding to a first high-frequency magnetic field value as a response to said first high-frequency current;
third means for extrapolating said first high-frequency magnetic field value to a second high-frequency magnetic field value by multiplication with a given constant reflecting a constant first ratio between high-frequency magnetic field strength values within said measuring space and at said predetermined calibration location for said coil;
fourth means for establishing a second ratio between said second high-frequency magnetic field value and said first high-frequency current amplitude value;
fifth means for calculating a second high frequency current amplitude value from said second ratio and a desired third high-frequency magnetic field value to be established within said measuring space; and
sixth means for setting said second high-frequency current amplitude value as an output of said transmitter.
Thus, the invention opens up numerous possibilities of carrying out nuclear magnetic resonants tomography measurements. For example, it is possible with the invention to run a mere calibration program the results of which being used for adjusting the nuclear magnetic resonance tomograph. Or else the invention may be used for controlling the high-frequency field strength continuously, in which case the before-described calibration program is caused to run automatically, and is used for the continuous adjustment and, if necessary, readjustment of the high-frequency field strength, without any need for the operator of the tomograph to start a calibration program manually before every new run. Finally, the invention opens up the possibility to provide a safety circuit which will detect the presence of an excessively strong high-frequency magnetic field and activate a corresponding emergency cut-off arrangement in the event a malfunction in the high-frequency transmitter circuit should occur.
For this purpose, the amplifier of the device according to the invention may, preferably, be adjustable as regards its amplification factor, and an amplification control input of the amplifier may be connected to an automatic control which has its input connected to the measuring coil.
Further, the input of the amplifier may be connected selectively to a nuclear resonance pulse generator or to a calibrated high-frequency generator so that a calibration program and a measuring program may be run either automatically, as described above, or manually.
Finally, the alarm device may be implemented in the described application by connecting the measuring coil to an automatic control provided with an alarm output.
A particularly preferred embodiment of the tomograph according to this invention employs a measuring coil for measuring the high-frequency field strength which is arranged outside the measuring space, in a toroidal space between a cylindrical inner wall and a cylindrical outer wall of a hollow-cylindrical strip resonator.
These measures provide the advantage that the measuring coil may be optimized, regarding its location, and can then be fixed in this optimized position, without the measuring sequence being disturbed in any way by this procedure, the toroidal space being anyway inaccessible for the object under investigation.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a very schematic overall view of a nuclear magnetic resonance tomograph illustrating the invention;
FIG. 2 shows a diagram illustrating the proportionality of the high-frequency field strengths inside and outside the measuring space of a high-frequency coil used within the tomograph of FIG. 1;
FIG. 3 shows another diagram illustrating the proportionality between the high-frequency field strength in the measuring space and the excitation current, as a function of the filling factor;
FIG. 4 shows a perspective view, partly cut open, of a probe head of the type preferably used in a tomograph according to the invention; and
FIG. 5 shows a radial section through the probe head illustrated in FIG. 4.
DESCRIPTION OF THE INVENTION
In FIG. 1, a nuclear magnetic resonance tomograph is indicated generally by reference numeral 10. The tomograph 10 comprises a magnet 11 of high field strength and high homogeneity. The magnet 11 may be a normally conductive or a superconductive magnet. The magnet 11 defines a longitudinal axis z and an axis Y extending perpendicularly thereto.
A patient 12 has been introduced into the magnet 11 in the direction of the z axis. The patient 12 is further surrounded by a rf coil 13 defining the measuring space for the patient 12. In addition, the interior of the magnet 11 contains gradient coils which are, however, not shown in FIG. 1 for the sake of clarity and which, besides, are generally known to the person of ordinary skill.
The rf coil 13 is fed via a rf line 14 from an amplifier 15 which has its input connected to a pulse generator 16 of usual design. The pulse generator 16 is capable of generating pulse programs, i.e. sequences of keyed rf signals where 90° and 180° pulses, for example, are linked to form conventional pulse programs. This, too, has been known before so that there is no need to explain it here once more.
Now, contrary to the known nuclear spin tomographs, the device according to the invention comprises at least one measuring coil 17 or 17' located outside the measuring space. The at least one measuring coil 17 is connected via a measuring line 18 to a measuring input 20 of an automatic control 19, while a reference input 21 of the automatic control 19 is connected to a calibrating voltage U c . The output of the automatic control 19 is connected to an amplification control input of the amplifier 15 which is adjustable as regards its amplification factor.
Another input of the amplifier 15 is connected to a rf generator 22 whose output is provided with a push-button 23.
Finally, the automatic control 19 is provided with an alarm output connection 25.
The operation of the device illustrated in FIG. 1 will now be described in more detail by way of the diagrams of FIGS. 2 and 3.
In normal operation of the nuclear resonance unit, the input of the amplifier 15 is connected to the pulse generator 16. The amplifier 15 sends a rf current I into the rf coil 13, via the rf line 14. As a result of the pulse program, a measuring current I m is supplied into the rf coil 13 in the described operating mode, when the keyed pulses are applied.
Consequently, the rf coil 13 generates a rf magnetic field with the field strength H 1 extending substantially in the y direction, as indicated in FIG. 1.
The rf coil 13 is loaded electrically by the patient 12 whose body tissue causes both dielectric losses and magnetic losses, due to eddy currents encountered. So, even if the value of the measuring current I m were measured, this would still be no measure of the active rf field strength H 1 as the quality of the rf coil 13 may vary within very broad limits, i.e. between Q=200 when the coil is largely unloaded or loaded by a very small patient 12, and Q=20 when the coil is heavily loaded by a patient 12 of high weight.
Now, in order to enable the rf field strength H 1 to be adjusted in a calibrated, i.e. reproducible manner, one first carries out a calibration measurement. This is done with the pulse generator 16 switched off. Instead, the amplifier 15 is controlled by the rf generator 22 whose frequency corresponds to the basic frequency of the pulse generator 16. By actuating the push-button 23, one then feeds a calibration current I c into the rf coil 13, via the rf line 14. This calibration current leads to a first rf field strength H 11 which, in principle, may be very low as this rf field strength is not intended to excite nuclear resonances in the patient 12.
The field lines produced in this manner also pass through the at least one measuring coil 17, with a field strength H p1 , which usually differs from the active rf field strength H 11 , the measuring coil 17 being located outside the measuring space.
The rf field strength H p1 passes through the measuring coil 17 and induces in the latter a measuring voltage which can be tapped via the measuring line 18.
Now, it can be determined for any kind of rf coil 13 by suitable laboratory measurements that the field strength H p in a measuring coil 17 arranged at any suitable position is proportional to the active field strength H 1 in the measuring space, and this largely independently of the degree in which the rf coil 13 is loaded by different test objects. This is as true for different space factors as for different positions which smaller test objects may assume inside the rf coil 13, so that hereafter the term "space factor" will be used for all these effects.
To say it in other words, this means that every object which is introduced into the rf coil 13 has the same effect on the active rf field strength H 1 and the field strength H p acting in the measuring coil 17, irrespective of its size or position.
On the other hand, it is also known for a given rf coil 13 that the active rf field strength varies in proportional relation to the rf excitation current when the test object remains unchanged, i.e. the space factor remains constant.
FIG. 2 now shows a straight line 30 representing the proportional relationship between the active rf field strength H 1 and the field strength H p measured in the measuring coil 17. The straight line 30 is a system constant and can be determined in the laboratory in advance, in the described way, for any given rf coil 13.
If, during the before-described calibration program, the known output signal of the rf generator 22 is applied momentarily to the rf coil 13, via the amplifier 15, i.e. when the rf current is adjusted to a calibrated value I c and a rf field strength H p1 is subsequently determined in the measuring coil 17, then the calibration point 31 on the straight line 30, pertaining to the field strength H p1 , leads to a rf field strength H 11 active in the measuring space.
This field strength H 11 , therefore, is the rf field strength active in the measuring space when the calibrating current I c is active as the rf excitation current.
FIG. 3 shows in this connection a diagram illustrating the dependence between the active rf field strength H 1 and the rf current I applied at any time, as a function of the space factor η. As has been mentioned before, H 1 and I show a proportional behavior, relative to each other, but their proportionality constant, i.e. the steepness of the straight line of the bundle of lines 35 in FIG. 3, is determined by the space factor η.
On the other hand, one has a measuring point in the diagram of FIG. 3 thanks to the before-described calibration program, i.e. the calibration point 36, the latter being defined by the calibration current I c and the active rf field strength H 11 determined on the basis of FIG. 2. The calibration point 36, therefore, determines the straight line 37 from among the bundle of lines 35 and, thus, the space factor η 11 prevailing at any time.
This completes the calibration process because the relationships between the active rf field strength H 1 and the rf excitation current I are now defined for the particular application or the particular patient 12 or, to say it in terms of physics, the particular space factor η 11 .
If, for example, one intends to adjust an active rf field strength H 12 which corresponds exactly to a flip angle of 90° or 180° for a given pulse length, then one only has to determine the matching rf measuring current I m by means of the straight line 37, as illustrated by the measuring point 38 in FIG. 3.
Given the described proportionality, it is, however, also possible to simply determine the relation H 12 /H 11 and to adjust the measuring current I m to the corresponding multiple of the calibrating current I c .
Regarding the block diagram of FIG. 1, this can be effected via the automatic control 19 whose reference input 21 is supplied with the calibrating voltage U c , while its measuring input 20 is supplied with the measuring voltage of the measuring coil 17. The measuring voltage U c represents the calibrating current I c so that the dependence ratio between the rf field strength H 1 and the rf current I given at any time can be determined by deriving the ratio or difference between the signals obtained at the inputs 20, 21, in combination with the known straight line 30 of FIG. 2. This proportionality, or the steepness of the straight line of the bundle of lines 35 in FIG. 3, can now be translated into an amplification factor for the amplifier 15 so that the output signal of the pulse generator 16, which has a predetermined amplitude, is translated into a measuring current I m adapted to the space factor η prevailing at any time, in response to this steepness or to the amplification factor.
If the nuclear spin tomograph 10 is to be calibrated with the patient 12 located in the measuring space, it is, thus, only necessary to actuate the push-button 23 momentarily, with the pulse generator switched off, in order to adjust the automatic control and/or the amplifier 15 as required. Once the pulse generator 16 has been switched on, its output can be set to a signal amplitude which exactly leads to the desired 90° or 180° pulse for the calibrated amplification factor of the amplifier 15.
During operation of the nuclear resonance measuring process, the automatic control 19 may perform an alarm function. This can be achieved by measuring the rf field active during the nuclear resonance measurement, using the measuring coil 17, and comparing the rf field so measured with an admissible limit value via the reference input 21. When the limit value is exceeded, the alarm output 25 is activated which may lead, for example, to the amplifier 15 being switched off.
The measuring coil 17 may be arranged at different locations, relative to the rf coil 13. It has been mentioned before that the respective position of the measuring coil 17 may be optimized empirically so that the straight line 30 in FIG. 2 can be determined and will then be valid for all loading conditions of the rf coil 1 3 It has been found in practical tests that the proportionality, i.e. the steepness of the straight line 30 in FIG. 2, is in fact slightly dependent on the space factor of the rf coil 13, but these variations are substantially less important than the errors encountered in practical operation of today's nuclear spin tomographs 10 as a result of inaccurate adjustments.
There is also the possibility to provide more than one measuring coils 17, 17' whose output signals are then combined to form a total signal, for example by forming the mean value thereof.
FIGS. 4 and 5 now illustrate a particular arrangement of the measuring coil 17 by way of example, which is however by no means meant to limit the invention.
FIGS. 4 and 5 show a substantially hollow-cylindrical resonator 40 whose cylindrical outer wall 41 and whose end walls 42 are closed for rf currents, While the cylindrical inner wall 43 is subdivided in the axial direction into conductive strips 44 and non-conductive slots 45. In FIG. 5, additional coupling elements 46a and 46b can be seen which are arranged in diametrically opposite positions in the toroidal space between the walls 41 and 43.
The resonator 40 is illustrated in FIGS. 4 and 5 very diagrammatically; additional details can be seen in DE-A-35 22 401. The reader is insofar referred to the disclosure content of that publication.
In FIG. 5, reference numeral 50 designates field lines of the rf magnetic field which extend through the measuring space in the cylindrical inner wall 43 largely homogeneously in radial direction relative to the longitudinal axis of the resonator 40.
Possible positions for the measuring coil 17 are designated by reference numeral 51. As can be seen best in FIG. 4, the measuring coil 17 consists, preferably, of a rod 52 extending in axial direction and carrying a wire loop 43 at its lower end, in the area of the space between the walls 41 and 43. The wire loop 43 is connected to the outside via supply lines 54 which lead to a measuring line 18.
In FIGS. 4 and 5, α designates a circumferential angle by which the positions 51 can be displaced relative to a longitudinal center plane extending perpendicularly to the plane of the coupling elements 46. In addition, the depth of penetration of the wire loop 53 into the space between the walls 41 and 43 is designated by z in FIG. 4.
By varying α and z, it is now possible to find the optimum position 51, with respect to azimuth (α) and depth (z). In this context, the optimum position is the one with the least possible dependence of the proportionality between H 1 and H p on the space factor η.
Practical tests have shown for a resonator 40 of the type illustrated in FIGS. 4 and 5 that an optimum position 51 is reached at a value α=45° and a depth z equal to approximately half the axial length of the resonator 40.
Further, it has been found that the optimum position so found is then valid for all units of a particular class of resonators 40, as used in practice for a given type of examinations. For, in practice a big resonator resonator 40 will be used for whole-body measurements, while another, smaller resonator will be used for head measurements, and a third, even smaller resonator will be used for measurements on limbs or small experimental animals. The described optimum position can be determined for each such type of resonators and will then be valid with reasonable accuracy for any space factor, and even for varying positions of the test object in the measuring space. | A nuclear magnetic resonance tomograph comprises a magnet surrounding a measuring space for receiving an object under test, e.g. a human body. A coil is provided for generating a high-frequency magnetic field within the measuring space. The coil is fed by a transmitter comprising a stage for adjusting the amplitude of a high-frequency current generated by the transmitter. A high-frequency magnetic field sensor is arranged at a predetermined calibration location outside the measuring space for measuring the high-frequency magnetic field strength prevailing at the predetermined calibration location. For calibrating the high-frequency magnetic field strength during a tomography measurement, the coil with the object under test inside is subjected to a test current and the resulting high-frequency magnetic field amplitude is sensed. From the value of the test current and the sensed high-frequency magnetic field strength one can calculate a measuring current to be fed into the coil for generating a desired high-frequency magnetic field strength within the measuring space. | 6 |
This invention relates to cable transportation systems, and more particularly to a sheave train assembly for supporting the haul cable of a cable transportation system, such as used to transport skiers by chair lift, gondola or the like.
BACKGROUND & SUMMARY OF INVENTION
Various cable transportation systems, such as chair lifts, gondola lifts, etc. are used to transport skiers from the bottom to the top of a ski run. Such lift apparatus typically comprises spaced tower structures having sheave train assemblies mounted thereon with multiple sheave units for engaging a movable endless haul cable which is driven by suitable drive means at the top and/or bottom of the ski lift. Some sheave units supportively engage the bottom of the cable and other sheave units may depressively engage the top of the cable. Passenger carrying devices such as chairs, gondolas and the like are suitably connected to the haul cable for movement between the bottom and top of the ski run. Such cable transportation systems are often operated in extreme low temperature weather conditions.
In general, the prior art sheave train assemblies comprise a plurality of rotatable sheave members which are rotatably mounted on associated support shaft members by bearing devices with associated lubrication apparatus. Typical sheave train assemblies may comprise 4, 6 or 8 sheave members. Pairs of the sheave members and sheave support shaft members are mounted on opposite ends of sheave support rocker arm apparatus pivotally movable about a central pivot axis. Pairs of the sheave support rocker arm apparatus are pivotally mounted on opposite ends of intermediate pivotal rocker arms which, in turn, may be mounted on a central main pivotal rocker arm. Each rocker arm is pivotally supported by central axle apparatus including grease-type lubrication apparatus. The central axle apparatus comprises a hub member rotatably mounted on a shaft member by axially spaced sleeve-type metallic bearing members with an annular grease chamber therebetween. In order to lubricate the axle assemblies, maintenance personnel must climb the lift towers which is a difficult, laborious procedure. In use, the rocker arm members ordinarily are subject to only very limited pivotal movement of no more than about 10° to 20°. Thus, the lubrication may not be uniformly applied to the entire circumference of the parts subject to relative rotation. Other problems with current apparatus are vibrations and noise created by relative movement between various parts and lack of cushioning between such parts.
A primary object of the present invention is to provide sheave train assembly which requires minimum lubrication with increased durability and decreased wear.
Another object of the invention is to also provide cushioning and vibration dampening means.
Another object of the invention is to reduce cost of construction and maintenance and repair.
In general, the objects of the present invention have been achieved by use of an elastomeric bushing means to couple relatively movable parts without use of lubricant. Each elastomeric bushing means comprise an elastomeric sleeve member mounted in compression in an annular chamber between an outer metallic sleeve member and an inner metallic sleeve member in a manner which enables limited relative arcuate torsional movement therebetween while also absorbing vibration and shock loads and reducing operational noise.
BRIEF DESCRIPTION OF THE DRAWINGS
Illustrative and presently preferred embodiments of the invention are hereinafter described and shown in the accompanying drawings wherein:
FIG. 1 is a schematic plan view of a sheave train assembly;
FIG. 2 is a longitudinal cross-sectional view of a bushing for use with the sheave train assembly;
FIG. 3 is a cross-sectional view of one form of a bearing assembly for rotatably supporting a pulley on a support shaft;
FIG. 4 shows a main rocker arm hub assembly;
FIG. 5 shows another main rocker arm hub assembly and an intermediate rocker arm hub assembly;
FIG. 5A is a cross-sectional view of a main rocker arm hub assembly;
FIG. 5B is a cross-sectional view of an intermediate rocker arm assembly;
FIG. 6 shows an intermediate rocker arm hub assembly;
FIG. 7 shows another intermediate rocker arm hub assembly;
FIG. 8 shows a sheave hub assembly; and
FIG. 8A shows a cross-sectional view of a sheave hub assembly.
DETAILED DESCRIPTION
FIG. 1 shows a conventional sheave train assembly 20 comprising a main central rocker arm means 22 pivotally supported on a main axle means 24 which is fixedly mounted on tower support structure 26. Intermediate rocker arm means 28, 30 are pivotally supported on intermediate axle means 32, 34 mounted on the opposite end portions of central rocker arm means 22. Sheave support rocker arm means 36, 37, 38, 39 (partially shown) are pivotally supported on axle means 40, 41, 42, 43, mounted on opposite end portions of intermediate rocker arm means 28, 30. Sheave means 44, 45, 46, 47, 48, 49, 50, 51 (partially shown) are rotatably mounted on shaft means 52, 53, 54, 55, 56, 57, 58, 59 fixed on opposite ends of sheave support arm means 36-39. Each of the sheave means is rotatable about its associated shaft means 52-59. Each of the pair of sheave means (eg. 44, 45) on each sheave support rocker arm means (eg. 36) are independently oppositely movable about the associated axle means (eg. 41). Each set of the four sheave means 44, 45, 46, 47 and 48, 49, 50, 51 on opposite ends of intermediate rocker arm means 28 and 30 are oppositely movable about the associated axle means 32, 34 which are also oppositely movable about central main axle means 24.
FIG. 2 shows an elastomeric bushing means 70 which is used in the present invention to mount the rocker arm means on the associated rocker arm axle means and to mount the sheave means on the associate sheave shaft means. In general, the bushing means comprises an annular inner rigid metallic sleeve member 72, an annular outer metallic rigid sleeve member 74, and an intermediate annular connecting member 76 made of elastomeric material. Inner sleeve member 72 is longer than outer sleeve member 74 to provide axially offset abutment surfaces 78, 80 whereby the inner sleeve member may be fixedly held relative to a support member to enable the outer sleeve member to turn relative to the inner sleeve member. The intermediate elastomeric sleeve member 76 is compressibly fixedly mounted on and retained between the surfaces 82, 84 and enables relative resilient displacement between the inner and outer sleeve members 72, 74 under torsional load. Bushing units of this type are of conventional design and commercially available from various sources such as from Metalastik Co. and Paulstra. Technical specifications are attached hereto and incorporated hereby by reference as Exhibit A and Exhibit B.
Presently commercially available bushing units of this type are available in various sizes with various compositions of elastomeric material which provide varying characteristics. Torsional displacement characteristics may vary from 8° to 35° degrees of relative angular deflection. For use in connection with the present invention angular deflection of 7 to 15 degrees should be sufficient. Radial load characteristics of available bushing units vary from a rate of 1600 to 350,000 or more pounds/inch; maximum load of 72 to 19,000 pounds; and maximum deflection of 0.018 to 0.075 inch or more. Type maximum angle of axial tilt varies from 1 degree to approximately 7°. In use in the present invention, a minimum angle of axial tilt is desired to maintain a substantially steady state parallel axes of rotation. In the present invention, the preferred characteristics of the bushing units are torsion twist angles of 7° to 15° and axial tilt angles of no more than 1° to 2°. The bushing unit should provide only limited relative longitudinal tiling movement of the outer sleeve member relative to the inner sleeve member about a central pivotal axis at an angle of less than 3°. The intermediate elastomeric material enables the desired amount of relative movement, while also dampening vibration and sound, and also eliminates the need for lubrication.
FIG. 3 shows one form of a hub assembly comprising an inner sleeve means 140 mounted on a bolt member 141; an outer support sleeve means 142; and a pair of oppositely spaced elongated elastomeric bushing units 144, 146. Inner sleeve means 140 comprises a rigid metallic sleeve member with a central bore 148, a central enlarged diameter hub portion 150, and elongated reduced diameter end portions 152, 154. Hub portion 150 provides annular radially extending shoulders 156, 158. Outer support sleeve means 142 comprises a rigid sleeve member 160 made of metallic material and having a central bore 161 and reduced diameter end portions 162, 163 providing annular shoulders 164, 165. The diameter of bore 161 is larger than the outside diameter of central portion 150 to provide an annular chamber 166 therebetween, and larger than the outside diameter of end portions 152, 154 to provide elongated annular bushing chamber 167, 168 therebetween. Each of the bushing means 144, 146 comprise a rigid inner sleeve member 172 fixed to end portions 152, 154, a rigid outer sleeve member 174 fixed to member 160, and an elastomeric member 176.
FIG. 4 shows a main rocker arm hub assembly comprising a shaft member 200 having an end portion 202 fixedly mounted in the tower structure 204 by suitable bolt devices 205, 206. A bushing unit 208 is mounted between shaft end portion 210 and a support sleeve member 212 fixedly connected to main rocker arm member 214. An end plate 216 and bolt devices 217, 218 retain the bushing unit 208 and the support sleeve 212 on shaft portion 210 with inner bushing sleeve member 221 held against a collar device 220. Outer bushing sleeve member 222 is fixedly mounted in support sleeve member 212. Elastomeric member 224 connects the inner and outer sleeve members 221, 222 as previously described.
FIG. 5 shows another main rocker arm hub assembly 230 and an intermediate rocker arm sub-assembly 232. The rocker arm hub assembly 230 comprises a shaft member 234 having an end portion 235 fixedly mounted on tower structure 236 by suitable bolt devices 237, 238. A bushing unit 240 is mounted on shaft end portion 242 and supports a sleeve member 244 fixedly connected to plate members 245, 246 of main rocker arm 248. Retainer plate member 250 and bolt devices 251, 252 retain the bushing unit 240 and the sleeve member 244 on shaft end portion 242 against collar means 254. As shown in FIG. 5A, bushing unit 240 comprises an outer sleeve member 255 fixed in sleeve member 244, an inner sleeve member 256 with opposite end portions 257, 258 fixedly abuttingly engaging plate 250 and collar means 254, and an elastomeric member 259.
The intermediate rocker arm hub assembly 232 comprises a bolt member 260 extending between and fixed to side plate members 261, 262 of the intermediate rocker arm assembly. A resilient coupling bushing unit 264 is mounted on bolt member 260 and supports a sleeve member 266 with end flanges 267, 268. A hub member 270 is mounted on sleeve member 266 and has a cable derail flange portion 272. As shown in FIG. 5B, bushing unit 264 comprises an outer sleeve member 274 fixed in sleeve member 266, an inner sleeve member 275 with opposite end portions 276, 277 fixedly abutting side plate members 261, 262 and an elastomeric intermediate connecting member 278.
FIG. 6 shows an intermediate rocker arm hub assembly 280 comprising a shaft member 281 with an enlarged diameter end portion 282 mounted in a sleeve member 283 in the main rocker arm member 284. A resilient bushing unit 286 is mounted on reduced diameter shaft end portion 288 and supports a sleeve member 289 extending between and fixedly connected to side plate members 290, 291. A retainer plate member 292 and suitable bolt devices 293 hold the assembly on the shaft member 281. Bushing unit 286 has an inner sleeve member 294 with opposite end portions 295, 296 fixedly abuttingly engaged with a shaft shoulder portion 297 and plate 292. Outer sleeve member 298 is fixedly mounted in member 289 and is resiliently movably supported by the intermediate elastomeric member 299 as previously described.
FIG. 7 shows an intermediate rocker arm hub assembly 300 including a cable derail catch device 302 having a hub portion 303 fixed to an outer sleeve member 304 connected to rocker arm plate members 306, 308. The construction and arrangement is otherwise similar to that of FIG. 6 with a bushing unit 310 mounted on shaft portion 288.
FIGS. 8 and 8A show a sheave hub assembly 320 comprising a bolt member 322 extending between and fixedly connected to side plate members 324, 325 of a sheave rocker arm. A resilient coupling bushing means 326 is mounted on the bolt member and extends between the plate members 324, 325. Bushing means 326 comprises an inner sleeve member 327, an outer sleeve member 328, and an elastomeric intermediate connecting member 329. The inner sleeve member 327 is fixedly clamped between the plate members 324, 325 by the bolt member. Bearing units 330, 331 are mounted on the outer sleeve member 328 of the bushing means by washer members 332, 333 and rotatably support hub portion 334 of the sheave 335 which is of conventional construction and engages a cable 336. In this case, the bushing means 326 serves as a sound and vibration dampening means which isolates the sheave and the bearings from the support shaft provided by the bolt member 322.
In general, during assembly, the bushing unit is press-fitted into the hub member so that outer sleeve member is fixed relative thereto. In the embodiments of FIGS. 4 and 5A, an abutment collar member is mounted on the shaft shoulder in fixed abutting engagement with the inner end portion of inner sleeve member which slides over the shaft end portion. In the embodiments of FIGS. 6 and 7, the inner sleeve member abuts a shoulder on the shaft. In the embodiments of FIGS. 5B and 8A, the inner sleeve abuts the side surfaces of the place members. In the embodiments of FIGS. 4, 5A and 6, an end plate member is bolted onto the shaft and is held in fixed abutting engagement with the outer end portion of inner sleeve member by the bolt members. The collar member and the plate member are held in axially spaced relationship from the adjacent end portions of the elastomeric member, the outer sleeve member and the hub member.
It is contemplated that the inventive concepts herein described may be variously otherwise embodied and it is intended that the appended claims be construed to include the alternative embodiments of the invention except insofar a limited by the prior art. | A sheave support system for supporting the sheaves of a multiple sheave assembly relative to a support structure, such as a ski lift tower, which comprises at least two sheave members rotatably mounted on the sheave assembly in spaced parallel relationship for supporting the ski lift cable; at least one main support shaft for movably supporting the sheave assembly relative to the ski lift tower; at least two intermediate support arms mounted on the main support shaft; and at least two intermediate support shafts mounted on opposite ends of the intermediate support arm for rotatably supporting the sheave. The support shaft means comprises a support shaft, a hub member mounted circumjacent the support shaft, and an elastic bushing device mounted between the support shaft and the hub member for connecting the hub member to the shaft member while enabling limited relative rotative movement therebetween of less than approximately 15 degrees and also limiting transmission of vibration therebetween. | 1 |
CROSS-REFERENCE TO RELATED APPLICATION
This application is a National Phase Patent Application of International Application Number PCT/DE01/04380, filed on Nov. 16, 2001, which claims priority of German Patent Application Number 100 57 007.0, filed Nov. 17, 2000.
BACKGROUND OF THE INVENTION
The invention relates to a lock system with a function controlling mechanism for controlling the lock states “unlocked”, “locked” and where applicable “theft-secured” as well as “child lock”, which is characterised by very short times for controlling the desired locking states and good suitability to various requirements with regard to construction space and functionality.
In the case of motor vehicles having a so-called passive-entry function in which the locking of the lock is carried out not by a key but by an interrogation as to authorised status initiated by operating the external door opener followed by motorised unlocking of the lock, it may not be possible for the door to be opened immediately because the lock cannot be unlocked quickly enough. It is indeed fundamentally possible to shorten the operating time of the lock by using more powerful and faster drives but this involves a greater expense of materials and thus higher costs.
DE 196 27 246 A1 provides a motor vehicle door lock which can occupy different function positions. By means of a lift magnet, additional security is provided whereby the lift magnet at the same time serves for rapid release of the lock wherein the locking elements of the lock are moved from the “theft-proof” state to the “unlocked” state. The lift magnet is controlled by actuating the external door opener and in the shortest possible time produces a closed force chain for transferring the operating force whereby the elements moved by the lift magnet are part of the force chain.
This approach has the drawback that the lift magnet has to be made relatively powerful in order to be able to ensure a sufficiently fast movement of the masses which are to be moved. This involves large structural sizes inconsistent with a space-saving compact design.
SUMMARY OF THE INVENTION
An object of the invention is a lock system with a function controlling mechanism, more particularly a function controlling mechanism with a passive entry function whose switch times, when changing between two functioning positions, are shortened to an extent which is not significant in the operation of the lock system and without having to increase the cost of the drive.
Advantageously the function controlling mechanism forms a simple compact functionally reliable structural unit which can be combined with electric and electronic components as necessary and readily integrated into different vehicle locking systems.
According to an aspect of the invention, all parts of the function controlling mechanism lie outside of the force flow between the operating element and the locking part so that the switch processes are not influenced by the masses which have to be moved. Furthermore the switch paths are kept very small.
In one aspect, at least one switch element (e.g. a points element) is advantageously provided which can be controlled by a drive and which, depending on its position, controls the movement of a coupling element on the operating element side which transfers the operating force, such that this coupling element enters into active relationship with a coupling element on the locking part side as necessary and transfers the positioning movement to the locking mechanism with the interposition of further elements (e.g. Bowden cable and/or lever mechanism). Operating element side and locking part side refer to sides of the function controlling mechanism, i.e. the lock system of the invention that the operating element and locking part are respectively connected to. The operating element or operating device may be an internal door opener or an external door opener. A lift magnet, a rotary magnet or a flap armature, which can switch back and forth between two end positions, can be used as the drive for the controllable switch element. Step motors or direct current motors with gears can also be used in other embodiments.
In order to provide the functional reliability of the switch processes, the involved elements are designed to preclude indeterminate intermediate positions. This is simply achieved through stops which the switch elements contact by means of the associated drive and which restrict the switch path of the switch element. The desired precision can however also be achieved by using bi-stable spring elements which advantageously jump over into one of two stable end positions.
In the case where guide tracks depict the displacement path of the coupling element on the operating element side, the one end position of the movable part (e.g. the points element) represents the establishment of the active connection for the purpose of transferring the operating force, and the other end position of the movable part represents the interruption of the active connection so that an operating force starting from a door opener cannot be transferred to the locking parts of the lock.
When using a guide track having at least one fork for the coupling element on the operating element side, the switch element which can be controlled between the two end positions, functions as the points element whereby a first fork leads the coupling element on the operating element side to engage with the coupling element on the locking part side and a second fork prevents engagement of the coupling elements.
The guide tracks for the various coupling elements on the operating element side can be formed in different ways, e.g. in the form of a slide path, a slot, a rail or the like in or on which the coupling element on the operating element side is guided with sliding action. The guide track can alternatively be formed as a transversely sliding or pivotal or limitedly rotatable rail or the like on which the coupling element disposed on the operating element side is guided whereby the transfer of the operating force can take place in one of the end positions of the rail.
In other embodiments, various different designs of the points switch elements may be used. Thus the points element can be mounted pivotal or rotatable relative to a base which supports or forms the guide track. When using a guide track which can be displaced in translation across its extension direction, the coupling element disposed on the operating element side is selectively moved to engage with the coupling element on the locking part side or it may be selectively moved so that such engagement is prevented.
Another structural variation for controlling the path of the coupling element disposed on the operating element side exists where the coupling element is mounted displaceable along a plane of adjustable incline whereby displacement of the coupling element disposed on the operating element side along the inclined or straight plane, prevents or produces its engagement on the coupling element on the locking part side. The conversion of the straight plane into an inclined plane can be carried out by swivelling a part mounted on a base or by sliding a preferably wedge-shaped part which after displacement releases the otherwise concealed inclined plane.
Another aspect of the invention provides that the coupling element disposed on the operating element side is guided along a transversally displaceable guide track whereby the displacement across the extension direction of the guide track selectively permits or prevents engagement of the coupling element disposed on the operating element side with the coupling element disposed on the locking part side.
In order to couple the operating forces which emanate from the door openers, a simple non-forked guide track may be provided for the operating element on the locking part side into which an operating lever connected to the coupling element on the lock side can be displaced so that the operating lever crosses the guide track and can enter into engagement with the coupling element. Moving the operating lever is likewise carried out by means of a drive which is activated through corresponding control commands or—in the case of emergency operation when the on-board electric supply fails—by actuating the locking cylinder,
In order to achieve the most compact construction possible for the function controlling mechanism, the force-transferring means, e.g. operating cable or operating rod linkage which are directly connected to the coupling elements disposed on the operating element side in the various embodiments, are mounted on the one side of a base plate or the like supporting the guide tracks whereas the means for force transfer connected to the coupling element on the locking part side are mounted on the other side of this base. The coupling elements disposed on the operating element side in the various embodiments, project sufficiently far beyond the base so that during their displacement along the guide track, an engagement can be produced with a part such as a pivotally mounted operating lever, connected to the coupling element on the locking part side. The device can be made more compactly and the cost of component parts considerably reduced through symmetrical construction of a part of the mechanical structural elements or function regions on the external door opener side and the internal door opener side. In one symmetric arrangement, the guide tracks for the coupling elements on the operating element side are positioned so that the transfer of the operating force to the coupling element on the lock side can be undertaken by a common operating element.
In another embodiment, the component parts and function regions may be positioned in superposed planes.
For manually controlling the different switch states of the lock, the function controlling mechanism has a switch lever which is pivotally mounted in its middle region. Its ends may include stops which are connected to followers of the control rod linkage which is connected to the drives. Between the pivotal axis of the switch lever and one of its ends, a force transfer element (e.g. cable) engages which is connected to the locking cylinder of the vehicle door so that when the locking cylinder is actuated in the “OPENING” or “CLOSING” direction, the switch elements can be brought into the corresponding switch positions for the purpose of emergency opening or emergency closing.
A pivotal operating lever may be advantageously mounted on the same axis with its ends engaging with the coupling elements which are displaceable along the guide tracks when the lock is unlocked and an operating force is introduced through one of the door openers. The operating lever is thereby pivoted and transfers to a force transfer element on the lock side engaging at a distance from the pivotal axis a setting path which finally leads to opening of the lock.
Another aspect of the invention combines the function controlling mechanism with an electronic lock control which inter alia ensures the so-called passive entry function wherein an interrogation of the access authorisation is carried out through remote means and then the lock may be moved into the unlocked state. An antenna integrated into the lock control or its housing ensures a short signal transmission path. It is also advantageous to allocate directly to the electronic lock control sensors or micro switches which signal the actuation of a door handle.
The function controlling mechanism and the electronic lock control may form one structural unit. A synergy effect can be achieved in that the conductor plate of the electronic lock control simultaneously serves as a mechanical support for the structural elements or function regions of the function control mechanism.
In an exemplary embodiment, the drives can be fixed and simultaneously electrically contacted on a base such as the conductor plate. The same applies to the sensors which monitor the existing lock states, plugs and switches. Furthermore the conductor plate can also undertake purely mechanical tasks e.g. through integration of the guide tracks for the coupling elements on the operating element side and the bearing sites, or similarly for the points elements and the pivotal axes.
A compact highly integrated mechanical-electronic function controlling device of this kind forms a functionally reliable unit which can be manufactured cost-effectively and which can be pre-checked with regard to all of its functions.
BRIEF DESCRIPTION OF THE DRAWING
The invention will now be explained with reference to some embodiments and the accompanying drawings in which:
FIG. 1 is a perspective view of an exemplary function controlling mechanism of the present invention which includes two base plates and switch elements which are located in the “UNLOCKED” position;
FIG. 2 is a plan view of the exemplary function controlling mechanism according to FIG. 1 ;
FIG. 3 is a plan view of the exemplary function controlling mechanism according to FIG. 1 , but in the “ACTUATED” position controlled through the internal door opener;
FIG. 4 is a plan view of the exemplary function controlling mechanism according to FIG. 1 , but in the “LOCKED” position;
FIG. 5 is a plan view of the exemplary function controlling mechanism according to FIG. 1 ; but in the “EMERGENCY UNLOCKED” position controlled through the locking cylinder;
FIG. 6 is a plan view of the exemplary function controlling mechanism according to FIG. 1 ; but in the “EMERGENCY LOCKED” position controlled through the locking cylinder;
FIG. 7 is a plan view of the exemplary function controlling mechanism according to FIG. 1 ; but in the “CHILD LOCK” position;
FIG. 8 shows a plan view of the exemplary function controlling mechanism according to FIG. 1 ; but in the “THEFT SECURED” position;
FIG. 9 is a diagrammatic view of an aspect of the present invention, including an exemplary points switch for the guide tracks of the coupling elements on the operating element side with a switch element which is transversely displaceable;
FIG. 10 is a diagrammatic view of an aspect of the present invention, including an exemplary points switch for the guide tracks of the coupling elements on the operating element side with an electromagnetic flap armature;
FIG. 11 is a diagrammatic view illustrating the points switch principle with swivel mounted switch element for function control;
FIG. 12 is a diagrammatic view of an operating lever displaceable in the path of a simple guide track for function control;
FIG. 13 is a diagrammatic view of simple guide tracks transversely displaceable in the engagement area of the operating lever for function control;
FIG. 14 is a cross-sectional view through a region of the device shown in FIG. 13 ;
FIG. 15 is a cross-sectional view through a region of the function controlling mechanism having a pivotal guide plane for the coupling element on the operating element side for function control;
FIG. 16 is a cross-sectional view through a region of the function controlling mechanism with a displaceable wedge for the coupling element on the operating element side for function control;
FIG. 17 is a diagrammatic view of the embodiments shown in FIGS. 15 and 16 ;
FIG. 18 is a diagrammatic view illustrating the points switch principle by using a rotary armature or rotary magnet for function control;
FIG. 19 is a diagrammatic view of mirror-parallel arranged fork-like guide tracks;
FIG. 20 is a diagrammatic view of the upper of several planes of a function controlling mechanism having a fork-like guide track;
FIG. 21 is a cross-section through the planes of the mechanism shown in FIG. 20 ;
FIG. 22 is a diagrammatic view of mirror parallel fork-like guide tracks and a pair of switch levers;
FIG. 23 is a diagrammatic view of an axially symmetrical function controlling mechanism;
FIG. 24 is a diagrammatic side view of a motor vehicle door with function devices; and
FIG. 25 is a diagrammatic view of a cross-section through a vehicle door.
DETAILED DESCRIPTION
The embodiment of a function controlling mechanism, illustrated in different functioning positions in FIGS. 1 to 8 , has a lower base plate 2 ′ and an upper base plate 2 spaced therefrom and on which drives 1 a , 1 b are arranged in the form of lift magnets in opposite corner regions. In other exemplary embodiments, drives 1 a and 1 b for the function controlling mechanism may be formed of components other than lift magnets. Each lift magnet, i.e. drives 1 a , 1 b , has an axially displaceable coupling rod 10 a , 10 b whose distal ends engage in respective openings 121 a , 121 b of swivel mounted switch elements 12 a , 12 b . The switch elements 12 a , 12 b are supported by axes 120 a , 120 b on webs 23 a , 23 b which separate the parallel guide tracks 21 a , 21 b , 22 a , 22 b formed in the base plate 2 , from each other. Switch elements 12 a and 12 b include a pointed section that rotates to contact stops, and switch elements 12 a and 12 b may therefore be alternatively referred to as points-like switch elements 12 a , 12 b . The forked parallel guide tracks are combined in the neutral guide track 20 a , 20 b in which the coupling elements 30 , 40 on the operating element side are mounted when no setting movement emanates from the door openers. For example, parallel guide tracks 21 a and 22 a form a forked configuration as they combine in neutral guide track 20 a which accommodates coupling element 40 . FIG. 1 also illustrates stop 200 .
The Bowden tube ends 3 , 4 on the operating element side are supported on fixing blocks 3 a between the base plates 2 , 2 ′. Bowden tube end 3 may be for transferring the operating force of an external door opener, or Bowden tube end 4 may be for transferring the operating force of an internal door opener. The Bowden tube ends 5 , 6 which are connected to the lock or the locking cylinder are suspended in respective fixing blocks 5 a , 6 a above the base plate 2 . Also the base bodies 32 , 42 of the respective coupling elements 30 , 40 connected to cable pulleys 31 , 41 , respectively, are mounted between the two base plates 2 , 2 ′ and ensure that the ends of the coupling elements 30 , 40 projecting beyond the opposing side of the base plate 2 do not tilt on stopping against the operating lever 7 . Bowden tube end 5 may be a connector element for transferring operating force to locking parts of the lock, and Bowden tube end 6 may be a connector element for transferring operating force of the locking cylinder.
In FIGS. 1 and 2 the switch elements 12 a , 12 b are located in the “UNLOCKED” position, i.e. an operating force introduced through the Bowden tube ends 3 , 4 and the cable pulleys 31 , 41 from the external door opener or internal door opener (i.e. the operating element), can be transferred to the cable pulley 5 which is connected to the locking parts of the lock. For this purpose an operating lever 7 is pivotally mounted on the base plate 2 along axis 71 . Ends 7 a , 7 b of operating lever 7 cross the inner guide tracks 21 a , 21 b of the forked areas and thus are in the engagement region of the coupling elements 30 , 40 when the switch elements 12 a , 12 b bear against the stops 210 a , 210 b and thus release the change-overs from the neutral guide tracks 20 a , 20 b into the guide tracks 21 a , 21 b.
If, in this state, one of the two door openers is actuated, the coupling element 30 , 40 is moved towards the corresponding end 7 a , 7 b of the operating lever 7 , which swivels about its axis 71 . FIG. 3 shows a device actuated from the internal door operator, whose operating force is transferred via the Bowden tube end 4 and the cable pulley 41 to the coupling element 40 and causes the coupling element 40 to be displaced and to rotate the operating lever 7 . This results in a displacement of the cable pulley 51 , which is connected to the locking parts of the lock and which is engaged via a coupling element 50 with the operating lever 7 at a distance from the rotary axis 71 . The oblong hole 70 serves as compensation for the cable pulley when the locking parts of the lock are in the so-called pre-catch position or when the door is opened but not in the closing position.
In FIG. 4 —in comparison to FIG. 3 —the switch element 12 b was swivelled by the drive 1 b via the coupling rod 10 b towards the inner stop 220 b , such that the outer guide track 22 b is opened for the coupling element 30 , which is connected to the external door opener via the Bowden tube end 3 and the cable pulley 31 , but the inner guide track 21 b is blocked. On actuating the external door handle it thus does not lead to engagement of the coupling element 30 with the operating lever 7 while the lock can be further actuated through the internal door handle. This switching state is termed “LOCKED”.
In order to be able to ensure emergency operation of the lock in the event of failure of the on-board electric supply, a switching lever 8 is provided which is likewise pivotally mounted on the axis 71 and engages with a coupling element 60 which is in active connection through a cable pulley 61 or a rod linkage with a locking cylinder. FIG. 5 shows the “EMERGENCY UNLOCKED” position in which the switch elements 12 a , 12 b are located in the position already shown in FIG. 2 so that the door lock can be opened by both door handles, i.e. inner and outer door handles. In the event of emergency unlocking by rotating the locking cylinder, the coupling element 60 is pressed against the switch lever 8 by the sufficiently stiff cable pulley 61 , such that the switch lever 8 is pivoted. Stops at the ends 8 a , 8 b of the switch lever 8 thereby enter into engagement with followers 11 a , 11 b , which are attached to the coupling rod 10 a , 10 b , such that the switch elements 12 a , 12 b , which are connected to the respective coupling rods 10 a , 10 b , are moved in their unlocking position. If the function controlling mechanism has been in its “LOCKED” or “THEFT PROOF LOCKED” state prior to the emergency unlocking operation, the operation of the locking cylinder then causes the switch elements 12 a , 12 b to be pivoted against stops 210 a , 210 b.
FIG. 6 shows the function controlling mechanism in the “EMERGENCY LOCKED” state. This is reached by an operating movement of the locking cylinder in the opposite direction, which, via the cable pulley 61 , causes the switching lever 8 to be pivoted, such that the stop at the end 8 b of the switch lever 8 is pressed against the follower 11 b on the side of the external door opener and, by the displacement of the coupling rod 10 b , the switch element 12 b is pivoted against the inner stop 220 b . Thus the engagement of the coupling element 30 , which is connected to the external door opener via the Bowden tube end 3 and the cable pulley 31 , with the associated end 7 b of the operating lever 7 is prevented. For safety reasons this does not apply to the coupling element 40 on the side of the internal door opener, such that a person accidentally locked in the vehicle can free himself. Therefore, the stop at the end 8 a of the switch lever 8 is open on one side and forms only a stop for the follower 11 a for the emergency unlocking operation.
FIG. 7 shows the “CHILD LOCK” position, in which the coupling element 40 on the side of the internal door opener upon actuation is deflected by the switch element 12 a into the outer guide track 22 a , such that the coupling element cannot engage with the operating lever 7 to unlock the door. The coupling element 30 , at the same time, upon actuation by the outer door opener is deflected into the inner guide track 21 b and, thus, engages with the operating lever 7 to unlock the door.
In the “THEFT PROOF LOCKED” position of FIG. 8 , the inner guide tracks 21 a , 21 b are blocked by the switch elements 12 a , 12 b so that actuation of the lock is not possible either through the external door opener nor through the internal door opener. Changing over the switch elements 12 a , 12 b into the “UNLOCKED” state can—as already explained in connection with the previously described figures—take place by controlling the drives 1 a , 1 b or by operating the locking cylinder.
In various embodiments, base plate 2 can also be formed as a conductor plate of an electronic control unit. In particular electronic elements mounted between the base plates 2 , 2 ′ are particularly well protected from mechanical damage. The second base plate 2 ′ can also function as a conductor plate as necessary. Monitoring the locked state can advantageously be carried out by sensors which sense the actual pivotal position of the switch elements 12 a , 12 b . In one exemplary embodiment, magneto-resistive elements may be advantageously used because they are comparatively insensitive to external influences.
The diagrammatic illustration of FIG. 9 shows a neutral guide track 20 which is forked into two parallel guide tracks 21 , 22 and a rhomboid shaped switch element 12 which is displaceable across the guide tracks and which is controllable by a drive 1 through a coupling rod 10 .
In another exemplary embodiment, the path of the coupling elements 30 , 40 may be controlled on the operating element side along the forking guide tracks 20 , 21 , 22 as shown diagrammatically in FIG. 10 . A pivotally mounted flap armature 100 is selectively controlled by coils 1 ′, 1 ″ which are arranged in the forked area on opposite sides of the neutral guide track 20 and which move the flap armature 100 by generating suitable magnetic forces and hold flap armature 100 in the desired position. Coils 1 ′, 1 ″ may also be referred to as electromagnets. In the illustrated armature position, the engagement of the coupling element 30 , 40 on the operating lever 7 is provided. Swivel movement of operating lever 7 operates on the coupling rod 51 and is transferred into a push movement that is directed up to the door lock.
FIG. 11 shows once again a diagrammatic illustration of the construction of a function controlling mechanism with forking guide tracks 21 a , 21 b , 22 a , 22 b and swivel switch elements 12 a , 12 b which are movable through coupling rods 10 a , 10 b between two end positions. Features and working principles of FIG. 11 are as described in conjunction with the embodiments of FIGS. 2 through 8 .
The illustrated embodiment of FIG. 12 has for each coupling element 30 , 40 on the operating element side only one simple (not-forked) guide track 20 a , 20 b . By using an operating lever which is basically divided into two parts 7 a ′ and 7 b ′ which are mounted displaceable independently of each other in a cassette 710 , the free ends of the parts 7 a ′, 7 b ′ can selectively be brought into the guide track 20 a , 20 b and thus into the engagement area of the coupling elements 30 , 40 . In this manner, the operating lever halves 7 a ′, 7 b ′ are coupled to the drives 1 a , 1 b through a coupling rod linkage 10 a , 10 ′ a , 10 b , 10 ′ b . An emergency actuation for the purpose of emergency opening or emergency closing can take place through the switch lever 8 which is mounted in the common pivotal axis 71 and which is connected to the locking cylinder through the connecting element 6 and the cable or rod linkage 61 .
Also the function controlling mechanism shown in FIG. 13 uses only simple (non-forked) guide tracks 20 . Compared with the embodiment of FIG. 12 the guide track 20 of FIG. 13 is a constituent part of a transversely displaceable part 24 which is mounted in a channel-like recess 25 of the base plate 2 . The coupling element 30 , 40 thereby engages through a slit 26 which is formed in the base plate 2 underneath the guide track 20 with a width designed so that there is sufficient clearance for the proposed transverse displacement of the coupling elements 30 , 40 (see also FIG. 14 ). According to FIGS. 13 and 14 , the operating lever 7 does not cross the transversely displaceable guide track 20 so that with the introduction of an operating force none of the coupling elements 30 , 40 can act on the associated free end of the operating lever 7 . This system is thus located in the “THEFT PROOF LOCKED” state.
A further possibility which selectively enables or prevents the engagement of a coupling element 30 , 40 on the operating lever 7 exists in selectively varying the projection height of the coupling elements 30 , 40 from the region between the base plates 2 , 2 ′ towards the operating lever 7 . For example, the projection height may be maximised when the operating force is to be transferred through the coupling element 7 to the locking parts of the lock (see FIGS. 15 and 16 ). If on the other hand a transfer of the operating force through at least one of the coupling elements 30 , 40 is to be prevented because, for example, the system is locked, theft proof locked or child locked, then the coupling element 30 , 40 may be guided along an inclined plane which reduces the projection depth to an extent which is less than required for engagement with the operating lever 7 .
FIGS. 15 and 16 show two exemplary embodiments that produce such inclined planes which represent the switching states of the function controlling device. In FIG. 15 , a part 27 is pivotally mounted on the base plate 2 ′ and its position determines the projection depth of the coupling element 30 , 40 . In FIG. 16 , a displaceable wedge 28 is provided whose wedge angle corresponds to that of the inclined plane underneath which is released during its displacement and then reduces the projection depth to a measure which lets the coupling element pass through under the operating lever. In the position of the web 28 shown in FIG. 16 this wedge forms with its outer contour, an extension of the plane of the base plate 2 ′ running parallel to the guide track 20 . FIG. 17 shows a diagrammatic plan view of the devices shown in cross-section in FIGS. 15 and 16 .
FIG. 18 shows diagrammatically the control principle already illustrated and described with reference to FIGS. 1 to 8 by using a neutral guide track 20 a , 20 b which is forked into two guide tracks 21 a , 21 b , 22 a , 22 b whereby the displacement path is controlled through a points-like switch element. The exemplary displacement element 12 ′ a , 12 ′ b is constructed on the principle of a rotary magnet or rotary armature which can be alternately rotated between two end positions.
FIGS. 19 to 23 show some variations of exemplary symmetrical arrangements of the parts and function regions of the function controlling mechanism according to the invention. FIG. 19 shows an exemplary symmetrical mirror arrangement of parallel and unidirectional guide tracks 20 a , 20 b , 21 a , 21 b , 22 a , 22 b . FIGS. 20 and 21 show a function controlling mechanism having a symmetrical construction relative to the base plate 2 ′ with superposed base plates 2 a , 2 b supporting the guide tracks 20 , 20 a , 20 b , 21 , 21 a , 21 b , 22 , 22 a , 22 b . These are associated with the drives 1 , the coupling elements 30 , 40 as well as the divided areas 7 a , 7 b of the operating lever which are mounted on a common axis 71 .
FIG. 22 shows—similar to FIG. 19 —symmetrical and unidirectional mounted guide tracks 20 a , 20 b , 21 a , 21 b , 22 a , 22 b whose switch elements (not shown) are likewise associated with mirror symmetrical drives 1 a , 1 b which can be switched through parts 10 a , 10 b , 8 ′, 8 ″, 61 . This embodiment has two switch levers 8 ′, 8 ″ whereby each individual part (i.e. each switch lever) is mounted on one side on the coupling rod 10 a , or 10 b of the drive 1 a , 1 b , and on the other hand in a swivel axis 71 , 81 which is fixed on the base plate 2 . Between these connecting points, operating means 61 engage on the switch lever 8 ′, 8 ″ in order to be able to initiate emergency operation through the locking cylinder as necessary. The operating lever 7 is pivotally mounted in the axis 71 and crosses the guide tracks 21 a , 21 b so that with a corresponding setting of the switch elements (not shown) an engagement can be produced with the coupling elements 30 , 40 . The operating lever 7 may also be formed to be U-shaped, for example, in the intersection area, so that the coupling element 30 can “tunnel under” the operating lever 7 without stopping against the same. Operating lever 7 may include bridging area 72 .
The function controlling mechanism according to FIG. 23 is constructed to be generally symmetrical relative to the swivel axis 71 ′ whereby the swivel axis 71 ′ is not anchored on the base plate 2 but can move slightly as a result of the selected lever kinematics in the case of the switch processes emanating from the drives 1 a , 1 b or the locking cylinder (see connecting element 6 ). Lever ends 7 ′ a and 7 ′ b are displaceable parts of the operating lever. An illustration of the points-like switch elements and their coupling rods with the drives has been omitted as these features have been discussed previously.
FIG. 24 shows in a diagrammatic illustration the side view of a vehicle door 9 with a function controlling mechanism FSM into which an electronic control for the lock 96 , as well as a window lifter, is integrated. The window lifter motor 97 is advantageously in direct connection with the function controlling mechanism FSM which is also provided with current according to this exemplary embodiment. FIG. 24 also illustrates gearing 98 . The operating forces and setting paths between the external door handle (i.e. door opener) 93 , the locking cylinder 93 ′, the internal door handle (i.e. internal door opener) 94 and the door lock 96 on the one hand, and the function controlling mechanism on the other, are transferred through Bowden cables or rod linkages 31 , 41 , 51 , 61 .
FIG. 25 shows a cross-sectional view of the described exemplary vehicle door. In FIG. 25 , the door body is divided into a wet space N defined by the outside door panel 90 and inside door panel 91 and thus support plate 92 connected thereto, and a dry space T which extends between the support plate 92 and the inside door trim 95 . As many function units as possible of the vehicle door are preferably preassembled on the support plate 92 in order to achieve one comprehensively pre-checkable assembly system. | A lock system is provided with a function controlling mechanism for control of the lock states unlocked, locked and optionally theft secure and child safety. The lock system is characterized by very short times for controlling the desired locking states and good suitability to various requirements with regard to construction space and functionality. The lock system comprises locking pieces, for example a turning latch or lock handle, in a lock for the mechanical locking of the door, at least one operating device in the form of an external door opener and/or an internal door opener, an optional locking cylinder, and elements for transmitting the operating force from the operating device to the locking pieces. The pieces of the function controlling mechanism (FSM), involved in controlling the locking state are not involved in the force path between the operating device and the locking pieces of the lock. | 8 |
RELATED APPLICATION
This application is a continuation of U.S. application Ser. No. 717,893, filed Mar. 29, 1985, and entitled "Fishing Lure."
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to sport fishing. More particularly, it relates to fishing lures of the type particularly adapted to deep sea or ocean fishing. It relates to means and method for providing a lure including a head and a tail wherein the tail may be changed without affecting the other portions of the fishing apparatus.
2. Prior Art
Fishing lures of many different appearances, and intended for the same class of sport fishing are well known. Previous expedients known to vary the appearance of a lure have relied upon relatively major changes in the equipment, or have relied upon removable portions. To the best knowledge and belief of the inventor, such prior expedients have involved structures which are substantially more complex or more expensive than the present invention, or are less rugged or less convenient to change in the field. Known United States patents which may be of interest are U.S. Pat. Nos. 4,380,884; 3,867,781; 4,006,551; 4,215,506; 3,947,989; 3,393,465; 3,359,674; 2,152,971; 4,163,337.
SUMMARY OF THE INVENTION
A fishing lure is provided. The fishing lure is particularly adapted for deep sea or ocean fishing. The type of lure with which this invention is concerned has a head and a tail portion together with one or more hooks. The overall appearance of the lure is intended to simulate the appearance of a bait fish or at least to be attractive to the game fish, so that the game fish will strike and be caught on the hooks.
A particular intent of the present invention is to provide means and method whereby the overall appearance of the lure may be altered to suit the conditions, for example the type of fish encountered, in a simple, inexpensive, reliable and quick manner. An object is to provide a single assembly of leader, head, and hooks, and a plurality of tails of varying appearance. Any one of the tails may be selectively firmly and easily affixed to the head, to change the overall appearance. Thus, there is no necessity to provide a large number of head, tail, leader and hook assemblies to attain this result.
Another object is to provide a fish lure in which the removable tail is firmly and positively engaged to the head so that the conditions to which it is subjected will not tend to cause the loss of the tail. Another object is to provide an affixation means which can be simply and easily manipulated under adverse conditions, and which will bear up under rough handling, and which will be relatively inexpensive.
The hooks are attached to the end of the leader. The head rides on the leader. The head is provided at the rear with a threaded stud through which the leader passes. The tail is provided with a threaded socket. The bore of the threaded socket is large enough so that it may be passed over the hooks from the rear, and engage the threaded stud.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side elevation of the fishing lure, partially fragmented.
FIG. 2 is an exploded view thereof, partially fragmented.
FIG. 3 is a cross-sectional view taken along line 3--3 of FIG. 1.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The fishing lure, generally designated 10, is of a type that is generally and preferably used in deep sea fishing. That is, it is adapted for being carried at relatively high speeds through ocean water, and to catch relatively large game fish. For the purpose of establishing context, it is noted that the typical gap in between the tip of the hook and the shank of the hook may be on the order of 3/4 of an inch, and the length of a typical lure from the front of the body to the end of the skirt, streamer or tail may be on the order of 11 inches. These dimensions are not in themselves critical.
The lure comprises a head generally designated 12. The head 12 is a solid piece, generally and preferably of any suitable synthetic plastic. It is preferably provided with means to make it simulate the head of a bait fish. For example, simulated eyes 36 are preferably provided. A convenient construction has a plastic simulation in roughly the color of a fish's head, surrounded by a clear plastic sheath to protect the pigment. The shape of the head is generally cylindrical, preferably tapered somewhat toward the front, and in general suggesting the head of a small fish.
At the rear of the head, it terminates in a threaded stud 18. Arranged longitudinally through the head, from front to back, centrally disposed, and running through the center of the threaded sutd 18 is a bore 20. A leader 22 is provided. This is preferably a length of nylon monofilament. In a typical embodiment, the diameter of this monofilament may be on the order of 1/16 of an inch. At one end, the leader 22 terminates in a loop, as shown at the right hand side of FIG. 1, or in any other convenient or known means whereby it may be attached to the main portion of the fishing line, not shown. As shown in FIG. 1, the end of the leader 22, at the right hand side, after being looped and intertwined, is bound together with permanent clips. The details of this termination structure are known art and are not part of the novelty of the present invention.
The leader extends through the bore 20. The external dimensions of the leader relate to the internal dimensions of the bore so that there is a snug but sliding fit preferably, although more clearance can be provided.
The leader 22 continues unbroken through the bore 20 and exits at the rear end of the stud 18. At least one hook is affixed to the rear end of the leader 22. Preferably, a multiplicity of hooks, very frequently two such hooks, are provided. As shown in FIG. 2, there is a first hook 26 and a second hook 28. These are conventional barbed fish hooks. One way of fastening the leader 22 to both hooks is run the leader along the shank of the first hook 26, then take it in a helix to hold its length against the shank, tie a simple knot to hold the helix in place, and then continue it to the second hook 28, where the tying procedure is repeated. The details of this tie are known art and are not part of the novelty of the present invention. Also, as shown in FIG. 2 a clip may be crimped around the leader 22 between the first hook 26 and the back of the stud 18 so that the travel of the head 12 rearwardly along the leader is limited.
In FIG. 1, the structure that has been described in connection with FIGS. 2 and 3 is shown in a complete assembled showing. In FIG. 1, the hooks 26 and 24 are shown facing in the same direction, whereas in FIG. 2 they are shown facing in opposed directions. These two showing simply illustrate casual arrangements of choice.
An important part of the structure is the provision of the skirt, streamer, or tail generally designated 14. The concept of such a tail as part of the fish lure is known to act to the effectiveness of the lure. The details of the tail 14 are best initially described in connection with FIG. 2. The tail 14 has a body 30, which is cylindrical and of the appoximately same outer dimension as the outer dimension of the head where the body 30 adjoins the head.
The body 30 is preferably made of a flexible tube of plastic. As shown, the major portion of the length of the tail is comprised of a plurality of strips 32, extending around the entire circumference of the tail. A typical embodiment might have about fifteen of such strips, although the exact number is not critical. One way of making the body and strip component is to provide a tube of flexible plastic material, and then to slit the tube along most of its length, so that the result is a plurality of strips hanging from a solid cylindrical portion. The tail 14 is preferably colored to approximate the color of a bait fish, or is colored or treated to provide any visual aspect found in the known art of fishermen to be attractive to the fish sought to be caught. In a typical embodiment, the length of the body may be about one inch and the length of the strips 32 may be on the order of seven inches.
Another portion of the tail 14 is a plug 34. This is a relatively more rigid cylindrical member provided with an internal female threaded socket 16. As best shown in FIG. 3, the socket 16 extends entirely through the plug 34. It is apparent that the body 30 fits over the plug 34 snugly. Preferably, it is affixed with adhesive or with some other positive fastening means so that it does not come loose.
In FIGS. 1 and 3, the tail 14 is shown assemblied to the head 12 to form a unitary structure. FIG. 1 best shows the entire fishing lure in its operative condition. The hooks lie roughly centrally within the circumference of the strips 32. As shown, one hook may conveniently lie within the actual shroud of the strips 32 and the other hook lie beyond the ends of the strips longitudinally. The leader is attached to the main fishing line. Typically, the boat trolls, moving through the water and trailing the lure behind it. The appearance and motion of the lure, including the wiggling of the strips 32 and the tail 14, attract fish which strike at the lure and are caught on the hooks.
Compared to many other types of sport fishing, this type of fishing is relatively rugged and it is very important that the structural integrity of the line, leader, lure, and hook assembly be maintained. Thus, the positive gripping action of the threaded stud and the threaded socket is very important, because it avoids the problems found in other expedients of undesired separations taking place.
Fisherman find that depending on the circumstances, different colors or configurations of lures are desirable in attracting the fish. The principal component of the appearance as far as the fish is concerned is the relatively major portion of the tail 14. It has been found that providing a selection of tails with different appearances to the fish is a desirable technique. Therefore, the fisherman wishes to be able to selectively change the tail as it is assembled to the head.
The tail 14 may be removed from the head by simply unscrewing it. Then, the tail is free to move backwards along the leader. The threaded socket 16 then constitutes a hole or passageway through which the hooks may be passed. It is apparent then when it is desired to pass the tail past a hook, it is moved along the shank and then moved in a curving line so that it follows the shape of the hook. It is found that this is convenient to do. When it is desired to replace a removed tail with another tail, the procedure is reversed, the threaded socket 16 being led along the curvature and then along the shank of each hook in turn. It is then assembled to the head 12 by engaging the threaded elements as has been described.
Not only does this structure provide a positive and secure affixation, but it permits removal and reaffixation by fisherman under sometimes adverse conditions, without requiring delicate operations. Also, the rough usage to which such devices are subjected is less likely to damage the present lure than certain past expedients, because the selective affixation structure in the present lure is inherently more rugged and less likely to get out of alignment or adjustment. The present invention thus provides a means by which a variety of effectively different lures may be provided without the necessity of providing a variety of complete assemblies. That is, a single leader with hooks and head may be selectively combined with a number of tails, to provide a variety of effective lures. | A fishing lure particularly adapted for deep sea sport fishing. The fishing lure assembly comprises a head, a tail, a leader, and at least one hook. The leader, head, and hook remain permanently assembled. The tail portions may be selectively changed to give the overall lure a different appearance, as may be suitable for the fishing conditions. The affixation means are simple, inexpensive, rugged, and capable of easy manipulation under adverse conditions. When assembled, the entire lure has structural integrity and reliability. | 0 |
REFERENCE TO PARENT APPLICATION
[0001] This application is a Continuation-In-Par of “Photomultiplier Tube Identifier”, U.S. Ser. No. 09/127,987, filed on Aug. 3, 1998, which is incorporated herein by reference.
FIELD OF INVENTION
[0002] The present invention relates to scintillation cameras. In particular, the invention relates to a method and apparatus for improving the quality of images produced during positron emission tomography.
BACKGROUND OF THE INVENTION
[0003] In the human body, increased metabolic activity is associated with an increase in emitted radiation. In the field of nuclear medicine, increased metabolic activity within a patient is detected using a radiation detector such as a scintillation camera.
[0004] Scintillation cameras are well known in the art, and are used for medical diagnostics. A patient ingests, inhales or is injected with a small quantity of a radioactive isotope. The radioactive isotope emits gamma rays that are detected by a scintillation medium in the scintillation camera The scintillation medium is commonly a sodium iodide crystal, BGO or other. The scintillation medium emits a small flash or scintillation of light, in response to stimulating radiation, such as from a patient. The intensity of the scintillation of light is proportional to the energy of the stimulating photon, such as a gamma photon. Note that the relationship between the intensity of the scintillation of light and the gamma ray is not linear.
[0005] A conventional scintillation camera such as a gamma camera includes a detector which converts into electrical signals gamma lays emitted from a patient after radioisotope has been administered to the patient The detector includes a scintillator and photomuliplier tubes. The gamma rays are directed to the scintillator which absorbs the radiation and produces, in response, a very small flash of light. An array of photodetectors, which are placed in optical communication with the scintillation crystal, converts these flashes into electrical signals which are subsequently processed. The processing enables the camera to produce an image of the distribution of the radioisotope within the patient.
[0006] Scintillation cameras are used to take four basic types of pictures: spot views, whole body views, partial whole body views, SPECT views, and whole body SPECT views.
[0007] A spot view is an image of a part of a patient. The area of the spot view is less than or equal to the size of the field of view of the gamma camera. In order to be able to achieve a full range of spot views, a gamma camera must be positionable at any location relative to a patient.
[0008] One type of whole body view is a series of spot views fitted together such that the whole body of the patient may be viewed at one time. Another type of whole body view is a continuous scan of the whole body of the patient. A partial whole body view is simply a whole body view that covers only part of the body of the patient. In order to be able to achieve a whole body view, a gamma camera must be positionable at any location relative to a patient in an automated sequence of views.
[0009] The acronym “SPECT” stands for single photon emission computerized tomography. A SPECT view is a series of slice-like images of the patient. The slice-like images are often, but not necessarily, transversely oriented with respect to the patient. Each slice-like image is made up of multiple views taken at different angles around the patent, the data from the various views being combined to form the slice-like image. In order to be able to achieve a SPECT view, a scintillation camera must be rotatable around a patient, with the direction of the detector head of the scintillation camera pointing in a series of known and precise directions such that reprojection of the data can be accurately undertaken.
[0010] A whole body SPECT view is a series of parallel slice-like transverse images of a patient. Typically, a whole body SPECT view consists of sixty four spaced apart SPECT views. A whole body SPECT view results from the simultaneous generation of whole body and SPECT image data. In order to be able to achieve a whole body SPECT view, a scintillation camera must be rotatable around a patient, with the direction of the detector head of the scintillation camera pointing in a series of known and precise directions such that reprojection of the data can be accurately undertaken.
[0011] Therefore, in order that the radiation detector be capable of achieving the above four basic views, the support structure for the radiation detector must be capable of positioning the radiation detector in any position relative to the patient. Furthermore, the support structure must be capable of moving the radiation detector relative to the patient in a controlled manner along any path.
[0012] In order to operate a scintillation camera as described above, the patient should be supported horizontally on a patient support or stretcher.
[0013] A certain design of gantry or support structure for a scintillation camera includes a frame upon which a vertically oriented annular support rotates. Extending out from the rotating support is an elongate support. The elongate generally comprises a pair of arms. The pair of arms generally extends through a corresponding pair of apertures in the rotating support. One end of the pair of arms supports the detector head on one side of the annular support. The other end of the pair of arms supports a counter balance weight. Thus, the elongate support is counterbalanced with a counterweight on the opposite side of the detector head.
[0014] With such a design of support structure for a scintillation camera, a patient must lie on a horizontally oriented patient support. The patient support must be cantilevered so that the detector head can pass underneath the patient. If the detector head must pass underneath only one end of the patient, such as the patient's head, the cantilevered portion of the patient support is not long enough to cause serious difficulties in the design of the cantilevered patient support. However, if The camera must be able to pass under the entire length of the patient, the entire patient must be supported by the cantilevered portion of the patient support. As the cantilevered portion of the patient support must be thin so as not to interfere with the generation of images by the scintillation camera, serious design difficulties are encountered.
[0015] Among the advantages associated with such as design of support structure is that a patient may be partially pass through the orifice defined by the annular support so that the pair of arms need not be as long, However, the patient support must be able to support the patient in this position relative to the annular support, must be accurately positionable relative to the annular support, and must not interfere either with the rotation of the annular support or with the cables which will inevitably extend from the detector head to a nearby computer or other user control.
[0016] The photomultiplier tubes in a scintillation camera generate electric signals. The signals are processed, and images are created corresponding to the radiation emitted by the patient.
[0017] From time to time, images are generated that contain one or more artifacts or flaws. Artifacts are often caused by one or more malfunctioning photomultiplier tubes. A malfunctioning photomultiplier tube may be generating incorrect signals, may be generating no signal at all, or the processing of the signals from a particular photomultiplier tube may not be proper.
[0018] To determine the cause of the artifact and then correct the artifact it is important to identify all malfunctioning photomultiplier tubes. However, inspecting and testing photomultiplier tubes is difficult, time consuming and expensive.
[0019] From time to time, images of poor quality are also generated. Of particular concern are the images produced by Position Emission Tomography. Position Emission Tomography (PET) is a practice common in the art wherein two detectors are placed with their fields of view at 180° to one another. After the patient ingests the isotope, positrons are emitted from areas where is isotope has gathered in the body. The positrons that are released from the body in opposite directions collide with electrons in the body and effectively form two gamma rays. The gamma rays are detected by the detectors and as mentioned above are used to generate images. However, in PET, only gamma rays originating from a collision between a positron and an electron that are detected at 180° (referred to as coincidence) from one another are considered true events. Preferably only true events are used to generate images.
[0020] Unfortunately what sometime occurs is that the gamma ray will ricochet off a second electron in the body before being emitted and the angle is changed. The two gamma rays will not be detected at 180° from one another, resulting in a “random” event. Random events are really just noise signals that when used to generate an image, cause poor quality imagery. It is known in the art that an increase in area (of field of view) results in an increase in the probability of random events. Since conventional P cameras use relatively large detectors with large fields of view and they commonly use the total data values for the entire detector head, the chance of using random events to generate an image is high. As well, since data from a large field of view must be processed, the time frame window during which data is analysed is large resulting in yet a higher probability of detecting random events.
[0021] In Constant Fraction Discrimination (CFDs) cameras, the probability of random events is also relatively high, resulting in poorer quality images. FIG. 1 illustrates the data obtained from a Constant Fraction Discriminator. Constant Fraction Discriminators use a constant fraction (or percentage) of the input pulse to precisely determine the timing of an event. Inaccuracies occur when two events are detected in such a short time frame such as to create overlap. In the data when two or more events overlay, it is impossible to separate them to obtain before an event in order to separate the data. As seen in FIG. 1, the data from areas A, B and C can be separated in order to analyse the individual events 1 and 2 .
SUMMARY OF THE INVENTION
[0022] An object of the invention is to provide a method and apparatus for improving a PET image quality. This is achieved by analysing individual photomultiplier tubes for true events and by providing time stamps to photomultiplier tube signals. Analysing data from individual photomultiplier tubes as opposed to entire detector field of views results in smaller areas and smaller amounts of data to be processed. This then permits smaller time frame windows to be used The use of time stamps also permits data before and after a particular event to be kept as record.
[0023] The invention relates to an apparatus for improving the quality of images produced by a scintillation camera during positron emission tomography wherein both true events and random events occur, comprising: a photomultiplier tube for generating a photomultiplier tube signal; means for generating a code signal identifying the photomultiplier tube; a clock for generating a clock signal providing a time stamp for the photomultiplier tube; a bus buffer for transmitting an encoded signal comprising the photomultiplier tube signal followed by the code signal and the time stamp; a data analyser for determining whether the encoded signal represents a true event; a position computing device for calculating the position of a true event; an image computer for generating an image of the events from a plurality of encoded signals and the positions of their corresponding events; and a display for displaying the image.
[0024] The invention also relates to a method for improving the image produced by a scintillation camera comprising an array of photomultiplier tubes, comprising the steps of: generating a photomultiplier tube signal after an event; generating a code signal identifying the photomultiplier tube; generating a clock signal providing a time stamp for the photomultiplier tube; generating an encoded signal comprising the photomultiplier tube signal followed by the code signal and the time stamp; determining whether the event is a true event; calculating the position of the event; generating an image from a plurality of encoded signals; and displaying the image.
[0025] One embodiment relates to an apparatus for improving The image produced a scintillation camera comprising an array of photomultiplier tubes, comprising: means for generating a photomultiplier tube signal after an event; means for generating a code signal identifying the photomultiplier tube; means for generating a clock signal providing a time stamp for the photomultiplier tube; means for generating an encoded signal comprising the photomultiplier tube signal followed by the code signal and the time stamp; means for determining whether Me event is a true event; means for calculating the position of the event; means for generating an image from a plurality of encoded signals; and means for displaying the image.
[0026] Other advantages, objects and features of the present invention will be readily apparent to those skilled in the art from a review of the following detailed description of preferred embodiments in conjunction with the accompanying drawings and claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0027] The embodiments of the invention will now be described with reference to the accompanying drawings, in which:
[0028] [0028]FIG. 1 illustrates the data obtained with a CFD;
[0029] [0029]FIG. 2 illustrates the basics of PET;
[0030] [0030]FIG. 3 is a drawing of an embodiment of the photomultiplier tube identifier of the present invention;
[0031] [0031]FIG. 4 is a drawing of the bus buffer of the embodiment of FIG. 3; and
[0032] [0032]FIG. 5 is a flowchart illustrating the operation of the data analyser.
[0033] Similar references are used in different figures to denote similar components.
DETAILED DESCRIPTION OF THE INVENTION
[0034] [0034]FIG. 2 illustrates the basics of PET, Briefly, when a collision occurs in the body, two gamma rays are emitted and detected by the detector (known as events). If it is determined that the events are true events (as detailed below), they are used in image generation. However, if one gamma ray, for example gamma ray 2 , ricochets to create event 3 rather than true event 2 , it causes a random or scattered event and is preferably not used in image generation.
[0035] [0035]FIGS. 3 and 4 illustrate an array of photomultiplier tubes 405 in a scintillation camera. A photomultiplier tube identifier 410 is an apparatus for identifying a photomultiplier tube in the array of photomultiplier tubes 405 .
[0036] The photomultiplier tube identifier 410 includes amplifier/integrators 415 , analog to digital converters (ADCs) 420 , bus buffers 425 , pull-up resistors 430 , a bus 435 , a position computing device 440 , an image computer 445 , a user display 450 and a clock 426 .
[0037] Output signals from individual photomultiplier tubes in the array of photomultiplier tubes 405 are amplified and integrated by the amplifier/integrators 415 . The output signals from the amplifier/integrators 415 are then digitized in the analog to digital converters 420 . The output signal from a digital to analog converter 420 corresponds to the strength of the signal from an individual photomultiplier tube in the array of photomultiplier tubes 405 .
[0038] The bus buffers 425 receive output signals from the digital to analog converters 420 . Some of the gates of the bus buffers 425 are also connected to the pull up resistors 430 . The gates of the bus buffer are set by the pull up resistors 430 to a logic high or logic low which correspond to the identities of the individual photomultiplier tubes from which signals have been obtained. To each output signal from the digital to analog converters 420 , the bus buffers 425 add a code below the least significant bits identifying the photomultiplier tube from which the signal was obtained. Thus, the output signals from the bus buffers 425 corresponds to the strength of the signals received from the array of photomultiplier tubes 405 plus a code identifying the photomultiplier tube from which the signals were obtained.
[0039] In addition, the clock 426 provides clock signals providing a continuously running clock or stream of time stamps to each photomultiplier tube identifier. The clock signals provide the time stamp for each photomultiplier tube output signal at a predetermined clock increment. The stream of time stamps maintain records of when events have taken place.
[0040] In a preferred embodiment, the clock increments in cycles from 0 to 256. That is, each cycle produces 256 time stamps, but any suitable number could be used depending upon the accuracy required.
[0041] In a preferred embodiment, time stamps are generated every two nanoseconds, but another suitable length of time can be chosen.
[0042] [0042]FIG. 4 illustrates a bit bus buffer 425 . Output signals 455 from a digital to analog converter 420 , in this case twelve most significant bits of signal data, are received by the bus buffer 425 . The twelve bit output signals 455 correspond to the specific photomultiplier tube providing the output signal. Logic values 460 from pull up resistors 430 , in this case 6 bits of data, provide a bard wired code corresponding to the identity of the specific photomultiplier tube. In this case, as the pull up resistors provide six bits of data, the signals from sixty four different photomultiplier tubes 405 may be encoded. As well, approximately ten bits of clock signals 461 , are also written into the bus buffer and encoded. While ten bits of time stamp data is preferable, any number of bits could be used.
[0043] Upon receipt of the enable command at 475 , the data (the data signal values, the photomultiplier tube identifier and time stamps) from the bus buffer is read onto the bus 435 . The signal values 465 , that is, the first twelve bits of data correspond to the output signal received from the digital to analog converter 415 . The code values 470 , that is, the next four bits of data, provide the code identifying the specific photomultiplier tube 405 providing the information. The time stamp values 428 provides the time data from the clock signals 461 . The signals 460 in FIG. 4 provide a code of 010011, ground being represented by 0 and VCC being represented by 1. If more codes are required, a larger bus buffer can be used, such as a twenty or thirty two bit bus buffer.
[0044] The first twelve bits of each encoded signal 480 are the signals values 465 , and six bits of each encoded signal 480 are the code values 470 while the remaining bits are the time stamp values 428 . The encoded signals 480 are received by a processing unit. Since the code values 470 are in the low part of the encoded signal 480 or data word used by the position computing device 440 , the change in value created by adding the code values 470 to the signal values 470 is negligible. Therefore, the code values 470 do not need to be removed before the encoded signal 480 is used by the position computing device 440 . For example, the encoded signal may represent the value 1,001,325,238. The final two digits, that is, eight and three, may be the code identifying the thy eighth photomultiplier tube in the array. The 0.038 value and the time stamp data could be removed from the encoded signal 480 prior to processing by the position computing device 440 and reattached to the signal 480 afterwards. However, such a calculation would not be beneficial as the 0.038 a negligible value compared with the value 1,001,325,238. If an artifact appears on the generated image, and the artifact can be traced to the data value 1,001,325,238, then photomultiplier tube number thirty eight can be repaired or replaced. Similarly, if an artifact appears on the generated image, and fewer data values traceable to photomultiplier tube number thirty eight than are statistically expected, then photomultiplier tube number thirty eight may need repairing or replacing.
[0045] Encoded signals 480 , including the tie stamp, are read onto the bus buffer 425 . This data for each multiplier tube is then fed across the bus 435 and may be stored in a temporary memory 428 . The data coming from a particular photomultiplier tube can be analysed by a data analyser 441 , If there is an event, the data before that event, and after the event is recorded. In the case of CFOs, this allows overlapping event signals to be separated into individual true event signals. In other words, if data from two events have overlapped, the data values for one event can be subtracted or removed from the data values for the second event. This is known in the art as deconvalving the events.
[0046] Similarly, the signals for all the photomultiplier tube outputs can be analysed for photomultiplier tubes that are at 180 degrees to one another. From this data, it can be determined whether an event is within a certain time window, and whether those photomultiplier tubes are in coincidence. This is accomplished by analysing the data for two photomultiplier tubes at 180 degrees within a very small time window, for example, two nanoseconds. The true events data is then transferred To a main memory 442 and then to processing and image generation. The other data (random data) is effectively useless and may be purged. In this way, the position computing device 440 can transmit information to the image computer 445 and then the display 450 quickly and inexpensively while retaining intact information identifying the specific photomultiplier tubes corresponding the specific data. Referring to FIG. 5, therefore, first individual tube values are analysed to determine whether an events are in coincidence and then to determine the location of the event.
[0047] Prior art systems typically operate in the following manner: when events occur, the location of the events are determined, and then whether the events are in coincidence is determined using the total data values from the entire detector heads.
[0048] As mentioned above, quality of PET imagery is affected by two factors: the probability of random events and the size of the time window.
[0049] Since the probability of random events increases as the field of view area increases, it is desirable to have less area to improve the PET images. Therefore, individual photomultiplier tubes are placed in coincidence which reduces the area, and the probability of random events is minimized. The data from individual photomultiplier tubes is used to determine coincidence as opposed to the data from the entire detector head. Note that it may be possible to have photomultiplier tubes that are skewed because it is where the events occur in the crystal that determine whether they are in coincidence.
[0050] Another way to improve PET images is to have smaller time windows during which data is analysed such that the time to pick up random events is reduced. Encoding a time stamp to each photomultiplier tube at predetermined times produces a stream of time stamps for each tube. Then each stream can be analysed to determined which tubes are in coincidence, Tubes in coincidence will have the same time stamp, or match a time stamp within a predetermined time window. By analysing individual photomultiplier tube data, smaller amounts of data are processed allowing a smaller time window to be used.
[0051] Numerous modifications, variations and adaptations may be made to the particular embodiments of the invention described above without departing from the scope of the invention, which is defined in the claims. | A method and apparatus for improving the image quality of positron emission tomography is disclosed. This is achieved by analysing individual photomultiplier tubes for true events. The apparatus includes a photomultiplier tube for generating a photomultiplier tube signal. A series of pull up resistors generates a code signal identifying the photomultiplier tube. A clock generates a time stamp to the photomultiplier tube signal. A bus buffer generates an encoded signal. A position computing device calculates the position of the photomultiplier tube. An image computer generates an image from a plurality of encoded signals. A display displays the image. Analysing data from individual photomultiplier tubes results in smaller areas and smaller amounts of data to be processed. This then permits smaller time franm windows to be used. The use of time stamps also permits data before and after an event to be recorded. | 0 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to a hydrostatic anti-vibration system for suppressing vibration of a construction utilizing motion of a hydraulic fluid filled in a tank. The invention also relates to a method for adjusting an active vibration frequency range to a natural period of the actual construction.
2. Description of the Related Art
Such type of hydrostatic anti-vibration system has been proposed in commonly owned Japanese Unexamined Patent Publication No. 5-60173. A brief discussion will be given of the prior proposed hydrostatic anti-vibration system with reference to FIG. 8. As shown in FIG. 8, the hydrostatic anti-vibration system generally comprises a tank 103 having a lower tank portion 101 of essentially rectangular configuration and hollow vertical extensions 102 extending upwardly from respective of the four corners of the lower tank portions 101. Water as an anti-vibration medium fills up the entire volume of the lower tank portion 101 and further fills the hollow vertical extensions 102 for approximately half of their heights with upper air containing spaces maintained thereabove. The air containing spaces of respectively adjacent hollow vertical extensions 102 are communicated through four ducts 105. At intermediate portions of the four ducts, intermediate tank portions 106 are defined. The intermediate tank portions 106 are filled with water to a level substantially equal to the level of water in the hollow vertical extensions 102.
Partitioning plate 107 depending from the ceilings of the intermediate tank portions 106 extend into the interior space of each intermediate tank for dividing the upper portion of the interior space of the intermediate tank, thereby defining substantially U-shaped water communication paths. Rotary shafts 108 are rotatably mounted on the lower ends of respective partitioning plate 107 in horizontal orientation along the lower edges of the partitioning plates. Pivotal plates 109 are secured on the rotary shafts 108 for pivotal movement with the rotary shafts in response to flow of the water contained in the intermediate tank portions 106. Coil springs 110 are provided between the partitioning plates 107 and the rotary shafts 108. The coil springs 110 exert a biasing spring force to rotary shafts 108 for restricting rotary motion thereof and thereby restricting pivotal motion of the pivotal plates 109. By appropriately adjusting the spring coefficients of the coil springs 110, resistance against pivotal motion of the pivotal plates 109 can be adjusted depending upon the natural period (natural frequency) of the construction of which vibration is to be suppressed.
The hydrostatic anti-vibration system is installed on the roof or top of the construction. According to vibration induced on the construction, the water in the tank 103 causes rocking motion. In this rocking motion, due to inertia moments of the water, water collides on the interior walls of the tank 103 with a delay to the natural period or vibratory phase of the vibration of the construction. According to the rocking motion of water in the tank 103, the water level in each hollow vertical extension 102 is varied, thus increasing or decreasing the air pressure therein. Variation of the air pressure in the air containing spaces of two adjacent of the hollow vertical extensions 102 is introduced to opposite sides of the substantially U-shaped water flow path in the respective intermediate tank portion 106, thus causing rocking water flow in such intermediate tank portion 106 along such U-shaped flow path. Against the water flow thus induced, the spring biased pivotal plate 109 serves to provide resistance. This resistance cancels vibratory energy of the construction. With the construction set forth above, high anti-vibration effect can be attained for horizontal bi-directional vibration with a relatively small size of the tank. Furthermore, such hydrostatic anti-vibration system is advantageous in comparison with a pendulum type anti-vibration system by requiring no externally exposed mechanically movable component. Furthermore, the tank may serve as a reservoir for drinking water in the case of emergency.
In the case where such anti-vibration system is desired to operate as a hybrid type anti-vibration system by adding an active driving device for a passive type operation system for suppressing vibration of the construction more effectively, it becomes necessary to make the natural frequency of the anti-vibration system consistent with the natural period of the construction. In practical implementation, the natural frequency of the hydrostatic anti-vibration may be determined on the basis of an approximated value of the natural period of the construction derived from calculation of construction of the primary body thereof. Then, on the basis of such natural frequency, the dimensions and volume of the tank, the amount of water to be filled and so forth are designed for the anti-vibration system. The anti-vibration system is thus constructed on the roof or in the vicinity of the top of the construction, according to the design thereof.
However, certain features of such prior proposed hydrostatic anti-vibration system need to be improved. Namely, in the construction set forth above, since the hollow vertical extensions 102 are provided at the four corners of the lower tank portion 101 and four intermediate tanks 106 are provided for communicating between the four hollow vertical extensions, the construction is complicated. Furthermore, it is possible to cause disturbance of the flow of the water by horizontal bi-directional composite vibrations.
Also, since in such prior proposed construction the respective upper spaces of the intermediate tank portions 106 separated by the partitioning plates 107 are communicated with respective corresponding adjacent air containing spaces of the hollow vertical extensions 102, when a fluid force is generated in the direction indicated by the arrow in FIG. 8, for example, compression of the air is caused at the air containing space of one of the hollow vertical extensions 102 (left side in the illustrated case). Compressed air is then introduced into the communicated side of the upper space of the intermediate tank portion 106. The air pressure thus introduced can serve to suppress water flow in the intermediate tank portion 106 induced by the vibration of the construction. In such case, both fluid forces serve to cancel each other, thus causing the anti-vibration system to be not effective in suppressing vibration of the construction.
In addition, since water in the tank 103 and water in the intermediate tank portions 106 are separated completely, each such respective water portion has to be managed independently of the others, thus causing management of the water levels to be cumbersome. Furthermore, water in the hollow vertical portions 102 of the tank 103 and water in the intermediate tank portions 106 may flow from one to the other when large amplitude vibration occurs. In such case, the water levels in the hollow vertical extensions and in the intermediate tank portions can be varied to cause variation of the anti-vibration characteristics. Therefore, at every occasion of variation of the water levels in the hollow vertical extensions and in the intermediate tank portions, adjustment of the water levels becomes necessary to maintain the desired anti-vibration characteristics. Furthermore, the natural period of the construction varies delicately depending upon variation of the weight of the construction due to interior construction, modification of the construction design, changing of layout and so forth, in practice. Therefore, in the sense of high precision, the natural period of the construction cannot be determined until completion of construction. Furthermore, even after completion of construction, the weight of the construction and weight distribution therein are variable depending upon conditions of use of the construction. Such variation of the weight or weight distribution of the construction may cause variation of the natural period. Thereby, the natural frequency of the anti-vibration system, that is designed based on that of the construction, may be out of the effective range in terms of anti-vibration effect. As a solution for this, it may be possible to design the anti-vibration system for accommodating such future possible variation of the weight and/or weight distribution of the construction by adjustment of the water amount and the internal pressure in the tank. However, even with this measure, adjustment of the water amount and internal pressure is very troublesome in practice.
SUMMARY OF THE INVENTION
In view of the drawbacks in the prior proposal, it is a first object of the present invention to provide a hydrostatic anti-vibration system which is simplified in construction and has a greater ratio of the amount of water that is effective for an anti-vibrative effect against a vibration in the horizontal direction, relative to the overall amount of water in a tank.
A second object of the present invention is to provide a hydrostatic anti-vibration system which can avoid mutual cancellation of fluid forces, and wherein variation of air pressure due to fluid forces in the main tank and an intermediate tank are positively used for boosting the fluid force.
A third object of the present invention is to provide a hydrostatic anti-vibration system which can constantly maintain fluid levels in the main tank and the intermediate tank at the same level and thus can achieve high stability of anti-vibration characteristics.
A fourth object of the present invention is to provide a hydrostatic anti-vibration system which can facilitate fine adjustment of a natural frequency of the hydrostatic anti-vibration system depending upon a natural period (natural frequency) of a construction.
A fifth object of the present invention is to provide an adjusting method for a passive anti-vibration system which facilitates fine adjustment of the natural frequency of the system depending upon the actual natural period of the construction and which permits quick adjustment.
According to one aspect of the invention, a hydrostatic anti-vibration system comprises:
a main tank provided to be on a construction to be suppressed from vibration and having a main tank body of substantially flat rectangular configuration, and hollow vertical extensions extended upwardly from peripheral edge portions of the main tank body and filled with a working liquid at a predetermined level with upper air chambers maintained thereabove;
ducts communicating with the upper air chambers of the hollow vertical extensions;
intermediate tank portions connected to respective ducts and containing a vibration suppressing liquid;
a pivotal plate disposed in each of the intermediate tank portions for separating the interior space of such intermediate tank portion into a pair of chambers respectively connected to corresponding of the ducts, said plate pivoting in response to flow pressure of the vibration suppressing liquid;
a damper for providing a resistance against displacement of the pivotal plate; and
an external adjusting mechanism associated with the damper for adjusting damping characteristics thereof and thereby adjusting the natural frequency of the anti-vibration system in relation to the natural frequency of the construction.
In the preferred construction, the intermediate tank portions are arranged outside of the main tank in parallel. Also, the ducts may be connected to the intermediate tank portion so that the arrangement of the pair of chambers separated by the pivotal plate may be in opposite phase to the arrangement of the upper air chambers of the vertical extensions connected thereto. In the alternative, the duct may be connected to the intermediate tank portion so that the arrangement of the pair of chambers separated by the pivotal plate may be in the same phase to the arrangement of the upper air chambers of the vertical extensions connected thereto.
The hydrostatic anti-vibration system may further comprise a conduit communicating the main tank body and each intermediate tank portion. Also, the hydrostatic anti-vibration system may further comprise as the adjusting mechanism a threaded shaft perpendicularly connected to a rotary shaft of the pivotal plate and a natural vibration frequency adjusting pendulum threadingly engaged to the threaded shaft for axial movement therealong.
According to another aspect of the invention, there is provided a method for adjusting a hydrostatic anti-vibration system including a main tank provided on a construction to be suppressed from vibration and having a main tank body of substantially flat rectangular configuration, and hollow vertical extensions extended upwardly from peripheral edge portions of the main tank body and filled with a working liquid at a predetermined level with upper air chambers thereabove, ducts connected to the upper air chambers of the hollow vertical extensions, intermediate tank portions connected to respective ducts and containing a vibration suppressing liquid, a pivotal plate disposed in each of the intermediate tank portions for separating the interior space thereof into a pair of chambers respectively connected to the corresponding ducts, the plate pivoting in response to flow pressure of the vibration suppressing liquid, and a damper for providing a resistance against displacement of the pivotal plate. The method comprises the steps of:
measuring an actual natural period of the construction to which the anti-vibration system is applied by vibration measuring equipment;
adjusting an external adjusting mechanism provided for the anti-vibration system for adjusting the natural vibration frequency of the anti-vibration system, depending upon the actual natural period of the construction measured by the vibration measuring equipment, to be consistent with the natural period of the construction.
Preferably, the method further comprising the steps of:
setting the natural frequency of the anti-vibration system depending upon a designed natural period of the construction before completion thereof;
adjusting the natural frequency of the anti-vibration system, after completion of construction to make the natural vibration frequency of the anti-vibration system to be consistent with the actual natural period of construction, by the external adjusting mechanism.
The external adjusting mechanism may include a threaded shaft perpendicularly connected to a rotary shaft of the pivotal plate and a natural vibration frequency adjusting pendulum threadingly engaged to the threaded shaft for axial movement therealong.
According to a further aspect of the invention, there is provided a hydrostatic anti-vibration system comprising:
a main container mounted on a top portion of a construction to which an anti-vibration effect is to be applied, and filled with a working liquid anti-vibration medium for converting vibration energy transmitted to the main container from the construction according to vibratory motion thereof, into a reciprocating flow of the working liquid anti-vibration medium in the main container for generating a vibratory counter force against the vibration force exerted on the construction;
two pairs of pneumatic chambers defined in upper portions of the main container, a first pair of the pneumatic chambers being arranged for causing pressure variation of pneumatic energy transmission medium therein in mutually opposite directions in response to reciprocating flow of the working liquid anti-vibration medium in a first direction, and second pair of the pneumatic chambers being arranged for causing pressure variation of pneumatic energy transmission medium therein in mutually opposite directions in response to reciprocating flow of the working liquid anti-vibration medium in a second direction perpendicular to the first direction and in a horizontal plane common therewith;
a first damping mechanism communicated with the first pair of pneumatic chambers for damping pressure variation in the first pair of pneumatic chambers and thereby damping reciprocating flow of the working liquid anti-vibration medium in the first direction;
a second damping mechanism communicated with the second pair of pneumatic chambers for damping pressure variation in the second pair of pneumatic chambers and thereby damping reciprocating flow of the working liquid anti-vibration medium in the second direction; and
an external damping force adjusting mechanism provided externally to and cooperated with respective of the first and second damping mechanisms for determining damping characteristics thereof for adjustment of the natural frequency of the anti-vibration system to a natural frequency of the construction.
According to a still further aspect of the invention, a hydrostatic anti-vibration system comprises:
a main container mounted on a top portion of a construction to which anti-vibration effect is to be applied, and filled with a working liquid anti-vibration medium for converting vibration energy transmitted to the main container from the construction according to vibratory motion thereof into a reciprocating flow of the working liquid anti-vibration medium in the main container for generating a vibratory counter force against the vibration force exerted on the construction;
two pairs of pneumatic chambers defined in upper portions of the main container, a first pair of the pneumatic chambers being arranged for causing pressure variation of pneumatic energy transmission medium therein in mutually opposite directions in response to reciprocating flow of the working liquid anti-vibration medium in a first direction, and a second pair of the pneumatic chambers being arranged for causing pressure variation of pneumatic energy transmission medium therein in mutually opposite directions in response to reciprocating flow of the working liquid anti-vibration medium in a second direction perpendicular to the first direction and in common horizontal plane;
a first damping mechanism communicated with the first pair of pneumatic chambers for damping pressure variation in the first pair of pneumatic chambers and thereby damping reciprocating flow of the working liquid anti-vibration medium in the first direction;
a first phase reversing means for reversing a phase of pressure variation between the first pair of pneumatic chambers in the main container and the first damping mechanism for accommodating a working liquid anti-vibration medium originated pressure variation, thereby for avoiding influence thereof on the anti-vibration effect of the anti-vibration system;
a second damping mechanism communicated with the second pair of pneumatic chambers for damping pressure variation in the second pair of pneumatic chambers and thereby damping reciprocating flow of the working liquid anti-vibration medium in the second direction; and
a second phase reversing means for reversing a phase of pressure variation between the second pair of pneumatic chambers in the main container and the second damping mechanism for accommodating a working liquid anti-vibration medium originated pressure variation, thereby for avoiding influence thereof on the anti-vibration effect of the anti-vibration system.
According to a yet further aspect of the invention, a hydrostatic anti-vibration system comprises:
a main container to be mounted on a top portion of a construction to which an anti-vibration effect is to be applied, and filled with a working liquid anti-vibration medium for converting vibration energy transmitted to the main container from the construction according to vibratory motion of the latter into a reciprocating flow of the working liquid anti-vibration medium in the main container for generating a vibratory counter force against the vibration force exerted on the construction;
two pairs of pneumatic chambers defined in upper portions of the main container, a first pair of the pneumatic chambers being arranged for causing pressure variation of pneumatic energy transmission medium therein in mutually opposite directions in response to reciprocating flow of the working liquid anti-vibration medium in a first direction, and a second pair of the pneumatic chambers being arranged for causing pressure variation of pneumatic energy transmission medium therein in mutually opposite directions in response to reciprocating flow of the working liquid anti-vibration medium in a second direction perpendicular to the first direction and in a common horizontal plane;
a first hydropneumatic damping mechanism communicated with the first pair of pneumatic chambers for damping pressure variation in the first pair of pneumatic chambers and thereby damping reciprocating flow of the working liquid anti-vibration medium in the first direction;
a second hydropneumatic damping mechanism communicated with the second pair of pneumatic chambers for damping pressure variation in the second pair of pneumatic chambers and thereby damping reciprocating flow of the working liquid anti-vibration medium in the second direction; and
conduit means for establishing a limited flow rate of communication of the working liquid anti-vibration medium between the main container and the first and second hydropneumatic damping mechanisms.
According to a still further aspect of the invention, a hydrostatic anti-vibration system comprises:
a main container to be mounted on a top portion of a construction to which anti-vibration effect is to be applied, and filled with a working liquid anti-vibration medium for converting vibration energy transmitted to the main container from the construction according to vibratory motion of the latter into a reciprocating flow of the working liquid anti-vibration medium in the main container for generating a vibratory counter force against the vibration force exerted on the construction;
two pairs of pneumatic chambers defined in upper portions of the main container, a first pair of the pneumatic chambers being arranged for causing pressure variation of pneumatic energy transmission medium in mutually opposite directions in response to reciprocating flow of the working liquid anti-vibration medium in a first direction, and a second pair of the pneumatic chambers being arranged for causing pressure variation of pneumatic energy transmission medium therein in mutually opposite directions in response to reciprocating flow of the working liquid anti-vibration medium in a second direction perpendicular to the first direction and in a common horizontal plane;
a first damping mechanism communicated with the first pair of pneumatic chambers for damping pressure variation in the first pair of pneumatic chambers and thereby damping reciprocating flow of the working liquid anti-vibration medium in the first direction;
first phase reversing means for reversing a phase of pressure variation between the first pair of pneumatic chambers in the main container and the first damping mechanism for accommodating a working liquid anti-vibration medium originated pressure variation, thereby avoiding influence thereof on the anti-vibration effect of the anti-vibration system;
a second damping mechanism communicated with the second pair of pneumatic chambers for damping pressure variation in the second pair of pneumatic chambers and thereby damping reciprocating flow of the working liquid anti-vibration medium in the second direction;
second phase reversing means for reversing a phase of pressure variation between the second pair of pneumatic chambers in the main container and the second damping mechanism for accommodating a working liquid anti-vibration medium originated pressure variation, thereby avoiding influence thereof on the anti-vibration effect of the anti-vibration system; and
an external damping force adjusting mechanism provided externally to and cooperated with respective of the first and second damping mechanisms for determining damping characteristics thereof for adjustment of the natural frequency of the anti-vibration system to a natural frequency of the construction.
According to a further aspect of the invention, a hydrostatic anti-vibration system comprises:
a main container to be mounted on a top portion of a construction to which an anti-vibration effect is to be applied, and filled with a working liquid anti-vibration medium for converting vibration energy transmitted to the main container from the construction according to vibratory motion of the latter into a reciprocating flow of the working liquid anti-vibration medium in the main container for generating a vibratory counter force against the vibration force exerted on the construction;
two pairs of pneumatic chambers defined in upper portions of the main container, a first pair of the pneumatic chambers being arranged for causing pressure variation of pneumatic energy transmission medium therein in mutually opposite directions in response to reciprocating flow of the working liquid anti-vibration medium in a first direction, and a second pair of the pneumatic chambers being arranged for causing pressure variation of pneumatic energy transmission medium therein in mutually opposite directions in response to reciprocating flow of the working liquid anti-vibration medium in a second direction perpendicular to the first direction and in a common horizontal plane;
a first hydropneumatic damping mechanism communicated with the first pair of pneumatic chambers for damping pressure variation in the first pair of pneumatic chambers and thereby damping reciprocating flow of the working liquid anti-vibration medium in the first direction;
first phase reversing means for reversing a phase of pressure variation between the first pair of pneumatic chambers in the main container and the first damping mechanism for accommodating a working liquid anti-vibration medium originated pressure variation, thereby avoiding influence thereof for anti-vibration effect of the anti-vibration system;
a second hydropneumatic damping mechanism communicated with the second pair of pneumatic chambers for damping pressure variation in the second pair of pneumatic chambers and thereby damping reciprocating flow of the working liquid anti-vibration medium in the second direction;
second phase reversing means for reversing a phase of pressure variation between the second pair of pneumatic chambers in the main container and the second damping mechanism for accommodating a working liquid anti-vibration medium originated pressure variation, thereby avoiding influence thereof on the anti-vibration effect of the anti-vibration system; and
conduit means for establishing a limited flow rate of communication of the working liquid anti-vibration medium between the main container and the first and second hydropneumatic damping mechanisms.
According to a yet further aspect of the invention, a hydrostatic anti-vibration system comprises:
a main container to be mounted on a top portion of a construction to which an anti-vibration effect is to be applied, and filled with a working liquid anti-vibration medium for converting vibration energy transmitted to the main container from the construction according to vibratory motion of the latter into a reciprocating flow of the working liquid anti-vibration medium in the main container for generating a vibratory counter force against the vibration force exerted on the construction;
two pairs of pneumatic chambers defined in upper portions of the main container, a first pair of the pneumatic chambers being arranged for causing pressure variation of pneumatic energy transmission medium therein in mutually opposite directions in response to reciprocating flow of the working liquid anti-vibration medium in a first direction, and a second pair of the pneumatic chambers being arranged for causing pressure variation of pneumatic energy transmission medium therein in mutually opposite directions in response to reciprocating flow of the working liquid anti-vibration medium in a second direction perpendicular to the first direction on a common horizontal plane;
a first hydropneumatic damping mechanism communicated with the first pair of pneumatic chambers for damping pressure variation in the first pair of pneumatic chambers and thereby damping reciprocating flow of the working liquid anti-vibration medium in the first direction;
first phase reversing means for reversing a phase of pressure variation between the first pair of pneumatic chambers in the main container and the first damping mechanism for accommodating a working liquid anti-vibration medium originated pressure variation, thereby avoiding influence thereof on the anti-vibration effect of the anti-vibration system;
a second hydropneumatic damping mechanism communicated with the second pair of pneumatic chambers for damping pressure variation in the second pair of pneumatic chambers and thereby damping reciprocating flow of the working liquid anti-vibration medium in the second direction;
second phase reversing means for reversing a phase of pressure variation between the second pair of pneumatic chambers in the main container and the second damping mechanism for accommodating a working liquid anti-vibration medium originated pressure variation, thereby avoiding influence thereof on the anti-vibration effect of the anti-vibration system;
an external damping force adjusting mechanism provided externally to and cooperated with respective of the first and second damping mechanisms for determining damping characteristics thereof for adjustment of the natural frequency of the anti-vibration system to a natural frequency of the construction; and
conduit means for establishing a limited flow rate of communication of the working liquid anti-vibration medium between the main container and the first and second hydropneumatic damping mechanisms.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will be understood more fully from the detailed description given, herebelow and from the accompanying drawings of preferred embodiments of the invention, which, however, should not be taken to be limiting to the invention, but are for explanation and understanding only.
In the drawings:
FIG. 1A is a perspective view of a first embodiment of a hydrostatic anti-vibration system according to the present invention;
FIG. 1B is a section taken along line A--A of FIG. 1A.
FIG. 2A is a partial enlarged section of the first embodiment of the hydrostatic anti-vibration system of FIG. 1B;
FIG. 2B is a section taken along line B--B of FIG. 2A;
FIG. 3 is a section similar to FIG. 2A but showing a modification of the first embodiment of the hydrostatic anti-vibration system according to the invention;
FIG. 4 is a plan view of a second embodiment of the hydrostatic anti-vibration system according to the present invention;
FIG. 5 is a plan view of a third embodiment of the hydrostatic anti-vibration system according to the present invention;
FIG. 6A is a plan view of the fourth embodiment of the hydrostatic anti-vibration system according to the present invention;
FIG. 6B is a section taken along line C--C of FIG. 6A;
FIG. 7 is a plan view of the fifth embodiment of the hydrostatic anti-vibration system according to the present invention; and
FIG. 8 is a sectional side elevation of the conventional hydrostatic anti-vibration system.
DESCRIPTION OF PREFERRED EMBODIMENTS
The preferred embodiments of the present invention will be discussed hereinafter in detail with reference to FIG. 1A to FIG. 7. In the following description, numerous specific details are set forth in order to provide a thorough understanding of the present invention. It will be obvious, however, to those skilled in the art that the present invention may be practiced without these specific details. In other instances, well-known structures are not shown in detail in order to not unnecessarily obscure the present invention.
First Embodiment
FIGS. 1A and 1B show the first embodiment of a hydrostatic anti-vibration system according to the present invention. The anti-vibration system includes a main tank 1 and a pair of intermediate tank portions 2 which are arranged in opposition to each other across the main tank 1. Each of the intermediate tank portions 2 is communicated with the main tank 1 via a respective pair of communication ducts 3.
The main tank 1 comprises a flat rectangular main tank body 4 and a hollow vertical extension 5 upwardly extended from the peripheral edge of the main tank body 4 and extending throughout the entire periphery thereof. Therefore, the main tank 1 is constructed in generally rectangular or dish-shaped configuration with a recessed central portion. The tank 1 is adapted to be installed on the roof or top or so forth of a construction or building. Water 6 as a working fluid or anti-vibration medium fills the entire interior space of the main tank, body 4 and is further filled to an intermediate height level of the vertical extension 5. Respective pairs of portions of the vertical extension 5 positioned in opposition to each other are adapted to serve for suppression of vibration exerted in respective directions perpendicular to the longitudinal directions thereof. Therefore, one pair of portions of the vertical extension 5 suppresses vibrations in rearward and forward horizontal directions, and the other pair suppresses vibrations in left and right horizontal directions. Adjacent portions of the vertical extension 5 are blocked from communication to each other so that the action of the water for suppressing vibration in one horizontal direction will not affect suppression of vibration in the other horizontal direction. Respective portions of the vertical extension 5 are closed at the top. Each pair of the portions of the vertical extension 5 are communicated with one of the intermediate tank portions 2 via the respective pair of communication ducts 3 with respective hydropneumatic damping mechanisms described below.
Each intermediate tank portion 2 is an enclosed tank with a rounded lower half. A partitioning plate 7 is disposed within the interior space of the intermediate tank portion 2 depending from the ceiling thereof at the center portion so that a substantially U-shaped water flow path is defined in the intermediate tank portion. Water 8 is filled in the intermediate tank portion 2 to a level high than the lower end of the partitioning plate 7. A rotary shaft 9 is rotatably supported at the lower end of the partitioning plate 7 to extend horizontally. The rotary shaft 9 is rigidly connected to a pivotal plate 10 for pivotal movement within the rounded lower half of the intermediate tank portion 2. The pivotal plate 10 thus constructed pivots in response to flowing motion of water 8 induced by vibration of the construction. The rotary shaft 9 extends from the intermediate tank portion 2. A coil spring 11 is disposed between the extended end of the rotary shaft 9 and the stationary wall of the intermediate tank portion 2 and forms a damper for exerting a spring force for providing a resistance against rotary motion of the rotary shaft 9.
As shown in FIGS. 2A and 2B, the rotary shaft 9 is rotationally supported by water tight seal bearings 12 provided at both sides of the intermediate tank portion 2. To the extended end of the rotary shaft 9 positioned outside of the intermediate tank portion 2 is connected a threaded shaft 13 to depend perpendicularly from the rotary shaft 9. The threaded shaft 13 carries a pendulum 14 which provides a rotational inertia moment and a restoration force toward an initial position. The pendulum 14 is threadingly movable along the threaded shaft 13 for varying a lever ratio and thereby varying the natural frequency. Fastening nuts 15 are provided at both axial ends of the pendulum 14. With this construction, at a stable condition, the threaded shaft 13 vertically depends from the rotary shaft 9 due to the mass weight of the pendulum 14 to situate the pivotal plate 10 at a position vertically depending from the rotary shaft 9. This position of the pivotal plate 10 hereafter will be referred to as the neutral position. When a vibration is caused in the construction or building, a rocking motion is imparted to water 6 and 8 in the main tank 1 and the intermediate tank portions 2. A force thus is exerted on the pivotal plates 10 due to energy of flowing water, thereby to cause pivotal movement of plates 10. The vibration frequency of each pivotal plate 10 is determined by a combination of the spring coefficient of the respective coil spring 11 and the rotational inertia force and restoration force to be induced by the respective pendulum 14. This further determines the vibration frequency of the overall anti-vibration system.
Namely, the inertia moment to be generated on the pendulum 14 is variable depending upon the axial position thereof on the threaded shaft 13. The inertia force thus generated by the pendulum is combined with the resistance against rotation of the rotary shaft 9 exerted by the coil spring 11. For instance, when the pendulum 14 is positioned close to the rotary shaft 9, the rotational inertia moment become smaller so that the resistance against rotation of the rotary shaft 9 becomes smaller, and when the pendulum 14 is positioned away from the rotary shaft 9, the rotational inertial moment of the pendulum becomes greater to provide greater resistance against rotation of the rotary shaft 9. The natural frequency is variable depending upon the resistance against the rotation of the rotary shaft 9.
The ducts 3 are connected to mutually opposing portions of the vertical extension 5. Thus, the phases of rocking motion of the water flow between the associated pairs of the portions of the vertical extension 5 are mutually opposite. By the arrangement of the ducts 3 illustrated in FIG. 1B, as shown by the arrows, the direction of the fluid force of water and the direction of compression of air is serial throughout the system, including through the substantially U-shaped flow path in the intermediate tank portion. Therefore, cancellation of the fluid forces due to opposite phases of action, as occur in the prior art, can be successfully avoided. Furthermore, since motion of water portions 6 and 8 in the main tank 1 and in the intermediate tank portion 2 are synchronized with each other, a high anti-vibration effect can be achieved with a small size system. Also, since the vertically extending portion 5 is communicated to the main tank body 4 along the peripheral edges of the latter in mutually blocked fashion, flow of water 6 will be smooth so that a large proportion of water 6 in the tank 1 will contribute to the anti-vibration effect, even though the overall amount of water contained in the main tank 1 is small. Therefore, the same magnitude of anti-vibration effect can be attained with smaller tank size, in comparison with the prior art.
FIG. 3 shows a modification of the foregoing first embodiment of the hydrostatic anti-vibration system according to the invention. In this modification, the rotational inertial moment and the restoration force to be applied by the pendulum 14 acts in a direction opposite to the direction of the spring force of the coil spring 11. The threaded shaft 13 is extended vertically upwardly from the extending end of the rotary shaft 9. The pendulum 14 is engaged to the threaded shaft 13 for axial threading adjusted movement therealong. Opposite axial ends of the pendulum 14 are fixed by fastening nuts 15. The inertia force and restoration force to be generated by the pendulum at the occurrence of vibration is opposite to the direction of the spring force of the coil spring 11. Therefore, such construction will permit adjustment of the vibration frequency of the system by shifting the pendulum 14 along the threaded shaft 13, and thereby adjusting the counter force against the spring force.
Discussion now will be made of the manner of adjustment of the anti-vibration system constructed as set forth above. Initially, in the condition where the pendulum 14 is removed from the threaded shaft 13, a vibration of the overall construction or building is measured in the per se known manner by means of not shown vibration measuring equipment. The measuring equipment can detect fine vibration (normal fine vibration) caused by wind or so forth even when no substantial vibration due to earthquake and so forth occurs. Since the measured vibration period is equal to the natural period of the entire construction, the natural period can be measured at any time.
Subsequently, the pendulum 14 is mounted on the threaded shaft 13 and positioned at a position closest to the rotary shaft 9. Then, by manually swinging the threaded shaft 13 for free swinging motion, the vibration period is again measured. Then, by shifting the axial position of the pendulum 14 by threadingly shifting the fastening nuts 15, measurement of the vibration period is measured repeatedly at different axial positions of the pendulum 14. Thus, the axial position of the pendulum 14, where synchronization of the pivotal motion of the pivotal plate 10 to the natural period of the construction, can be established. Then, at the synchronized position, it is confirmed with a vibration gauge positioned at the top end of the construction or building that the amplitude of the vibration of the construction becomes minimum. Then, the pendulum 14 is fixed at the axial position where synchronization is established by tightening the fastening nuts 15. In addition, when the length of the threaded shaft 13 is not enough to adjust the vibration period, a different weight of pendulum 14 may be used so that synchronization can be established within a range of the adjustable stroke of the threaded shaft 13.
As set forth above, according to the embodiment constructed as set forth above, water 6 collides on a wall of the tank 1 with a delay to the natural period or vibratory phase of the vibration of the construction. According to rocking motion of water in the tank 1, the water level in each hollow portion of vertical extension 5 is varied to increase or decrease the air pressure therein. Variation of the air pressure at each air containing space of each portion of the hollow vertical extension 5 is introduced at both sides of the substantially U-shaped water flow path in the respective intermediate tank portion 2 to cause rocking water flow along the U-shaped flow path thereof. Against the water flow thus induced, the spring biased pivotal plate 10 serves to provide resistance. This resistance cancels vibratory energy of the construction. With the construction set forth above, a high anti-vibration effect can be attained for horizontal bi-directional vibration with a relatively small size of the tank.
Furthermore, the displacement characteristics or flow resistance characteristics of the pivotal plate 10 can be easily adjusted by varying the axial position of the pendulum 14 or by adjusting the spring coefficient of the coil spring 11. By adjustment of the displacement characteristics of the pivotal plate 10, the anti-vibration characteristics of the overall system can be synchronized with the natural frequency of the construction or the building. Also, the intermediate tank portions 2 can be placed at any arbitrary positions. Furthermore, since the intermediate tank portion 2 can be placed outside of the main tank, adjustment of the flow resistance for the rotary plate 10 can be facilitated. In addition, since two intermediate tank portions 2 are employed for obtaining anti-vibration effect for two horizontal directions, the construction of the anti-vibration system can be simplified. Furthermore, since adjustment of the anti-vibration characteristics against one direction of horizontal vibration can be done by adjusting only one portion, adjustment of the characteristics adapting to the vibration characteristics of the construction or building becomes easier.
It will be appreciated that, while the coil spring 11 is a primary element for producing resistance against pivotal movement of the pivotal plate 10 and the pendulum 14 is employed as an element for adjusting the anti-vibration characteristics, it is possible to employ only pendulum 14 for producing the resistance against pivotal movement of the pivotal plate 10 and for adjustment of the anti-vibration characteristics. Also, while the resistance against pivotal motion of the pivotal plate 10 is provided by the coil spring 11, it is possible that the pivotal plate can be coupled with an active drive such as a motor, hydraulic actuator and so forth for actively suppressing vibration of the construction.
Second Embodiment
Next, discussion will be made of the second embodiment of the hydrostatic anti-vibration system according to the present invention. It should be noted that like reference numerals to the foregoing first embodiment denote like elements.
As shown in FIG. 4, two intermediate tank portions 2 are positioned in the recessed central portion of the main tank body 4 surrounded by the vertical extension 5. Two spaces defined in each intermediate tank portion 2 by the respective partitioning plate 7 are communicated with respective mutually opposing portions of the vertical extension 5 through ducts 3 to cause fluid flow in reversed phases. Therefore, the fluid forces in two spaces of one intermediate tank portion 2 are opposite in phase to the adjacent portions of the vertical extension 5, thereby certainly avoiding mutual cancellation. Since the intermediate tank portions 2 are arranged on the main tank body 4, the length of the ducts 3 can be shortened and the overall size of the anti-vibration system can be made smaller.
Third Embodiment
FIG. 5 shows the third embodiment of the hydrostatic anti-vibration system according to the present invention. Two spaces defined in each intermediate tank portion 2 by the respective partitioning plate 7 are communicated with respective mutually opposing portions of the vertical extension 5 through the ducts 3 to cause fluid flow in the same phase.
Fourth Embodiment
FIGS. 6A and 6B show the fourth embodiment of the hydrostatic anti-vibration system according to the invention. Four vertical extensions 5 are provided at respective four corners of the main tank body 4 in communication with the latter. Four intermediate tank portions 2 are provided between adjacent vertical extensions 5.
Fifth Embodiment
FIG. 7 shows the fifth embodiment of the hydrostatic anti-vibration system according to the invention. The bottom of the intermediate tank portion 2 and the main tank body 4 are communicated through a conduit 16 so that the water levels in the vertical extensions 5 and in the intermediate tank portion 2 are constantly maintained equal. The diameter of the conduit 16 is selected in such a manner that the water levels in the vertical extensions 5 and in the intermediate tank portion 2 are equal in the static state, but that the anti-vibration effect will not be affected, the small diameter of the conduit 16 provides sufficient water flow restriction. Even when water flows through the ducts 3 between the main tank body 4 and the intermediate tank portions 2 to cause a difference of the water levels due to large amplitude vibration, water will flow through the conduit 16 to gradually equalize the water levels. With this construction, it becomes unnecessary to manage the water levels in the main tank body 4 and in the intermediate tank portions 5 to maintain then at equal level. It should be appreciated that the connection between the vertical extensions 5 and two spaces defined in the respective intermediate tank portion 2 may be established in equal phase (as shown by solid lines) or in reverse phase (as shown by broken lines).
Although the invention has been illustrated and described with respect to exemplary embodiments thereof, it will be understood by those skilled in the art that the foregoing and various other changes, omissions and additions may be made therein and thereto without departing from the spirit and scope of the present invention. Therefore, the present invention should not be understood as limited to the specific embodiments set forth above but to include all possible embodiments which can be embodied within a scope encompassed and equivalents thereof with respect to the feature set forth in the appended claims. | A hydrostatic anti-vibration system includes a main tank provided on a construction to be suppressed from vibrating and having a main tank body of substantially flat rectangular configuration. Hollow vertical extensions extend upwardly from peripheral edge portions of the main tank body and are filled with a working liquid at a predetermined level with upper air chambers maintained thereabove. Ducts communicate the upper air chambers of the hollow vertical extensions. Intermediate tank portions are disposed at the intermediate portions of respective ducts and contain a vibration suppressing liquid. A pivotal plate is disposed in each of the intermediate tank portions to separate the interior space of the intermediate tank portion into a pair of chambers respectively connected to corresponding portions of the duct. The plate pivots in response to flow pressure of the vibration suppressing liquid. A damping mechanism provides a resistance against displacement of the pivotal plate. | 4 |
FIELD OF THE INVENTION
[0001] The invention relates to an interlock mechanism interconnecting the reel and a fore-and-aft adjustable cutterbar of a harvesting header.
BACKGROUND OF THE INVENTION
[0002] Typically, a header for a harvesting machine includes a cutterbar which is operable to cut standing crop as the machine moves forward and a rotatable reel which carries tines to engage the standing crop and sweep it towards the cutterbar for cutting and then carry the cut material towards an auger before releasing it. The auger usually consolidates the cut crop material centrally of the header before it is passed to the body of the machine for processing. The distance between the cutterbar and the auger is critical and in general the optimal position depends on the type and condition of the crop to be harvested. Therefore some header types have been provided with a cutterbar mounted to a forwardly extendable cutting table, enabling the operator of the harvesting machine to adapt its configuration when the crop condition or type changes.
[0003] When harvesting down crops, i.e., crops that are not standing in a normal upright position, the relationships between the reel, the cutterbar and the auger is equally critical and, in general, the reel should be disposed so that the path described by the outer ends of the tines first enters the down crop forwardly of the cutterbar and below the level thereof for lifting the crop, then sweep closely over the cutterbar and finally pass in close proximity along the auger.
[0004] Headers are known in which the cutterbar is vertically flexible along its length so that it can follow local irregularities in the ground. With such headers, it is necessary to be able to adjust the height of the reel relative to the highest point of the cutterbar at any given instant, otherwise the cutterbar is likely to foul the reel on flexing with consequential damage to one or both components. To this end, headers having flexible cutterbars have been fitted with means for automatically adjusting the position of the reel on vertical flexure of the cutterbar.
[0005] Similar problems may occur when the cutterbar of an extendable header is set to forwardmost position. Then the cutterbar will enter into the reel path that is required otherwise for harvesting down crops with a retracted cutting table. The tines or the bars of the reel may then damage the cutterbar or vice versa. Measures must be taken to prevent such interference and limit the path of the reel tines when the header is extended.
[0006] EP-A-0 250 649 describes an interlock mechanism including a linkage mechanism between the movable cutting table and the hydraulic actuators on each side of the header that position the reel in a vertical direction. The interlock mechanism includes a bell-crank lever pivotally mounted on the corresponding header side wall. The linkage interconnects the cutterbar and the lever, whereas the other lever arm holds the lower end of the actuator. The mechanism adjusts the position of the actuator and hence of the reel in response to a fore-and-aft adjustment movement of the cutterbar so as to maintain the minimal spacing between the reel and the cutterbar substantially constant.
[0007] Another existing mechanism, as used in the Varifeed™ headers of New Holland, uses a cam system for limiting the vertical position of the reel arm. The system comprises a linkage whereby a first arm is fixed to the movable cutterbar table and a second arm is fixed to the frame below the reel arm. At the end of the second leg a cam is fixed which makes contact with a roller installed on the reel arm when this arm is lowered. When the cutterbar moves forward, the first leg will pull on the second leg and rotate the cam, thereby pushing the roller upwards. As such, the reel arm is pushed upwards, hereby lifting the reel and avoiding interference with the cutterbar.
[0008] These known systems have some disadvantages. The connection point between the reel arm and the interlock mechanism, or the contact point between the cam and the roller is close to the rotation point of the reel arm. Considering the weight of the reel and the accelerations caused by operation on a bumpy field, the load on the interlock mechanism or the cam is high. Furthermore, the load is transferred directly to the frame, which is not advantageous for frame deformation and lifetime. Another disadvantage for the cam system is that the hydraulic lift cylinder is fixed to the frame, while the reel arm can be forced upwardly by the cam. Hereby, when extending the header and lifting the reel, the cylinder rod gets pulled outwards little resulting in oil or air getting drawn through the sealing of the cylinders.
[0009] As illustrated by DE-A-195 08 887, it is also conceivable to provide a sensor on the reel arm for contacting a cam surface on the movable cutterbar table when the cutterbar is extended. A control system reacts to the contact signal of the sensor by loading the hydraulic actuator and raising the reel arm until the sensor is disengaged from the cam. Such system entirely relies on the proper and continuous operation of the sensor, which is positioned in a vulnerable forward position close to the crop. Hence, it does not have the reliability of mechanical systems. Furthermore, it limits the available stroke of the actuator and the consequent vertical range of the reel.
[0010] It is an object of the present invention to provide a header with a fore-and-aft adjustable cutterbar to suit various crops and crop conditions and which avoids interference between the reel and the cutterbar upon adjustment of the cutterbar.
SUMMARY OF THE INVENTION
[0011] According to the present invention there is provided an extendable header for a harvesting machine having a frame, a cutterbar mounted on the frame operable to cut standing crop, the cutterbar being adjustable relative to the frame in a fore-and-aft direction, and a reel rotatably supported between a pair of reel arms pivotally mounted on the frame and operable to sweep crop material towards and over the cutterbar, a hydraulic cylinder extending between each reel arm and a corresponding side wall of said header frame to effect a generally vertical movement of said reel, and an interlock mechanism operably interconnecting the cutterbar and the hydraulic cylinder at each side of the header for adjusting the vertical position of the reel in response to a fore-and-aft movement of the cutterbar to avoid interference between the reel and the cutterbar, said interlock mechanism including a linkage mechanism at each side of the header, wherein each linkage mechanism comprises a body connected to the cutterbar and extending along a corresponding side wall of said header frame, said body following the generally horizontal movement of the cutterbar, and interconnecting means between said body and the hydraulic cylinder at each side wall of the header frame, said interconnecting means comprising guiding means for guiding the hydraulic cylinder in a generally vertical movement, and the body in a generally horizontal movement, said body further comprising adjustment means for effecting said vertical movement of the hydraulic cylinder in relation to said horizontal movement of the cutterbar.
[0012] In one embodiment said body is a plate with a generally wedge-like (triangular) shape being adapted to lift/lower the hydraulic cylinder accordingly as the body is moved forwardly or rearwardly by the cutterbar.
[0013] In another embodiment said body is a plate with a wedge-defining slot or groove applied into the body, having a shape adapted to lift/lower the hydraulic cylinder accordingly as the body is moved forwardly or rearwardly. The use of a slot or groove restricts the upward movement of the cylinder and the reel for a given position of the body.
[0014] Advantageously, the adjustments means, e.g. the shape of the wedge or of the slot, are configured for maintaining substantially constant the spacing between the reel and the cutterbar as the body is moved. Hence, once the operator has set an optimal spacing, this spacing will not be altered upon adjusting the forward position of the cutterbar.
[0015] The invention may provide adjustment means comprising a wedge-like or triangular shape applied along an edge or a side of said body, or into said body, along or into which the hydraulic cylinder is moved vertically as the body moves horizontally. Said triangular shape is adapted to lift/lower the hydraulic cylinder accordingly as the body is extended/retracted.
[0016] Advantageously the guiding means for the hydraulic cylinder comprise a generally vertical slot connected to the frame, whereby said vertical slot comprises a bearing ) connected to the hydraulic cylinder.
[0017] In a preferred embodiment the guiding means for the body comprise one or more rollers or bearings at each side of the body, at the upper and lower side of the body, for supporting the body in a generally horizontal movement.
[0018] In one embodiment the body is at least partly guided by the same guiding means as the hydraulic cylinder, such as e.g. the bearing in the vertical slot that is used for the vertical movement of the hydraulic cylinder.
[0019] The invention also provides interconnecting means comprising a functional connection between the guiding means of the hydraulic cylinder and the adjustment means of the body. In one embodiment the hydraulic cylinder interconnects with the cutterbar by sliding the bearing in the vertical slot along the wedge-like shape of the body connected to the cutterbar.
[0020] According to an advantageous embodiment of the present invention the hydraulic cylinder is supported fully by the upper ridge of a wedge-like shape of the body.
[0021] In one embodiment the hydraulic cylinder could be replaced by a fixed connection, meaning that the reel arm is connected to the vertical slot via a non-actuating connection.
[0022] The present invention has some important advantages over the prior art. High reaction loads on the frame are avoided, since the entire reel system is supported at a point remote from the pivot of the reel arms. Hereby frame deformation and lifetime are optimised. The arrangement also avoids outwards pulling movement on the cylinders during cutterbar extension, such that no oil will be drawn through the sealing of the cylinders. Furthermore, there is no reduction of the available stroke of the vertical lift cylinder, even when the knife is fully extended.
BRIEF DESCRIPTION OF THE FIGURES
[0023] The invention will now be described in further detail, by way of example only, with reference to the accompanying drawings, in which:
[0024] FIG. 1 is a side view of an extendable header in a fully retracted position, the header comprising a movable cutterbar table, an adjustable reel and a height control mechanism between the reel and the cutterbar according to a first embodiment of the invention;
[0025] FIG. 2 is a side view of the extendable header of FIG. 1 in a fully extended position; and
[0026] FIG. 3 is a side view of a reel height control mechanism between the reel and the cutterbar according to an alternative embodiment of the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0027] FIG. 1 illustrates a header 10 comprising a main frame 11 , a cutterbar 12 mounted on an extendable cutterbar table 13 , a transverse auger (not shown) mounted in an auger trough 14 , and a reel 15 mounted for rotation between the forward ends of a pair of reel arms 16 , the other ends of which are pivotally connected at 17 to the frame 11 such that the reel 15 can be raised and lowered. The reel 15 carries transverse tine bars 18 fitted with tines 19 which are arranged to maintain a fixed orientation as the reel 15 rotates, in a conventional manner. The outer tips of the tines 19 describe a circular path. When the header is operating in down crops, the reel 15 is positioned as close as possible to the cutterbar 12 in order to optimise the cooperation between the reel 15 and cutterbar 12 . More specifically the arrangement is such that the tine path extends as close as possible to the ground forwardly of the cutterbar 12 to lift down crop for presenting it to the cutterbar 12 to pass crop to the auger for consolidation centrally of the machine for passage through a central opening (not seen in the drawings) in the rear wall 23 of the header for processing by a conventional combine harvester (not shown) to which the header is, in use, fitted.
[0028] The operator can vary the position of the reel 15 in a generally vertical direction by means of a hydraulic cylinder 20 , which is pivotably connected to the reel arm 16 , and in a generally horizontal direction by means of a further cylinder 21 . This second cylinder is arranged between a lug on the reel arm 16 and a reel bearing 22 , which is slideably mounted on the front end of the reel arm 16 .
[0029] Depending on the nature and condition of the crop to be harvested, the position of the cutterbar 12 has to be adjusted relative to the auger, and the reel 15 is adjusted relative to the cutterbar 12 . In accordance with the present invention, the cutterbar 12 is adjustable in a generally fore-and-aft direction of the harvesting machine for which the header 10 is intended. The reel 15 is adjustable towards the ground and as close as possible towards the cutterbar 12 in each of its forwards positions.
[0030] Upon adjustment of the cutterbar 12 and/or the reel 15 , interference between the reel tines 19 and the cutterbar 12 could occur if no precautions are taken. This is due to the fact that the cutterbar 12 and the reel 15 are adjustable in a plane intersecting with the tine path 11 of the reel 15 when the latter is in its lowermost position. Preferably, the reel tines 19 should reach below the level of the cutterbar 12 when the reel 15 is positioned for harvesting down crops. Forward adjustment of the cutterbar 12 inevitably would result in damage to the reel tines 19 in the first place, but eventually also to the cutterbar 12 in case the reel tines 19 are made of spring steel, as is conventional, rather than of synthetic material (plastic) as has been proposed in recent years.
[0031] In order to prevent said interference between the cutterbar 12 and the reel 15 , the present invention provides an interlock mechanism 70 between the reel 15 and the cutterbar 12 .
[0032] FIGS. 1 and 2 illustrate different embodiments of the present invention whereby the interlock 70 prevents interference by raising the reel 15 upon adjustment of the cutterbar 12 in the forward direction. Similarly, the interlock 70 lowers the reel 15 when the cutterbar 12 is retracted so as to maintain the vertical clearance between said reel 15 and the cutterbar 12 substantially constant.
[0033] The interlock 70 comprises on each side of the header a linkage mechanism which interconnects the reel arm 16 and the cutterbar 12 for limitation of the lowermost position of the reel 15 in relation to the forward position of the cutterbar 12 . The reel 15 is connected to the header frame 11 by a reel arm 16 . According to the invention the space between the reel 15 and the cutterbar 12 is controlled by a hydraulic lift cylinder 20 moveably connected to the cutterbar 12 .
[0034] Each linkage mechanism comprises a hydraulic cylinder 20 having an upper end connected to the reel arm 16 and a lower end to a portion of the frame 11 . The hydraulic cylinder 20 is connected to the frame 11 via the embodiments of the present invention. According to the present invention, this connection to the frame is not fixed, but movable.
[0035] FIGS. 1 and 2 illustrate a first embodiment wherein a side portion 30 of the frame 11 comprises a substantially vertical slot 33 and two bearings 35 , 36 , an upper movable bearing 35 and a lower fixed bearing 36 . The lower end hydraulic cylinder 20 is connected to the upper bearing 35 , which is movable in the upright slot 33 . A body 32 , connected to the movable cutterbar table 13 , is guided inbetween the two bearings 35 , 36 whereby the upper ridge of the wedge-like shape 34 of the body 32 moves the upper bearing 35 as the body is moved horizontally. The side of the wedge 34 closest to the back of the frame 11 has the bigger wedge side.
[0036] When the cutterbar 12 is adjusted from the fully retracted position of FIG. 1 to the fully extended position of FIG. 2 , the wedge-like body 32 is pulled out, thus imparting a lifting to the associated hydraulic cylinder 20 relative to the header frame 11 , whereby the related reel arm 16 , and hence reel 15 , is lifted. The top angle of the wedge shape 34 is chosen such that the distance between the reel 15 and the cutterbar 12 is maintained substantially constant on horizontal adjustment of the cutterbar 12 . The relative horizontal position of the reel 15 and the auger equally is maintained substantially constant on adjustment of the cutterbar 12 as the pivot connection 17 of the reel arm 16 on the frame 11 is chosen close to the auger axis. The height of wedge shape 34 is specifically adapted to avoid interference between the reel 15 and the cutterbar 12 when the hydraulic cylinder 20 is fully retracted and the reel 15 is in its lowermost position. The shape 34 further is adapted to keep the distance between the reel 15 and the cutterbar 12 quasi constant.
[0037] In an alternative embodiment the lower bearing 36 is replaced by one or more bearings fixed to the frame, either located under the vertical slot, or located at any other position for supporting the wedge body 32 .
[0038] Each linkage system may further comprise a damper or spring to prevent the reel from jumping up and down when the cutterbar 12 is not fully extended. However, it has been experienced that the weight of the reel 15 itself provided enough vertical load to maintain contact between the bearing 35 connected to the hydraulic cylinder 20 and the upper ridge of the wedge 32 .
[0039] The upper bearing 35 may comprise a transversely positioned stub shaft and a roller mounted thereon, which is engaged by the ridge of the wedge body 32 . Advantageously the roller is profiled for maintaining the vertical position of the body 32 during its movement. The lower bearing 36 may comprise a similar arrangement for guiding the lower edge of the body 32 .
[0040] According to another embodiment of the present invention there may be provided one or more extra upper bearings for guiding the body.
[0041] In one embodiment the wedge-like shaped body 32 further has an extra top ridge extension towards the back of the frame in order to allow the bearing 35 of the hydraulic cylinder 20 to follow the shape 34 .
[0042] In a second embodiment the frame 11 comprises a substantially vertical slot 33 with one bearing 35 connected to the hydraulic cylinder 20 ; wherein said bearing is also running in a rearwardly and upwardly inclined slot 40 comprised in the body 32 ′; the body is guided inbetween upper rollers 42 and lower rollers 43 whereby the wedge-like shape 34 of the rearwardly inclined slot 40 moves the bearing 35 in the vertical slot 33 as the body 32 ′ is moved horizontally.
[0043] FIG. 3 illustrates the second embodiment of an interlock mechanism according to the invention, wherein the connection between the hydraulic cylinder 20 and the frame 11 is similarly connected to the frame by a shaft with a bearing 35 that can slide in an upright slot 33 . Each linkage system further comprises a side plate or body 32 ′ connected on one side to the movable table 13 of cutterbar 12 and on the other side to the frame 11 . The side plate can slide between three pairs of rollers, each pair comprising a roller 42 on the upper side and a roller 43 on the lower side. The side plate 32 ′ comprises a rearwardly and upwardly inclined slot 40 wherein the bearing 35 of the hydraulic cylinder 20 can slide. As such, the connection of the hydraulic cylinder 20 is actually an interaction between an upright slot 33 for the connection to the reel 15 and a horizontal slot 40 for the connection to the cutterbar 12 , where inbetween the side plate 32 ′ can move.
[0044] When the cutterbar 12 is adjusted from the fully retracted position to the extended position, the side plate 32 ′ connected to the cutterbar 12 is pulled out, thus imparting a lifting to the lower end of the hydraulic cylinder 20 relative to the header 10 , whereby the related reel arm 16 , and hence reel 15 , is lifted. The shape 34 of the horizontal slot 40 in the side plate 32 ′ is specifically adapted to avoid interference between the reel 15 and the cutterbar 12 and to keep the distance between the reel 15 and the cutterbar 12 quasi constant.
[0045] The specifically adapted wedge shape 34 of the side plate slot 40 may also be provided by any other means. In one embodiment the wedge-like shape is a groove instead of a slot, wherein the reel arm 16 bearing can slide. In another embodiment an outer sliding mechanism may be provided, e.g. one comprising slide blocks instead of roller bearings.
[0046] In one embodiment the movable body supporting for the hydraulic cylinder is connected directly to the cutterbar 12 . In another embodiment the support is connected indirectly to the cutterbar 12 , e.g. by a linkage system.
[0047] The interlock 70 between the reel 15 and the cutterbar 12 remains operative irrespective of a relative fore-and-aft position of the reel 15 in the event fore-and-aft reel adjustment means are provided.
[0048] In one embodiment the reel arm 16 may comprise a separate hydraulic cylinder 20 to control the fore-and-aft position of the reel 15 . In another embodiment one hydraulic cylinder 20 for each linkage system controls both the height and the fore-and-aft position of the reel 15 , e.g. when the hydraulic cylinder is connected directly to the reel bearing 22 . Extension or retraction of the cylinder 20 then simultaneously lifts the reel arm 16 and slides the bearing 22 rearwardly or forwardly over the reel arm 16 .
[0049] Thus the present invention provides a header with a cutterbar which is adjustable generally fore-and-aft of the machine to which the header is fitted, this adjustment automatically altering the position of the reel relative to the cutterbar by virtue of the provision of the interlock mechanism between these two components whereby interference between these two components, upon fore-and-aft adjustment of the cutterbar, automatically is avoided. It will also be understood by one skilled in the art that an automatic adjustment of the reel position in response to the fore-and-aft movement of the cutterbar is particularly important under circumstances where the cutterbar movement can be accomplished on the go, i.e., during operation of the combine.
[0050] It will be understood that changes in the details which have been described and illustrated to explain the nature of the invention will occur to and may be made by those skilled in the art upon a reading of this disclosure within the principles and scope of the invention. As an example, it will be appreciated that the interlock mechanism 70 may be disposed between the cutterbar 12 and the pivot 17 for the reel arms 16 , whereby cutterbar movement results either in rotation of the reel arms 16 about the pivot 17 or shifting of the reel arm pivot axis 17 itself so as to maintain a substantially constant reel/cutterbar gap. It will be appreciated that linkage mechanisms other than those illustrated in the drawings may be employed in the interlock arrangement.
[0051] It will be appreciated that the hydraulic cylinder 20 for the vertical positioning of the reel is fully supported by the wedge-like body 32 , 34 , whereas in known systems the support was weak.
[0052] Furthermore, the interlock mechanism may be hydraulic; e.g. the wedge-like shaped plate connected to the cutterbar may be replaced by a hydraulic cylinder so that, as the cutterbar is adjusted, the length of the cylinder changes. A smaller body in the shape of a wedge or a cam may then be used to adjust the correct vertical movement of the reel arm 16 in relation to the horizontal movement of the cutterbar. In a further embodiment the oil displaced by the cylinder can be used for lifting the reel. | A header for a harvesting machine having a frame, a cutterbar mounted on the frame operable to cut standing crop, the cutterbar being adjustable relative to the frame in a fore-and-aft direction, and a reel rotatably supported between a pair of reel arms pivotally mounted on the frame and operable to sweep crop material towards and over the cutterbar, a hydraulic cylinder extending between each reel arm and a corresponding side wall of said header frame to effect a generally vertical movement of said reel, comprising an interlock mechanism operably interconnecting the cutterbar and the hydraulic cylinder at each side of the header for adjusting the vertical position of the reel in response to a fore-and-aft movement of the cutterbar to maintain substantially constant the spacing and avoiding interference between the reel and the cutterbar. | 0 |
RELATED APPLICATIONS
This application is a divisional of application Ser. No. 09/476,637, filed Dec. 31, 1999, which is a divisional of U.S. patent application Ser. No. 29/104,917, filed May 1, 1999 now issued as U.S. Pat. No. D 426,630.
BACKGROUND
The present invention relates to ceiling fans.
A typical ceiling fan will include a down rod assembly suspended from the ceiling, a motor having a motor shaft connected to a lower portion of the down rod assembly and a motor body which rotates about the motor shaft, a motor housing secured to either the motor shaft or the down rod assembly which is stationary and surrounds the motor, blade mounting arms which are connect to the motor body and extend out of an opening of the motor housing or below the motor housing, and a hub attached to the motor shaft below the fan blades and fan blade arms.
Because the motor housing of a typical ceiling fan encloses the motor, the motor housing must have various openings to allow the escape of heat from the motor. However, the openings in the motor housing complicate the design of the motor housing and may limit the escape of heat from the motor because of the limited availability of the apertures in the motor housing. Therefore, there is a need for a motor housing that will provide the motor with better heat transfer than a typical motor housing.
Many ceiling fans include lighting fixtures which are incorporated into the hub. However, end users may want the versatility of changing between the option of not having a lighting fixture, or the option of having a lighting fixture. Therefore, there is a need for a ceiling fan with the ability to quickly change between the option of having a lighting fixture, and the option of not having a lighting fixture.
SUMMARY
In one embodiment, the present invention comprises a ceiling fan having a motor connected to a plurality of fan blades, a cage surrounding the motor with a fan blade opening, wherein the fan blades extend outwardly through the fan blade opening and the fan blade opening provides clearance for the fan blades to rotate without contacting the cage. In a further embodiment, the cage is a wire cage.
In another embodiment, the present invention comprises a ceiling fan having a motor with a motor shaft, a hub canister containing a lighting fixture, and a detachable hub cover and a detachable light cover, wherein the detachable hub cover and light cover are interchangeable covers for the hub canister. In a further embodiment, the invention further includes hub light electrical leads with hub light electrical connectors, and the light fixture further includes fixture electrical leads with fixture electrical connectors that mate with the hub light electrical connectors. In another further embodiment, the hub canister further includes hub protrusions and the hub cover and the lighting cover further include channels to receive the hub protrusions, thereby securing the respective hub cover or light cover to the hub canister.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other features, aspects, and advantages of the present invention will become better understood with regard to the following description, appended claims, and accompanying drawings where:
FIG. 1 shows a perspective view of one embodiment of the present invention, illustrated as a ceiling fan;
FIG. 2 shows a top plan view of the ceiling fan from FIG. 1;
FIG. 3 shows a side elevational view of the ceiling fan from FIG. 1;
FIG. 4 shows a bottom plan view of the ceiling fan from FIG. 1;
FIG. 5 shows an enlarged partial bottom plan view of the ceiling fan from FIG. 1, with a hub cover removed to illustrate a portion of a lighting kit; and,
FIG. 6 shows a side elevational view of the ceiling fan from FIG. 1, illustrating the alternate embodiments with a hub cover or a lighting cover.
DETAILED DESCRIPTION
Referring now to the figures, there is shown an embodiment of the present invention illustrated in the ceiling fan 10 . The ceiling fan 10 generally includes a down rod assembly 100 , a motor 200 , fan blades 300 , an upper body 400 , a hub assembly 500 , and a cage 600 .
The down rod assembly 100 includes a down rod 110 secured at one end to the location that the ceiling fan 10 depends from, and secured at a second end to a down rod mounting flange 120 . The down rod mounting flange 120 is secured to the shaft (not shown) of the motor 200 . Electrical wires for powering and controlling the ceiling fan 10 pass through the down rod 110 to the motor 200 .
The upper body 400 is secured to the down rod mounting flange 120 . A direction switch 410 is disposed on the upper body 400 . The electrical powering and control of the ceiling fan 10 is well known in the art; therefore, in the interest of brevity, are not explained in detail here.
The fan blades 300 include a fan blade body 320 which is secured to a fan blade arm 310 . The fan blade arms 310 are secured to a motor body 210 of the motor 200 . In the embodiment illustrated, there are three fan blades 300 . However, it is to be understood that any number of fan blades 300 could be used in the ceiling fan 10 .
A hub body 510 or cannister of the hub assembly 500 is secured to the lower half of the shaft (not shown) of the motor 200 , the down rod mounting flange 120 , or both. The hub body 510 includes cover mounting protrusions 512 extending inwardly from the hub body 510 . The hub cover 520 includes hub cover mounting passages 522 in the sides of the hub cover 520 for engaging the cover mounting protrusions 512 in the hub body 510 , thereby securing the hub cover 520 to the hub body 510 in a detachable manner.
The cage 600 includes an upper cage section 610 and a lower cage section 620 . The upper cage section 610 is secured to the upper body 400 and depends downwardly therefrom. The lower cage section 620 is secured to the hub body 510 and extends upwardly therefrom. A cage fan blade opening 630 exists between the upper cage section 610 and the lower cage section 620 for the fan blades 300 to extend outwardly through. As illustrated, the upper cage section 610 and the lower cage section 620 are formed of a wire material to maximizing the openness of the cage 600 while maintaining protection of the motor 200 . In this manner, the cage 600 protects the motor 200 without placing restrictions on the fan blades or inhibiting the transfer of heat from the motor 200 via radiation and convection.
In one embodiment of the present invention, the ceiling fan 10 includes a lighting kit 700 . The lighting kit 700 has a lighting fixture 710 and a light cover 720 . The lighting fixture 710 includes a lighting socket 711 which is mounted inside the hub body 510 by a socket bracket 712 . Fixture electrical socket leads 713 from the light socket 711 have fixture electrical connectors 714 for connection of the lighting kit. Hub light electrical leads 530 extend through an electrical lead opening 514 in the hub body 510 , and have hub light electrical connectors 534 for connection with the fixture electrical connectors 714 . A light bulb 715 is disposed in the light socket 711 . A light cover 720 is either transparent or translucent is used in place of the hub cover 520 for the lighting kit 700 . The electrical leads for supplying the lighting fixture 710 pass through the down rod 110 and the motor shaft (not shown) in a manner that is commonly known to a person of ordinary skill in the art. Light cover mounting passages 722 in the sidewalls of the light cover 720 engage the cover mounting protrusions 512 in the hub body 510 for securing the light cover 720 to the hub body 510 in a detachable manner. By supplying the ceiling fan 10 with the lighting kit 700 , a user can decide between a non-lighted fixture and a lighted fixture by deciding on using the hub cover 520 , or connecting the socket electrical connectors 714 to the hub light electrical connectors 534 and using the light cover 720 in place of the hub cover 520 .
It is thus believed that the operation and construction of the present invention will be apparent from the foregoing description of a preferred embodiment. While the device and method shown are described as being preferred, it will be obvious to a person of ordinary skill in the art that various changes and modifications may be made therein without departing from the spirit and scope of the invention, as defined in the following claims. Therefore, the spirit and scope of the appended claims should not be limited to the description of the preferred embodiments contained herein. | A ceiling fan having a down rod assembly, a motor, fan blades, an upper body, a hub assembly, and a cage. The cage provides an open enclosure for protecting the motor. The hub includes a hub canister and a hub cover. A lighting kit includes a lighting fixture within the hub canister and a lighting cover that is interchangeable with the hub cover. | 5 |
This is a continuation of copending application Ser. No. 07/516,183 filed on Apr. 30, 1990, now abandoned.
BACKGROUND OF THE INVENTION
This invention relates to structural injection molded parts and more particularly to an improved method and apparatus for forming such parts.
Structural injection molded parts are parts formed of an injection molded resin material with one or more sheets of reinforcing fabric or material embedded in the resin to enhance the structural strength of the part. Structural injection molded parts are finding increased application in many industries because they possess the moldability and formability characteristics of injection molded parts and yet have sufficient strength to enable them to be employed in applications where structural strength is critical. Whereas various methods and apparatus have heretofore been proposed to produce structural injection molded parts, the prior art methods and apparatus have been unduly complicated and expensive.
SUMMARY OF THE INVENTION
This invention is directed to the provision of an improved method and apparatus for producing structural injection molded parts.
The invention methodology includes the steps of providing a mold assembly including a female mold part defining a concavity and a male mold part defining a convexity sized to fit into the concavity of the female mold part to define a mold cavity corresponding to the shape of the part to be molded; positioning reinforcing material over the concavity of the female mold part; moving the male mold part convexity into the female mold part concavity to position the reinforcing material in the mold cavity; and injecting resin into the mold cavity to produce a structural injection molded part. This methodology allows all of the steps necessary to produce a structural injection molded part to be performed in a single continuous process.
According to a further feature of the invention methodology, the method includes the further step of trimming the material to the shape of the part after the material is moved into the mold cavity. This methodology allows the necessary trimming function to be readily incorporated into the invention methodology.
According to a further feature of the invention methodology, a closed loop cutting blade is positioned in surrounding relation to one of the mold parts and the trimming step is performed by moving the cutting blade relative to the surrounded mold part. This methodology provides a compact and efficient package for performing the forming and trimming functions.
According to a further feature of the invention methodology, the mold and the cutting blade it surrounds are part of and movable with a common die set assembly with a lost motion drive connection between the mold and the cutting blade. The trimming step is accomplished by lost motion movement between the mold and the cutting blade.
According to a further feature of the invention methodology, the trimming step is performed before the resin injecting step. This arrangement allows the resin injection step to be confined to the configuration and extent of the finished part.
According to a further feature of the invention methodology, a seal is provided around the peripheral edge of the female mold concavity to preclude the escape of resin from the mold cavity.
According to a further feature of the invention, the trimming step is performed with a closed loop cutting blade and the seal is provided proximate the inner periphery of the cutting blade. This arrangement allows a convenient means of precluding the escape of resin between the male mold and the cutting blade.
According to a further feature of the invention methodology, the male mold part is positioned within the cutting blade and defines an annular interface with the cutting blade, a seal is position-ed around the male mold part at the interface between the male mold part and the cutting blade, and means are provided to press the seal into the interface between the male mold part and the cutting blade following the trimming step. This arrangement ensures that there will be no leakage of resin between the cutting blade and the mold part.
According to a further feature of the invention methodology, before the male mold part is moved into the female mold part concavity, the reinforcing material is clamped around the periphery of the concavity. This arrangement allows selective control of the movement of the material into the mold cavity as the male mold part convexity is moved into the female mold part concavity.
According to a further feature of the invention methodology, the reinforcing material is substantially non-stretchable and the clamping step includes selectively controlling the clamping pressure to allow material to selectively slip pass the clamping interface to allow the male mold part to move into the concavity.
According to a further feature of the invention methodology, the clamping step includes selectively varying the clamping pressure around the clamped peripheral interface to provide a varying clamping force on the material as measured around the clamping interface. This arrangement allows the slippage as between the clamping means and the material to be selectively controlled to selectively control the movement of the material into the mold cavity.
According to a further feature of the invention methodology, the resin injecting step is performed by introducing resin into the mold cavity through the female mold part. This arrangement simplifies the introduction of the resin into the mold cavity.
The apparatus according to the invention includes a mold assembly including a female mold part defining a concavity and a male mold part defining a convexity sized to fit into the female mold part concavity; and means for moving the mold parts between a retracted position in which the male mold part convexity is withdrawn from the female mold part concavity and an inserted position in which the male part convexity is positioned within the female mold part concavity to define a mold cavity therebetween corresponding to the shape of the part to be molded and further define an access opening therebetween at the periphery of the concavity providing access to the mold cavity from a location external to the mold assembly whereby to allow a sheet of reinforcing material to be positioned over the concavity with the mold parts in their retracted position whereafter the mold parts may be moved to their inserted positions to position the sheet within the mold cavity with edge portions thereof extending through the access opening to a location external to the mold cavity; and means for injecting resin into the mold cavity to impregnate the sheet of reinforcing material and form a reinforced structural injection molded part. This arrangement allows a single apparatus to perform all of the major steps required to produce a structural injection molded part.
According to a further feature of the invention apparatus, the apparatus further includes means for trimming the edge portions of the sheet. This arrangement allows the invention apparatus to further incorporate the means to trim the part to its final configuration.
According to a further feature of the invention apparatus, the trimming means comprises a cutting blade mounted in surrounding relation to the male mold part and mounted for cutting movement relative to the male mold part. This arrangement provides a convenient and compact package that provides an effective means for trimming the part.
According to a further feature of the invention apparatus, the mold and the cutting blade it surrounds are part of and moveable with a common die set assembly with a lost motion drive connection between the mold and the cutting blade. The trimming step is accomplished by lost motion movement between the mold and the cutting blade.
According to a further feature of the invention apparatus, the apparatus further includes means for clamping the edge portions of the sheet. This arrangement allows the apparatus to control the movement of the sheet into the mold cavity.
According to a further feature of the invention apparatus, the clamping means comprises pressure plate means positioned in surrounding relation to the male mold part. This arrangement provides a compact and efficient package and provides effective control of the movement of the material into the mold cavity.
According to a further feature of the invention apparatus, means are providing for sealing the mold cavity proximate the access opening to the mold cavity. This arrangement ensures that resin will not escape from the mold cavity during the resin injection operation.
According to a further feature of the invention apparatus, the sealing means includes a seal structure mounted in surrounding relation to the male mold part. This arrangement provides a convenient means of sealing the mold cavity.
According to a further feature of the invention apparatus, the seal structure is mounted on the periphery of the male mold part and the apparatus further includes pressure plate means positioned in surrounding relation to the male mold part within the cutting blade and having an edge engaging the seal structure. This arrangement allows the seal to be pressed into the sealing interface to further enhance the sealing function.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a fragmentary perspective view of the invention apparatus;
FIG. 2 is a cross-sectional view taken on line 2--2 of FIG. 1 and showing the mold parts in their inserted disposition;
FIG. 3 is a cross-sectional view similar to FIG. 2 but showing the mold parts in their retracted disposition;
FIG. 4 is a cross-sectional view taken on line 4--4 of FIG. 2;
FIGS. 5A, 5B and 5C are detail views taken within the circle 5 of FIG. 2;
FIG. 6 is a perspective view of the female mold part;
FIG. 7 is a perspective view of the male mold part; and
FIG. 8 is a perspective view of a structural injection molded part formed utilizing the method and apparatus of the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The invention apparatus is intended for use with a conventional press, hydraulic or otherwise, including a bed 10 and a head 12 movable toward and away from each other in known manner to actuate apparatus positioned between the head and the bed.
The invention apparatus comprises a die set adapted to be positioned between bed 10 and head 12 and including a lower die set assembly 16 and an upper die set assembly 18.
Lower die set assembly 16 includes a mixing head 20, a bottom plate 22, a bottom or female mold 24, an injection nozzle 26, corner bushings 28, and stop blocks 30.
Mixing head 20 includes flange portions 20a for bolting the mixing head to the upper face of press bed 10 and defines a central reaction chamber 20b opening at 20c in the upper face of the mixing head.
Bottom plate 22 has a rectangular configuration generally conforming to the configuration of mixing head 20 and bed 10 and is suitably secured to the upper face of the mixing head.
Bottom or female mold 24 is suitably and centrally secured to the upper face 22a of bottom plate 22 and defines a mold concavity 24a having a size and configuration determined by the size and configuration of the part to be formed. As best seen in FIG. 6, mold 24 has an annular configuration and includes a-cutting barrier in the form of an annular strip 32 positioned in an annular groove on the upper face 24b of the mold in surrounding relation to mold cavity 24a. Strip 32 may be formed for example of aluminum, polyethylene, nylon, steel, brass or other appropriate material and is intended to receive a cutting edge of the cutting blade of the invention apparatus during the trimming operation.
Injection nozzle 26 is positioned in a central aperture 22b of bottom plate 22 and includes an upper end portion 26a extending upwardly through a central aperture 24c in bottom mold 24 and a lower portion 26b positioned in the opening 20c of mixing chamber 20b with the central passage 26c of the nozzle opening at its upper end in the lower wall 24d of mold cavity 24a and opening at its lower end in mixing chamber 20b so as to provide communication between mixing chamber 20b and mold cavity 24a.
Bushings 28 are provided at the four corners of bottom plate 22 and project upwardly from the top face 22a of bottom plate 22.
Stop blocks 30 project upwardly from the top face 22a of bottom plate 22 at locations intermediate the corners of the bottom plate.
Upper die assembly 18 includes a mounting plate 36, risers 38, a top plate 40, an upper or male mold 42, a male mold mounting and stop system, a cutting blade 46, a seal 48, a seal pressure plate assembly, and a material pressure plate assembly.
Mounting plate 36 is suitably secured as by bolting to the bottom face 12a of press head 12.
Risers 38 extend rigidly downwardly from mounting plate 36.
Top plate 40 is secured at its upper face 40a to the lower edges 38a of risers 38 and has a size and configuration generally conforming to bottom plate 22.
Upper or male mold 42, as best seen in FIG. 7, includes a main body portion 42a, an annular ledge or lip portion 42b, and a convex lower portion 42c. Lower portion 42c is sized to fit within lower mold concavity 24a to define a mold cavity therebetween with lip or ledge 42b seating around the upper face of the concavity 24a proximate the cutting barrier 32.
Liquid ducts 58 are provided in upper and lower molds 42,24 to allow a cooling or heating liquid to be circulated through the molds to maintain a desired mold temperature.
The male mounting and stop system includes a pair of rods 60 rigidly secured to the upper face 42d of male mold 42 and extending upwardly therefrom for passage through bores 40b in top plate 40; a pair of outriggers or beams 62 positioned above top- face 40a of top plate 40; a pair of springs 64 positioned respectively in downwardly opening bores 62a provided in beam 62 and engaging the upper ends of rods 60; and rods 66 extending downwardly from the ends of beam 62 through apertures 40c in top plate 40 for stopping engagement at their lower ends 66a with the upper ends 30a of stop blocks 30. Rods 60, beams 62 and springs 64 comprises a lost motion drive connection between male mold 42 and surrounding cutting blade 46, which is rigidly mounted to top plate to. This lost motion drive connection provides for independent, lost motion movement between cutting blade 46 and male mold 42 as hereinafter described.
Cutting blade 46 is in the form of a closed loop steel blade rigidly secured to the underface 40d of top plate 40 in surrounding relation to main body portion 42a of male die 42. The lower edge of cutting blade 46 is beveled to define an annular cutting edge 46a.
Seal 48 is an annular elastomeric member and is positioned on the upper face 42e of lip 42b. Seal 48 includes a mounting or flange portion 48a seated on the lip upper face 42e and a main body triangular portion 48b seated on the angled outer peripheral face 42f of lip 42b and slidably engaging at its outer periphery 42g with the inner periphery 46b of cutting blade 46 proximate the lower end edge of the cutting blade. A ring member 69 is secured to male mold main body portion 42a to securely mount seal 48 with respect to the male mold. The seal pressure plate assembly includes an annular pressure plate 70 and a plurality of power cylinders 72. Pressure plate 70, as best seen in FIG. 4, has an annular configuration conforming in size and shape to the annular configuration of the triangular portion 48b of seal 48 and is positioned concentrically and slidably within the inner face 46b of cutter 46. As shown, pressure plate 70 may comprise a single unitary annular member or, alternatively, may comprise a series of segments together making up the annular configuration of the pressure plate. Power cylinders 72 are positioned on the upper face 40a of top plate 40 in an annular pattern corresponding to the annular shape of pressure plate 70 and each includes a piston rod 74 extending downwardly through an aperture in top plate 40 for engagement with the upper edge 70a of annular pressure plate 70.
The material pressure plate assembly includes an annular pressure plate 80 positioned in surrounding relation to cutting blade 46 and a plurality of power cylinders 82. Whereas pressure plate 80 may comprise a single unitary annular member, preferably, and as shown, pressure plate 80 is formed of a series of pressure plate segments 80a-j together defining an annular configuration in surrounding relation to cutting blade 46.
Power cylinders 82 are mounted on the top face 40a of top plate 40 and arranged in an annular pattern corresponding to the annular configuration of pressure plate 80. Each power cylinder 82 includes a piston rod 84 extending downwardly through-an aperture in top plate 40 for securement to the top edge of pressure plate 80. As shown, a power cylinder 82 and a piston rod 84 is associated with each segment of the pressure plate so that the pressure plate segments may be individually controlled to vary the pressure applied along the lower edge 80k of the pressure plate assembly as measured around the periphery of the pressure plate.
Operation
With the die set in the retracted or fully open position as seen in FIG. 3 and with cylinders 82 extended to move the pressure plate segments 80 to a location wherein the composite lower face 80k of the pressure plate segments is below or leading the bottom or leading surface 42e of the male die, a sheet of component, reinforcing material 90 is laid over the concavity 24a of the female die 24 with peripheral portions 90a of the sheet extending respectively beyond the side edge surfaces 24e, f, g, and h of the female mold. Sheet 90 may comprise, for example, one or more sheets of woven fiberglass material having a total thickness of, for example, 1/4 inch.
The press is now actuated in a manner to move head 12 downwardly toward bed 10 so as to move the upper die set 18 downwardly toward the lower die set 16. As the lower faces 80a of the pressure plate- segments 80 contact the upper face of sheet 90 to clamp the sheet against the annular upper face 24b of the female mold, the upper die set continues downwardly and cylinders 82 are actuated in a manner to gradually retract piston rods 84 so as to maintain clamping force on sheet 90 while allowing the upper die set to continue its downward movement. As the upper die set continues downwardly as allowed by the retracting movement of piston rods 84, the convexity 42c of die member 42 contacts the upper face of sheet 90 and, with continued downward movement of the upper die set, begins to move into the concavity 24a of the lower mold.
Since the fiberglass material of sheet 90 is essentially non-stretchable, the downward movement of convexity 42c into concavity 24a is accompanied by slippage of the component material 90 at the interface between the lower faces 80a of the pressure plate segments and the upper face of the sheet to allow the sheet to move downwardly into concavity 24a along with male mold convexity 42c. The pressure of the fluid delivered to the various cylinders 82 is selectively varied, as measured around the periphery of the annular pattern of the cylinders, to provide selectively varying force against the sheet along the annular undersurface 80a of the pressure plate segments so as to allow the sheet to move smoothly and efficiently downwardly with the convexity 42c into the cavity 24a.
This selective pressure as applied in varying degrees around the annular interface between the pressure plate segments 80 and the component material may be accomplished with a single unitary pressure plate 80 but, in most situations, is more effectively accomplished, as illustrated, by forming the pressure plate 80 of a series of pressure plates segments 80a-80j with at least one cylinder 82 associated with each segment to allow the individual segments to be individually adjusted with respect to the amount of pressure applied by that segment to the component material as the material slips between the interface of surface 80a and the upper face of the female mold for movement into concavity 24a.
The lower limit of movement of male mold 42 into concavity 24a is determined by engagement of the lower faces 66a of rods 66 with the upper faces of stop blocks 30. This delimited position of downward movement of male mold 42 is adjusted to provide a mold cavity 100 of desired dimensions between the convexity 42c of male mold 42 and the concavity 24a of female mold 24.. The downwardly delimited stop position of the male mold also defines an annular access opening 102 between the lower annular face 42g of lip 42 and the annular upper face 24b of the female mold. Annular access opening 102 will be seen to provide access to the mold cavity 100 at a location-external to the mold assembly so as to allow the sheet 90 to be positioned within the cavity 100 by the downward movement of convexity 42c into concavity 24a while allowing the edge portions 90a of the sheet to extend outwardly through access opening 102 to a location external to the mold cavity on all sides of the mold cavity.
After the male mold reaches its delimited downward position, as determined by engagement of surfaces 66a,30a, the upper die set continues to move downwardly an incremental amount, as seen by a comparison of FIGS. 5A and 5B, to allow the lower edge 46a of the cutting blade 46 to move downwardly through the sheet 90 and sever the sheet so as to trim the sheet to a shape conforming to the closed loop internal periphery of the cutting blade. As seen in FIG. 5B, the upper die set is moved downwardly to a point where the lower sharpened edge of the cutting blade may move slightly into the material of the cutting barrier 32 so as to ensure a total and effective cut. The relative movement as between the male mold 42 and the remainder of the upper die set 18, including the cutting blade, is made possible by the lost motion drive connection provided by rods 60 and springs 64.
After the upper die set has completed its downward movement to the position seen-in FIG. 5B, cylinders 72 are actuated to extend piston rods 74 and press the lower ends of the piston rods downwardly against the upper edge 70a of pressure plate 70 and thereby press the lower edge of the pressure plate against the upper edge of seal 48 so as to, as best seen in FIG. 5C, tend to extrude the lower edge of triangular seal portion 48b downwardly into the interface between blade 46 and male mold lip 42 so as to coact with the cutter blade to ensure that the annular edge of mold cavity 100 is effectively sealed.
Specifically, the inner face 46b of cutter blade 46 effectively precludes fluid leakage radially outwardly out of cavity 100 through annular opening 102, and seal 48 effectively precludes fluid leakage upwardly out of cavity 100 between the male mold and the cutter blade.
Resin is now injected into mold cavity 100 through passage 26c of nozzle 26. The resin is injected under pressure and moves upwardly through the material 90 within the cavity 100 so as to effectively and completely permeate the material 90 and totally fill the cavity 100 with resin and with the component material with movement of the resin beyond the annular edge of the cavity precluded by the inner surface 46b of blade 46 and by seal 48.
The resin injected through nozzle 26 into the mold cavity is preferably a two part reaction type mixture wherein the two ingredients of the resin are mixed in chamber 20b and, during the "cream" time of the resin, the resin is injected through nozzle 26 into the mold cavity by a suitable injection mechanism in the form of a screw or the like (not shown) so as to enter the mold cavity and totally permeate the material 90 throughout the mold cavity.
Following a suitable cure time which will of course vary depending on the part being formed and the nature of the resin employed, upper die set 18 is moved upwardly by head 12 of the press to return the die set to the retracted position seen in FIG. 3, whereafter the formed structural injection molded part 110 is removed from the mold cavity, with the aid of ejectors if necessary, and the invention apparatus is ready to begin another injection molding cycle. The part 110, as seen in FIG. 6, comprises a bumper beam for use on a motor vehicle to support the finish facia of the bumper in the completed motor vehicle.
The invention method and apparatus will be seen to provide a simple and effective system for forming structural injection molded parts utilizing a single apparatus to perform all of the necessary steps required to form the part and allowing all of the steps of the methodology to be performed in an efficient, compact and continuous manner.
Whereas a preferred embodiment of the invention has been illustrated and described in detail, it will be apparent that various changes may be made in the disclosed embodiment without departing from the scope or spirit of the invention. | A method for forming structural injection molded parts includes the steps of positioning a closed-loop cutting blade in surrounding relation to one of a male and female mold which together define a mold cavity corresponding to the shape of a part to be molded, positioning reinforcing material over the female mold, moving the male mold into the female mold to position the reinforcing material in the mold cavity, thereafter moving the cutting blade independently of the mold which it surrounds to trim the reinforcing material, and injecting resin into the mold cavity to produce a structural injection molded part. The cutting blade and the mold which it surrounds are part of and movable with a common die set assembly having a lost motion drive connection between the mold and the cutting blade, such that the trimming step is accomplished by lost motion movement between the mold and the cutting blade after the male and female molds have been mated. The method also includes the step of selectively controling the clamping pressure on the reinforcing material about the peripheral interface of the molds. | 1 |
[0001] This application is a continuation-in-part of U.S. application Ser. No. 11/087,640, filed Mar. 24, 2005, and is entitled to that priority date, in whole or in part, for priority. The complete disclosure, specification, drawings and attachments of U.S. application Ser. No. 11/087,640 are incorporated herein in their entireties by reference.
FIELD OF INVENTION
[0002] The present invention relates to a method and device for creating holographic, microstructure, refractive or reflective images on flexible graphic arts, and converting or packaging substrates. More particularly, the present invention relates to a method of impressing such images from a master film into an energy-curable coating on a flexible substrate in a pre-determined registration with one or more printed images on the substrate.
BACKGROUND OF INVENTION
[0003] Coatings are used extensively by the graphic arts printing industry to protect and enhance products. The graphic arts printing industry and its packaging segment commonly apply coatings and other finishes to aesthetically and protectively improve printed materials and substrates, including business cards, catalogues, brochures, posters, publication covers, folding cartons, blister cards, shrink wrap films, and labels. Merchandisers are seeking a product that appeals to the consumer with a unique design and graphic appearance that differentiates their product from the rest.
[0004] Holographic, microstructure or refractive images, and other surface finishing techniques, are widely used in a variety of decorative and security applications, including throughout the graphic arts and converted industries to create flexible substrates and materials with a unique and distinctive look. Holographic and other microstructure or refractive images are applied to printed material to capture the visual attention of the viewer by producing elaborate visual effects via light refraction and reflection. Such applied imagery can produce different viewing effects depending on the viewing angle, light source, and image details. Additionally, holograms and other microstructure imagery are often used to authenticate the genuineness of a product and increase the difficulty of counterfeiting.
[0005] Due to the mechanical application techniques involved, all graphic arts coatings and finishes, including mirror, textured, and holographic finishes, are apt to vary in the quality of the finished product. Oftentimes, in order to perform such coatings and finishes, a printed substrate must be removed from the printing press where the ink was applied and placed in separate machines that perform the duties of coating, ultraviolet curing, and the like. This results in a variation in appearance and an inconsistent look being presented to the purchasing consumer, who is attracted to the sales appeal of an aesthetically appealing finished printed product.
[0006] The predominant method of applying holograms to flexible substrates has been the lamination of an embossed holographic film such as PET (polyethylene terephthalate) or BOPP (biaxially oriented polypropylene) to the substrate. This method provided a decorative effect and served as a deterrent to counterfeiting; however, it consumed additional raw materials, it prevented the recycling of paper and paperboard substrates, and it increased manufacturing costs.
[0007] An alternative method for applying holographic and other microstructure images used heating, as disclosed in U.S. Pat. No. 5,155,604, and while eliminating the need for lamination, it created other important drawbacks. For example, applying holograms to rigid resin substrates with a heated cylinder to form microstructure images in a hardened resin substrate can produce image distortion because of the substantial heat and pressure required to impress the image into the rigid substrate. Similarly, applying further heating to previously heat-impressed films, such as the heat necessary to apply shrink film webs with microstructure images to container surfaces, can distort the images, effectively causing them to disappear or to lose some of their holographic or other refractive properties. Moreover, many graphic arts, converting, and packaging substrates are heat sensitive, and exposure to temperatures at or above 30° C. would damage or destroy the substrate.
[0008] A method employed in the prior art for casting holograms or other images in registration with printing on a substrate uses a holographic or other image embedded in a cylinder or film; consequently, it can transfer shim lines or other unwanted patterns to the finished product. For example, electroformed metal masters may be welded together or plastic masters may be ultrasonically butt-welded, or a number of masters may be adhered to the surface of the cylinder with the impressing surfaces of the masters facing out. In each case seams are present which can be impressed onto the receiving substrate along with the intended imagery.
[0009] Systems for impressing holographic and other microstructure or refractive images into a layer of curable liquid resin using cylinders with adjacent relief image masters (as described above) and then curing are also known. These systems suffer shortcomings in addition to those stemming from the seams between adjacent masters on the cylinder. For example, it is difficult to maintain accurate registration between the impressing image on the cylinder and printing on the substrate carrying the curable liquid resin. This problem is exacerbated when the system is run at high speed. Indeed, current systems for impressing holographic and other microstructure or refractive images into a layer of curable liquid resin using cylinders with adjacent relief image masters offer no means for fine tuning the alignment between the impressing image on the cylinder and printing on the substrate carrying the curable liquid resin.
[0010] As manufacturers have increased their use of holography and diffractive patterns to improve security, counterfeiters have responded by developing increasingly sophisticated counterfeiting methods. Counterfeiters may use an exposed cast surface image itself to create a duplicate master of a holographic, refractive, or diffractive effect.
[0011] Packaging professionals seek visual impact, functionality, recyclability and sustainability, and cost effectiveness. Visual impact drives shelf appeal; it improves market differentiation; and it improves packaging value added. Functionality is a requirement, for no matter how good a package or product looks, it must perform on the packaging line and on the shelf. Current environmental awareness increases the need for packages and products that are recyclable and sustainable. Last, a package or product must be affordable; consequently, the methods used to produce the package or product must be cost effective.
[0012] Accordingly, what is needed is an environmentally friendly, cost effective method or apparatus for creating holographic, microstructure, refractive and reflective images in registration on a substrate, which may eliminate repeat lines, reduce image distortion, and is compatible with temperature sensitive substrates. Further, there is a need for a method or apparatus that achieves accurate registration at high speed and accommodates large images.
SUMMARY OF INVENTION
[0013] In one exemplary embodiment, the method for applying a cast finish to a printed substrate includes the steps of sealing the ink on a printed surface of the printed substrate with a coating to form a coated surface, laminating a film onto the coated surface of the printed substrate, curing the coated surface of the printed substrate with ultraviolet lighting through the film, removing the film from the coated surface of the printed substrate, and moving the substrate to a stacking unit. If a spot effect is desired, the sealing step can be replaced with the step of spot sealing the ink on the printed surface of the printed substrate with a coating.
[0014] The film used to create the finish on the substrate may be a transparent film. However, the finish can be altered by changing or altering the film itself. If an embossed effect is desired, a film with an embossed design can be used. Likewise, if a gloss effect is desired, a gloss film can be substituted. Also, if a holographic or reflective finish is desired, a holographic film or a film with a holographic image or design can be laminated onto the coated surface of the printed substrate.
[0015] In another embodiment, an apparatus or machine for performing the steps of the method for applying a cast finish to a printed substrate includes a coating unit for sealing the ink on the printed surface of the printed substrate with a coating to form a coated surface; a laminating unit for laminating the printed substrate with the film; a film handling unit for retaining, unwinding, and rewinding a roll of film; a series of ultraviolet lights for curing the coated surface of the printed substrate with ultraviolet lighting; a stacking unit for retaining the printed substrate; and a series of belts and rollers for moving the printed substrate through the machine. The machine can be a roll-fed or sheet-fed type machine and is manufactured to attach to an existing printing or coating press such that the process all takes place inline.
[0016] The finish or finished image that is applied to the printed substrate can be varied by altering the appearance of the film itself. Thus, when the film is laminated against the coated surface of the printed substrate and cured with the ultraviolet light, the resulting finish or decorative image is cast by the film onto the printed substrate. Once the substrate is cured, the film may be peeled away, rewound, and used four more times on successive substrates.
[0017] Another exemplary embodiment employs a master web that can be any length desired, with repeating impressing images regularly spaced along the web. In yet another embodiment, the master web may be a continuous loop, adjustable for repeat length and with repeating impressing images regularly spaced along the web loop. In order to transfer the images from the master web at an impressing station, the surface of the web carrying the impressing images is nipped against the surface of a flexible substrate carrying printing overlaid with an energy curable coating that is either continuous across the web or selectively spot coated. After the impressed image is applied to the energy curable coating at this impressing station in registration with the printing on the flexible substrate, the resin is cured through the master web by UV lamps, electron beam, or other energy cure unit. Post cure, a stripping roller separates the master web from the flexible substrate, and the flexible substrate is delivered for additional processing or use as desired.
[0018] This embodiment of an energy curable coating impressing system may be used in-line with conventional printing systems that apply printing to the flexible substrate ahead of the energy curable coating application and impressing steps. Alternatively, printing may be applied after the energy curable coating application/impressing steps, or both before and after the energy curable coating application/impressing steps. Also, the energy curable coating application/impressing system may be used in a standalone fashion where printing is applied to the flexible substrate web in a separate discrete step at a remote location. Additionally, printing may be applied to one or both sides of the flexible substrate, including optionally overprinting the energy curable coating after it is cured. As an anti-tampering method for certain security applications, a removable coating may be laid down over the energy curable coating in such an overprinting step to hide the microstructure image until access is required to establish the product's bona fides by wiping away the removable coating to reveal the microstructure image.
[0019] In one embodiment, the master web and the flexible substrate are both provided with registration marks that are aligned in accordance with the invention before the master web impressing image is nipped to the energy curable coating to ensure accurate registration between the impressed image in the energy curable coating and the printing on the flexible substrate. The registration marks may be any type of mark that is detectable by a register control scanner such as printed rectangles, triangles or other geometric shapes, cross hairs, or bulls eyes known to the art.
[0020] In another exemplary embodiment, there are no actual registration marks of the flexible substrate. Instead, virtual registration marks are created by monitoring the position of a print cylinder in an energy-curable coating station by means of an encoder known to the art and measuring and tracking the actual length of the flexible substrate fed through the energy-curable coating unit. This predetermined length must be determined in advance to allow for the fine tuning of either the master roll or the substrate web to prevent any accumulated difference and to ensure that a consistent repeat is maintained between the images on the substrate web and the impressing images on the master web.
[0021] In yet another embodiment, the master web and a sheet fed flexible substrate are both provided with registration marks that are aligned in accordance with the invention before the master web impressing image is nipped to the energy curable coating to ensure accurate registration between the impressed image in the energy curable coating and the printing on the flexible substrate. This may be accomplished with a unique fine-tuning step by varying the line speed of a conveying mechanism for a sheet fed flexible substrate.
[0022] In another exemplary embodiment, the invention accomplishes registration using unique iterative steps in which the images on the master web are spaced apart or have a “repeat” distance slightly less than the intended spacing (or “repeat”) of the impressed images in coordination with the printed images on the flexible substrate so that the master web can be stretched on-the-fly, in increments or by varying amounts, to establish and then to maintain continuous registration of the impressed image and the printing on the flexible substrate. The on-the-fly stretching process relies on sensing the arrival of registration marks on the master web at a predetermined master web register scanner location chosen to correlate with the arrival of the registration marks on the flexible substrate at another predetermined substrate register control scanner location where simultaneous arrival of the registration marks of the master web and flexible substrates at these predetermined locations indicates proper registration of the impressed images and the printed images on the flexible substrate. Thus, when the registration marks on the master web arrive at the master web register scanner before the registration marks on the flexible substrate arrive at the substrate register control scanner, correction by on-the-fly variable stretching of the master web is carried out as described below. When there is no such image dislocation, no correction is applied. Also, since the practical stretching range of the master web is limited and varies depending on the material and thickness of the master web, where the image dislocation exceeds the practical stretching range of the master web, the image alignment typically will proceed in successive or iterative stretching steps until full alignment is achieved.
[0023] On-the-fly variable stretching is accomplished by running the master web through at least two powered nip stations where the master web speed nip station (the nearest to the impressing station) has a line speed corresponding to the line speed of the flexible substrate through the impressing station and the line speed of the master web tension nip station is decreased as necessary causing the master web to stretch between the two nip stations until the registration marks on the master and flexible substrates arrive at the nip point of the impression station simultaneously. The master and carrier registration mark arrivals are monitored by register control scanners at these locations that send the register mark data to an electronic register control system known to the art to control the line speed of the upstream nip pair as appropriate to achieve the necessary stretching of the master web. The stretching of the master web is thus continuously adjusted by the electronic register control system which receives and processes an error signal indicative of the extent to which the registration marks on the master and flexible substrates are out of alignment. This process may be facilitated by generally “pre-aligning” the images before start up so that the number of iterations of correction can be minimized.
[0024] In another embodiment, the on-the-fly variable stretching is applied to a web-fed flexible substrate using the stretching technique described above with respect to the master web to achieve an on-the-fly continuous registration between the impressed image and the printing on the flexible substrate. This is accomplished by adjusting the speed of a servo-controlled substrate web tension nip. The substrate web tension nip is continuously adjusted by an electronic register control system which receives and processes a signal indicative of the extent to which the registration marks on the master and substrate web are apart.
[0025] Accordingly, one embodiment of the present invention includes preparing a flexible substrate with uniformly spaced image registration marks at regular intervals. An energy-curable coating may be applied to the flexible substrate either uniformly or in selected spots (“spot coating”). Spot coating is preferred for shrink film flexible substrates where the amount of energy-curable coating is to be minimized since large amounts or broadly applied energy curable coating can produce distortions in the film when it is later shrunk, e.g., onto a container. A master web carrying a uniformly spaced impressing image and registration marks at regular intervals is supplied. Electron beam or UV curing energy is transmitted through the master web to cure or harden the energy curable coating; afterwards, the master web is separated from the flexible substrate to leave a cast image on the flexible substrate. The master web may typically be provided on a supply roll although it also may be in the form of a continuous belt. Where the master web is in the preferred form of a supply roll, it may be rewound and reused without reconditioning.
[0026] In a further exemplary embodiment, rapidly achieved and maintained accurate alignment of the registration marks of the flexible substrate and the master web is accomplished. This may be achieved by an apparatus including: (1) register scanners which sense the location of the registration marks on the flexible substrate and the master web; (2) an electronic register control system programmed to monitor error signals representing the on-the-fly deviation in the alignment of the master web and flexible substrate registration marks and makes determinations of the amount of stretching that must be applied to the master web in order to bring the registration marks into alignment; and (3) means for achieving the appropriate stretching to produce the desired alignment. Further, the stretching may be generally accomplished in increments that do not exceed the maximum acceptable elastic limits of the carrier film being used. For example, the elastic limit would be up to approximately 1.5%-3.0% for oriented polypropylene master web as a percent of length.
[0027] The flexible substrate and master webs can be any appropriate sufficiently flexible material. Preferably, in one embodiment the flexible substrate will have a thickness in the range of about 10-100 mil (0.254-2.54 mm). For example, the flexible substrate may be heat shrinkable film, polyethylene terephthalate, polypropylene, oriented polypropylene, polyvinyl chloride, polystyrene, amorphous polyethylene terephthalate, polyethylene, paper, metal foil, coiled metal. In another preferred embodiment the flexible substrate will be a heat shrinkable film. Appropriate heat shrinkable films include oriented polystyrene, glycol-modified polyethylene terephthalate, and polyvinyl chloride. For such heat shrinkable films, the film thickness will generally be in the range of about 30-80 microns.
[0028] The impressing image may be chosen to produce impressed images including, for example, holographic, varying texture images (e.g., matte film), stereograms, light-defracting devices, optical lenses, and lenticular surfaces.
[0029] The energy-curable coating may be any known flowable liquid energy-curable that can be rapidly cured by the application of ultra-violet radiation, electron beam, or other radiation curing method. For example, UV curable flowable liquid coatings may be used or coatings curable with electron beam radiation may be used. Examples of UV curable resins include, but are not limited to, UV curable overprint varnishes, free radical and cationic energy-curable coatings, and UV curable lithographic inks.
[0030] In one embodiment of the invention, the energy-curable coating will be curable with UV radiation and the master web will be sufficiently transparent or translucent to permit the UV radiation to pass through to cure the energy-curable coating.
[0031] In yet another exemplary embodiment, the master web comprises a cold foil film. An energy-curable coating will be applied to the flexible substrate either uniformly or in selected spots. Spot coating is used when a “foil stamp” reflective image is desired. UV curing energy is transmitted through the cold foil master web to cure a high adhesion energy curable coating such as Cork Industries' CU-1137HG-21VS. Suitable commercially available high adhesion energy curable coatings in this class are available, for example, from Cork Industries, 500 Kaiser Drive, Folcroft, Pa. 19032. The high adhesion energy curable coating strips metal from the cold foil in a wet lamination process known to the art. In another embodiment, an auxiliary energy cure unit is added between the coater and the master web nip. The coater applies an energy curable pressure sensitive coating to the flexible substrate either uniformly or in selected spots, the auxiliary energy cure unit activates the coating, the substrate is nipped to the cold foil master web, and the pressure sensitive energy curable coating strips metal from the cold foil in a dry lamination process known to the art. Afterwards, the master web is separated from the flexible substrate to leave a reflective metal image on the flexible substrate. The master web will typically be provided on a supply roll, and it may be rewound for reconditioning.
[0032] These and other features of the present invention will become readily apparent upon further review of the following specification and drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0033] FIG. 1 is a flowchart showing the steps of a method for applying a cast finish to a printed substrate according to the present invention.
[0034] FIG. 2 is a side view, partially in section, of an embodiment of an apparatus for applying a cast finish to a printed substrate according to the present invention.
[0035] FIG. 3 is a diagrammatic representation of a system in accordance with an exemplary embodiment of the present invention in which registration between printed images on a web fed flexible substrate and impressed holographic and other microstructure or refractive images also on the flexible substrate is achieved.
[0036] FIG. 4 is a diagrammatic representation of a system in accordance with an exemplary embodiment of the present invention in which registration between printed images on a sheet fed flexible substrate and impressed holographic and other microstructure or refractive images also on the flexible substrate is achieved.
[0037] FIG. 5 is a diagrammatic representation of a system in accordance with an exemplary embodiment of the present invention in which registration between printed images on a web fed flexible substrate and impressed holographic and other microstructure or refractive images also on the flexible substrate is achieved by means of a continuous loop master web used in lieu of the master web shown in FIG. 3 .
[0038] FIG. 6 is a diagrammatic representation of a system in accordance with an exemplary embodiment of the present invention in which registration between printed images on a sheet fed flexible substrate and impressed holographic and other microstructure or refractive images also on the flexible substrate is achieved by means of a continuous loop master web used in lieu of the master web shown in FIG. 4 .
[0039] FIG. 7 a is a diagrammatic representation of a system in accordance with an exemplary embodiment of the present invention in which a sub-side frame is installed and can be lifted for minimizing the waste on the master web and product itself, where the master web is in contact with the flexible substrate.
[0040] FIG. 7 b is a diagrammatic representation of the system of FIG. 7 a where the sub-side frame is in the lifted position.
[0041] FIG. 8 a is a diagrammatic representation of a system in accordance with an exemplary embodiment of the present invention in which the impression cylinder is moved downward for easier substrate web transporting, where the impression cylinder is in the up, or engaged, position.
[0042] FIG. 8 b is a diagrammatic representation of the system of FIG. 8 a where the impression cylinder is in the down, or disengaged, position.
[0043] FIG. 9 a is a diagrammatic representation of a system in accordance with an exemplary embodiment of the present invention in which wet or dry lamination cold foiling is achieved.
[0044] FIG. 9 b shows a cold foil reflective image made by the method of FIG. 9 a.
DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS
[0045] In one exemplary embodiment, the present invention comprises a method and device for applying a cast finish to a printed substrate. Finishes, including embossed, gloss, and holographic finishes, are used throughout the graphic arts printing industry to create printed materials with a unique and distinctive look. All graphic arts coatings and finishes, due to the mechanical application techniques involved, are apt to vary in the quality of the finished product. In one embodiment, the present invention offers a new method and apparatus by which the graphic arts printing industry may include finishes and decorative design images on common printed substrates, thereby providing a consistently high quality and visually aesthetic finished product.
[0046] As shown in FIG. 1 , in one embodiment the process begins by sealing the ink that has been printed onto a substrate with a coating process to form a coated surface. The coating process can include coating the printed substrate with a UV coating or any other radiation type coating process that is accepted in the industry. The printed substrate is a printed material that has completed the printing process in a standard printing press.
[0047] The next step involves laminating a film onto a coated surface of the printed substrate. The film is cast such that the entire printed surface of the substrate is covered by a layer of film. Depending on the desired finish, different films can be used, including transparent film, gloss film, holographic film, or any such film with an embossed design. Next, ultraviolet light is used to cure the coated surface of the printed substrate. The ultraviolet light is applied to the coated surface while the film is laminated on top of it, resulting in the desired finish or design image being fixed on the printed substrate. After the ultraviolet curing has been finished, the film is removed from the surface of the printed substrate and the finished substrate is moved to a stacking unit. The stacking unit is where all of the completed substrates are collected after the process has been applied.
[0048] FIG. 2 shows an exemplary embodiment of an apparatus that may be used to carry out the method for applying a cast finish to a printed substrate. The apparatus is a machine that includes a coating unit 114 for sealing the ink on the printed surface of the printed substrate with a coating, a laminating unit 124 for laminating the printed substrate with the film, a film handling unit 122 for retaining, unwinding, and rewinding the film, a series of ultraviolet lamps 126 for curing the printed surface of the printed substrate with ultraviolet lighting, a stacking unit 116 for retaining the printed substrate, and a series of belts 118 and rollers 120 for moving the printed substrate through the machine. The machine is a roll-fed or sheet-fed type machine that is designed to be attached to a standard printing or coating press, allowing all of the steps of the present invention to occur inline with the printing process itself. The machine can be designed to retrofit any and all of the printing presses that are currently being used in the industry.
[0049] In one particular embodiment, the method described herein takes place at temperatures less than 40 degrees C. Further, no material is transferred from the film to the coating on the flexible substrate, whereby the film can be used multiple times without re-treating. In addition, in one embodiment, light pressure or no pressure is applied after the film is applied to the surface of the flexible substrate. It will be understood that the term “substrate” as used herein refers to plastic, paper, cardboard, metal, or any other flexible material utilized by those in the graphic arts printing industry.
[0050] FIG. 3 shows another embodiment of an apparatus for transferring holographic and other microstructure or refractive images onto a web-carried energy curable coating in registration with printing on the flexible substrate impressed is illustrated. The graphic arts or converting flexible substrate 14 may be any web-like material which is capable of being passed through a printing press-type apparatus. For example, the flexible substrate may be PET, polypropylene, oriented polypropylene, PVC, polystyrene, APET, polyethylene, coated and uncoated papers, foils, thin metal or coil, paperboard, or the like. One particularly desirable flexible substrate is heat-shrinkable film. Flexible substrate 14 in the illustrated embodiment is oriented polystyrene suitable for shrink wrap applications and includes flexible substrate registration marks 6 which are printed onto the web (and would not be thick enough to be apparent in the view of FIG. 3 but have been enlarged here in order to make them visible).
[0051] Flexible substrate 14 is advanced through a web tension control nip 12 to an energy curable coating station 10 , and the coater applies a spot or full flood coat of an energy curable coating onto the surface of the flexible substrate web 14 using an appropriate coating apparatus and process. The energy curable coating station may be of any conventional design and may use, for example, gravure, flexographic, lithographic or silk screen techniques to apply the energy curable coating.
[0052] The energy curable coating may be any known flowable liquid resin that is rapidly curable by the application of actinic radiation, including particularly UV radiation, electron beam radiation, and LED light. Examples of classes of suitable energy curable coatings include UV curable overprint varnishes, free radical and cationic energy curable coatings, curable lithographic inks, and the like. Suitable commercially available energy curable coatings in these classes are available, for example, from Cork Industries, 500 Kaiser Drive, Folcroft, Pa. under the trademarks and product designations CORKURE™ CU-1170HG-38, CU-1170HG-49, CU-2038HG-25, CU-1164HG-14, and CU-1137HG-21VS.
[0053] The coated flexible substrate 14 is advanced past a substrate register control scanner 16 toward an impression cylinder 18 where it passes through a nip point formed by the powered impression cylinder 18 and an infeed nip roller 26 . Alternatively, infeed nip roller 26 may be powered. The energy curable coating is impressed by impression images on a master web 20 at this point (as explained below), as the flexible substrate advances at a pre-determined line speed “x”. As the energy curable-coated flexible substrate moves around the impression cylinder following the infeed nip roller 26 , it passes under an energy cure unit 28 which will supply the radiation required to cure the coating through the master web to fix the microstructure images impressed in the surface of the resin coating, as also explained below. Thus, where the energy curable coating is a UV coating, the master web 20 will be clear or translucent to UV light, and energy cure unit 28 will comprise one or more UV lamps of a power sufficient to cure the resin coating as the flexible substrate moves rapidly past the lamp(s). Preferably the UV lamp(s) are located in a protective housing positioned close to the periphery of impression cylinder 18 . After the flexible substrate carrying the cured coating exits the area below the radiation source, it is advanced between an outfeed stripping roller 27 and an idler roller 40 . No external pressure is applied to the master web and the flexible substrate between the infeed nip roller 26 and the outfeed stripping roller 27 . The flexible substrate is advanced for further processing or delivery (not shown) as desired.
[0054] One embodiment of the invention is also supplied with a master web 20 carrying a pre-formed microstructure image. The image may comprise, for example, a uniformly spaced series of surface relief hologram impression images or other relief light diffraction impression images. These impression images may include, for example, holographic images, varying texture images (e.g., matte film), stereograms, light-defracting devices, optical lenses, and lenticular surfaces. The master web will typically be supplied from a master web unwind roll 21 as shown in FIG. 3 , although alternatively it may be in a continuous belt form as shown in FIG. 5 . The master web may include a series of master registration marks.
[0055] The master web is advanced from the master web unwind roll 21 to a master web rewind roll 22 . The master web is drawn through a master web tension nip 23 at a first master line speed “y” which will be less than or equal to the flexible substrate line speed “x”. The master web next enters and moves over an optional master web compensator section 29 and through a second powered master web speed nip 24 through which the master web 20 is next advanced at speed “x” which is equal to the flexible substrate line speed. Master web tension nip 23 is powered and operates at a controllable variable speed to cooperate with master web speed nip 24 in producing the desired degree of stretch in the master web, as explained below.
[0056] A master web register scanner 25 is positioned opposite the master web compensator section 29 . This sensor is designed to determine when master web registration marks pass this location. The registration marks may be illuminated and imaged through an optical path and the image information from the detected beam continuously processed using an electronic register control system which generates an error signal dependent upon the displacement of master registration marks in relation to the flexible substrate registration marks. Additionally, edge scanners (not shown) can be used to ensure proper tracking of the master and flexible substrates.
[0057] The master web 20 then passes over infeed nip roller 26 and is thus nipped to the coated flexible substrate to impress microstructure on the master web into the surface of the energy curable coating on the flexible substrate. The energy curable coating and its impressed image are then cured by the energy cure unit(s) 28 to fix the image. After the master web passes and moves past the energy cure unit(s) 28 , it travels over an outfeed stripping roller 27 to a powered rewind roll 22 .
[0058] Images on the master web 20 are spaced at a repeat distance less than the intended repeat distance of the impressed images on the flexible substrate (corresponding to the similarly repeating printed images on the flexible substrate) so that the master web can be stretched as necessary to place the impressed images onto the flexible substrate in the proper alignment. The master web is stretched on-the-fly, in increments or by varying amounts, to establish and then to maintain continuous registration of the impressed image and the printing on the flexible substrate.
[0059] The on-the-fly stretching process relies on sensing the arrival of the registration marks on the master web associated with the impressing images at master web register scanner 25 which correlates with the arrival of the registration marks on the flexible substrate at flexible substrate register control scanner 16 where simultaneous arrival of the registration marks of the master and flexible substrates at these predetermined locations indicates proper registration of the impressed images and the printed images on the flexible substrate. Thus, when the registration marks on the master web arrive at the master web register scanner before the registration marks on the flexible substrate arrive at the flexible substrate sensor correction by on-the-fly variable stretching of the master web is carried out. This on-the-fly variable stretching is accomplished by running the master web through the powered master web tension nip 23 and the powered master web speed nip 24 where speed nip 24 runs at the line speed of the flexible substrate and the line speed of the tension nip 23 is decreased as necessary to stretch the master web between the two nip stations until the registration marks on the master and flexible substrates arrive at their predetermined master and flexible substrate sensor locations simultaneously.
[0060] The data regarding arrival of the registration marks at register control scanners 16 and 25 is sent to an electronic register control system common to modern printing technology (not shown). The electronic register control system is programmed using known techniques to control the line speed of the upstream nip pair as appropriate to achieve the necessary stretching of the master flexible substrate. The stretching of the master web is thus continuously adjusted by the electronic register control system which receives and processes an error signal indicative of the extent to which the registration marks on the master and flexible substrates are out of alignment. In one preferred embodiment, a master web compensator section 29 maintains web tension adjustments by removing any slack in the master web.
[0061] In another embodiment, images on the master web 20 are spaced at a repeat distance equal to the intended repeat distance of the impressed images on the flexible substrate (corresponding to the similarly repeating printed images on the flexible substrate) so that the master web speed can be advanced or retarded as necessary to place the impressed images onto the flexible substrate in the proper alignment. The master web speed is varied on-the-fly, in increments or by varying amounts, to establish and then to maintain continuous registration of the impressed image and the printing on the flexible substrate. The master web 20 registration process relies on sensing the arrival of the registration marks on the master web associated with the impressing images at master web register scanner 25 which correlates with the arrival of the registration marks on the flexible substrate at flexible substrate register control scanner 16 where simultaneous arrival of the registration marks of the master and flexible substrates at these predetermined locations indicates proper registration of the impressed images and the printed images on the flexible substrate. Thus, when the registration marks on the master web arrive at the master web register scanner before the registration marks on the flexible substrate arrive at the flexible substrate sensor correction by advancing the speed of the master web is carried out. This on-the-fly speed adjustment is accomplished by running the master web through the powered master web speed nip 24 where speed nip 24 speed is increased or decreased as necessary until the registration marks on the master and flexible substrates arrive at their predetermined master and flexible substrate sensor locations simultaneously.
[0062] In another embodiment of the invention, on-the-fly variable stretching of the flexible substrate is accomplished by running the flexible substrate 14 through a powered web tension control nip 12 , and the line speed of the tension nip 12 is decreased as necessary to stretch the flexible substrate web between the tension nip 12 and the infeed nip 26 until the registration marks on the master and flexible substrates arrive at their predetermined master and flexible substrate sensor locations simultaneously.
[0063] FIG. 4 shows another embodiment of an apparatus for transferring holographic and other microstructure or refractive images onto a sheet-carried energy curable coating in registration with printing on the flexible substrate. The graphic arts or converting sheeted flexible substrate 30 may be any sheeted material which is capable of being passed through a printing press-type apparatus. One particularly desirable sheeted flexible substrate is folding carton paperboard. Sheeted flexible substrate 30 in the illustrated embodiment includes substrate registration marks 6 which are printed onto the sheeted substrate (and would not be thick enough to be apparent in the view of FIG. 4 but have been enlarged here in order to make them visible).
[0064] In one embodiment, images on the master web 20 are spaced at a repeat distance equal to the intended repeat distance of the impressed images on the sheeted flexible substrate 30 (corresponding to the similarly repeating printed images on the flexible substrate) so that the sheeted substrate speed can be advanced or retarded as necessary to place the impressed images onto the sheeted flexible substrate in the proper alignment. The sheeted substrate 30 speed is varied on-the-fly, in increments or by varying amounts, to establish and then to maintain continuous registration of the impressed image and the printing on the sheeted substrate. The master web 20 registration process relies on sensing the arrival of the registration marks on the master web associated with the impressing images at master web register scanner 25 which correlates with the arrival of the registration marks on the sheeted flexible substrate at flexible substrate register control scanner 16 where simultaneous arrival of the registration marks of the master and flexible substrates at these predetermined locations indicates proper registration of the impressed images and the printed images on the flexible substrate. Thus, when the registration marks on the master web arrive at the master web register scanner before the registration marks on the sheeted flexible substrate arrive at the flexible substrate sensor correction by advancing the speed of the sheets is carried out. This on-the-fly speed adjustment is accomplished by conveying the sheets with a powered infeed conveyor 31 where speed is increased or decreased as necessary until the registration marks on the master and flexible substrates arrive at their predetermined master and sheeted flexible substrate sensor locations simultaneously.
[0065] FIG. 5 shows another embodiment of an apparatus for transferring holographic and other microstructure or refractive images onto a web-carried energy curable coating in registration with printing on the flexible substrate impressed is illustrated. In this embodiment, a master web 20 will be in a continuous belt form. To accommodate a wide range of image repeat lengths, an impression length compensator unit 50 varies the master web path distance by increasing or decreasing the web path between compensator tension nip 54 and compensator speed nip 53 . Web alignment rollers 51 and 52 respond to a master web edge guide (not shown).
[0066] FIG. 6 another embodiment using a master web 20 in a continuous belt form for transferring holographic and other microstructure or refractive images onto a sheet-carried energy curable coating in registration with printing on the flexible substrate.
[0067] FIGS. 7 a and 7 b illustrate an alternative embodiment of the invention utilizing a sub-side frame. An infeed nip roller 26 , an outfeed stripping roller 27 , and energy cure unit(s) 28 can be lifted to take the master web 20 off impression to minimize production changeover time. FIG. 7 a is a diagrammatic representation of the invention where the master web 20 is in contact with the flexible substrate. FIG. 7 b depicts the master web 20 off impression; that is, out of contact with the flexible substrate.
[0068] FIGS. 8 a and 8 b illustrate an alternative embodiment of the invention utilizing a moving impression roller 18 . An impression roller 18 can be raised or lowered to place the master web 20 on or off impression to minimize production changeover time. FIG. 8 a is a diagrammatic representation of the invention where the master web 20 is in contact with the flexible substrate. FIG. 8 b depicts the master web 20 off impression; that is, out of contact with the flexible substrate.
[0069] FIG. 9 a illustrates another embodiment, where the master web comprises a cold foil film 60 . A coater 10 applies an energy-curable coating to the flexible substrate either uniformly or in selected spots. Energy cure unit(s) 28 transmit UV curing energy through the cold foil master web to cure a high adhesion energy curable coating such as Cork Industries' CU-1137HG-21VS. As depicted in FIG. 9 b , the high adhesion energy curable coating 11 strips metal 62 from the cold foil master web 60 in a wet lamination process known to the art. In another embodiment, an auxiliary energy cure unit 19 is added between the coater 10 and the master web infeed nip 26 . The coater 10 applies an energy curable pressure sensitive coating 11 to the flexible substrate either uniformly or in selected spots, the auxiliary energy cure unit 19 activates the coating, the substrate is nipped to the cold foil master web 60 , and the pressure sensitive energy curable coating 11 strips metal 62 from the cold foil master web 60 in a dry lamination process known to the art. Afterwards, the master web is separated from the flexible substrate to leave a reflective metal image on the flexible substrate.
[0070] Thus, it should be understood that the embodiments and examples described herein have been chosen and described in order to best illustrate the principles of the invention and its practical applications to thereby enable one of ordinary skill in the art to best utilize the invention in various embodiments and with various modifications as are suited for particular uses contemplated. Even though specific embodiments of this invention have been described, they are not to be taken as exhaustive. There are several variations that will be apparent to those skilled in the art. | An apparatus and method for preparing a flexible substrate with uniformly spaced images and corresponding physical or virtual registration marks at regular intervals, applying an energy curable coating to the flexible substrate either uniformly or in selected spots, and providing a master web carrying uniformly spaced impressing images and corresponding registration marks at regular intervals, where accurate alignment of the registration marks of the flexible substrate and the master web is achieved by stretching the master web to align the registration marks. One embodiment of the apparatus comprises scanners which sense the location of the registration marks on the flexible substrate and the master web; an electronic register control system programmed to monitor error signals representing the on-the-fly deviation in the alignment of the master and flexible substrate registration marks and makes determinations of the amount of stretching that must be applied to the master web in order to bring the registration marks into alignment; and means for achieving the appropriate stretching of the master web to produce the desired alignment. | 1 |
BACKGROUND OF THE DISCLOSURE
The present invention is directed to an attachment for a lawn trimmer, particularly, to an attachment for converting a flexible line cord lawn trimmer to a lawn edger so that the flexible cord of the trimmer may be used for both trimming and edging the lawn.
Lawn edgers, both gasoline and electric powered, have been known and used for many years. Line trimmers, for example, nylon cord trimmers, which have the capability of being used as either a lawn edger or a lawn trimmer are also known to the prior art. However, nylon cord trimmers presently available are difficult to use as lawn edgers because the user must orient the line trimmer so that the orbit of the cutter line is perpendicular to the ground and parallel to the sidewalk or the curb being edged. Furthermore, the user must position and hold the line trimmer, while in motion, a sufficient distance above the ground and away from the concrete so that the nylon cord does not strike the concrete or the ground with such force that it wears abnormally.
Typically, nylon cord trimmers presently available include a motor housing having a shaft extending from the housing at an acute angle. A D-shaped handle is generally located about the midpoint of the shaft and a pistol-grip handle having a trigger, which must be depressed to electrically energize the line trimmer motor, is attached to the terminal end of the shaft. When using this type of device as a lawn edger, the housing is rotated so that the grip portion of the handle is facing upwardly. Also, the shaft of the line trimmer must be held by the D-shaped handle in a position so that the motor housing is oriented such that the orbital plane of the cutter line is perpendicular to the ground. This typically requires the user to stoop over and grasp the D-shaped handle with one hand and hold the pistol-grip of the handle in the other hand to keep the line trimmer properly oriented for edging. Since the pistol-grip of the handle is facing upwardly in this position, the user cannot depress the dead-man type switch with his index finger and must therefore press the switch with his thumb. While in this rather awkward position, the user must also walk along the lawn edge, at all times attempting to keep the line trimmer housing properly oriented so that a straight edge can be cut. This is extremely difficult to accomplish and very tiring for the user to maintain such an awkward position for an extended period of time in order to edge the lawn.
Attachments for line trimmers are available as exemplified by U.S. Pat. No. 4,224,784 to Hanson, et al., and other conversion systems disclosed therein. The Hanson device comprises an attachment incorporating a collar with support legs attached to it and wheels attached to the support legs. A U-shaped brace is attached to the support legs holding them at an angle to each other. The collar is positioned about the shaft extending from the line trimmer motor housing. The line trimmer is oriented so that its face is perpendicular to the ground. The collar is secured to the shaft with the head of the line trimmer between the ends of the U-shaped brace and spaced above the ground.
The prior art lawn edging devices have several disadvantages which are overcome with a novel lawn edger attachment of the present disclosure. Edging with the attachment of the present disclosure mounted on a nylon cord trimmer produces a straighter, wider, deeper and cleaner cut than edging with a hand held line trimmer or a conventional metal blade edger. The apparatus of the present disclosure is provided with a downwardly extending edge guide which extends into the trench separating the edge of the sidewalk or curb from the lawn. The edge guide contacts and slides along the vertical surface of the sidewalk or curb, enabling the user to form a cut which is substantially parallel to the sidewalk or curb.
Another significant advantage provided by the apparatus of the present disclosure is safety. Most debris from cutting, including grass, dirt, and small hard objects removed from the area being edged, is deposited back on the lawn, rather than flying onto the sidewalk, street or into the operator's face, eyes or other exposed areas of the body. When edging is performed with a nylon cord trimmer without a deflection shield, flying debris presents a serious danger to the operator and/or passersby. The apparatus of the present disclosure includes a curved deflection shield which directs debris toward the lawn and away from the operator. In addition, when using the present apparatus, the operator walks beside, not behind the lawn edger, further reducing the chance of personal injury.
A further advantage of the apparatus of the present disclosure is the ease of temporarily converting a lawn trimmer into a lawn edger by attaching the apparatus of the present disclosure to the lawn trimmer by means of a single wing nut. The usefulness of the lawn trimmer as a trimmer is not impaired or diminished when the edging apparatus is detached from the lawn trimmer.
SUMMARY OF THE INVENTION
The lawn edger attachment of the present invention comprises a substantially planar base plate which may be mounted to the base of the trimmer housing of a commercially available flexible line card lawn trimmer. The base plate includes an aperture formed therein which permits the spool and line housing of the lawn trimmer to extend through the aperture and project beyond the surface of the base plate. A deflection shield extends partially about the base plate and terminates at one end to form a cord cutter edge. An edge guide extends downwardly from the base plate for guiding the lawn trimmer along the sidewalk or curb. The edge guide cooperates with a trimmer housing bracket and pair of wheels to form a lower assembly for rolling the line trimmer along the edge of the sidewalk. The nose portion of the trimmer housing is received in the bracket and a bolt and wing nut secure the opposite end of the base plate to the trimmer housing base, and therby securely mounting the base plate to the trimmer housing.
BRIEF DESCRIPTION OF THE DRAWING
So that the manner in which the above recited features, advantages and objects of the present invention are attained and can be understood in detail, a more particular description of the invention, briefly summarized above, may be had by reference to the embodiments thereof which are illustrated in the appended drawings.
It is to be noted, however, that the appended drawings illustrate only typical embodiments of this invention and are, therefore, not to be considered limiting of its scope, for the invention may admit to other equally effective embodiments.
FIG. 1 is a perspective view of the invention as attached to a standard nylon cord trimmer converting the trimmer to a lawn edger;
FIG. 2 is a side view of the lawn trimmer attachment of the present invention;
FIG. 3 is an end view of the lawn trimmer attachment of the invention;
FIG. 4 is a sectional view of the lawn trimmer attachment of the invention taken along line 4--4 of FIG. 2;
FIG. 5 is a partial, enviromental side view of the lawn trimmer attachment mounted to a conventional lawn trimmer;
FIG. 6 is a partial sectional view of the lawn trimmer attachment of the invention taken along line 6--6 of FIG. 5;
FIG. 7 is a partial sectional view of an alternate embodiment of the lawn trimmer attachment of the invention; and
FIG. 8 is a side view of the alternate embodiment of the lawn trimmer attachment.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring first to FIG. 1 of the drawings, the apparatus of the invention is shown mounted to a commercially available portable lawn trimmer. The lawn trimmer includes a trimmer housing 10 suporting a shield plate 12 which is perpendicularly disposed to the trimmer housing 10. A spool and line housing 14 projects outwardly from the flat planar surface of the shield plate 12 and is operatively connected to an electric motor housed within the trimmer housing 10. A shaft 16 extends angularly upwardly from the trimmer housing 10. A D-shaped handle 15 is located at about the midpoint of the shaft 16 providing a convenient hand hold for the operator of the lawn trimmer. A pistol grip handle 17 is also provided at the terminal end of the shaft 16. The description thus far is of a typical, commercially available lawn trimmer which during normal usage has the base and shield plate 12 disposed substantially parallel to the ground for grass trimming purposes. In FIG. 1, the trimmer housing 10 of a conventional line trimmer has been rotated so that it is perpendicular to its usual horizontal operating position relative to the ground. The D-shaped handle 15 has also been rotated 180° on shaft 16.
Referring now to FIG. 2, the apparatus of the present disclosure is generally identified by the reference numeral 20. The apparatus 20 comprises a substantially flat base plate 22. The base plate 22 is defined by a pair of straight edges 24 and 26 which intersect at right angles forming two sides of the base plate 22. A curved edge 27 joins the straight edges 24 and 26 defining a substantially flat pie-shaped surface. An upstanding deflection shield 28, best shown in FIGS. 3 and 4, is formed along the curved edge 27 extending from the distal or terminal end of the edge 24 to the edge 26. The deflection shield 28 terminates adjacent the edge 26 at an angled surface defining a cord cutter edge 30 for trimming or cutting excessive lengths of line cord. The deflection shield 28 is integrally formed with the base plate 22 as shown in FIG. 4 and includes a concave interior surface 32 extending upwardly from the base plate 22 and terminating at the edge 33 of the deflection shield 28. The concave surface 32 of the deflection shield 28 enables grass clippings and debris to be deflected away from the base plate 22, and thereby away from the user of the lawn trimmer.
Referring again to FIG. 2, an edge guide 34 is shown which extends below the edge 26 of the base plate 22. The edge guide 34 is mounted to the base plate 22 by mounting bolts 36. When using the apparatus of the invention, the edge guide 34 extends into a trench 35 formed between the lawn and the sidewalk or curb. The edge guide 34 engages the vertical side of the sidewalk or curb, as best shown in FIG. 6, for guiding the lawn trimmer in a straight path while edging. The trench 35 may be formed by any suitable means, as for example, with an edger having a metal blade, or the apparatus of the present disclosure. Once the tranch 35 is formed, it is easily maintained with regular use of the lawn edger of this invention.
Further details of the apparatus 20 are shown in FIGS. 3 and 4. The assembled apparatus 20 includes a bracket 38 and a pair of wheels 40. The wheels 40 are disposed in a parallel relationship with the back face 41 of the base plate 22. The bracket 38 separates the wheels 40 from the base plate 22. The lower assembly of the apparatus 20 comprising the edge guide 34, bracket 38, and wheels 40 is mounted to the base plate 22 by the bolts 36 which extend through aligned holes in the edge guide 34, bracket 38, and wheels 40. A bushing 42 is interposed between the bracket 38 and the wheels 40 about a bolt 36 enabling the wheels 40 to freely rotate about the bolts 36. A lock washer 44 and nut 46 secure the wheels 40 about the bolts 36.
The base plate 22 includes an aperture or hole 50 for receiving the spool and line housing 14 therethrough. The hole 50 is sized and shaped to the spool and surrounding structural projections on the shield plate 12 of the trimmer housing 10. The irregular shape of the hole 50 shown in FIG. 2 permits the base plate 22 to fit about an upstanding surrounding border around the spool and line housing 14 of the trimmer housing 10 shown in FIG. 1. It is understood that the size and shape of the hole 50 shown in FIG. 2 is for illustrative purposes only. The hole 50 may be circular, oblong, or any other shape permitting the base plate 22 to lie flat against the substantially flat surface of the shield plate 12. A tab 52 having a hole 54 extending therethrough provides a means for anchoring the top of the base plate 22 to the shield plate 12 of the trimmer housing 10.
Referring now to FIGS. 5 and 6, the apparatus 20 of the invention is shown mounted to a conventional, commercially available lawn trimmer. Prior to mounting the base plate 22, a hole is drilled through the upper portion of the shield plate 12 in alignment with the hole 54 formed in the tab 52 for receiving a bolt 49 therethrough.
Once a matching hole has been drilled in the shield plate 12, the apparatus 20 may be easily mounted to the trimmer housing 10. The nose portion 11 of the trimmer housing 10 is received in the bracket 38 as shown in FIG. 6. The base plate 22 is pressed against the shield plate 12 and the hole 54 is aligned with the hole previously formed through the upper portion of the shield plate 12. The bolt 49 is positioned so that it extends through the aligned holes. A wing nut 47 is threaded onto the bolt 49 extending through the shield plate 12 and hole 54 of the tab 52 anchors the upper end of the base plate 22 to the shield plate 12. In this manner, the base plate 22 is securely mounted to the motor housing 10 and the conversion of a lawn trimmer to a lawn edger is complete.
Referring now to FIGS. 7 and 8, an alternate embodiment of the lawn trimmer attachment of the invention is shown. The modified lawn trimmer attachment is substantially identical to the attachment 20 described and shown in FIGS. 1-4. Therefore, like reference numerals have been employed to identified like elements. In the alternate embodiment of FIGS. 7 and 8, the base plate 22 includes an oblong hole 60 for receiving the spool and line housing 14 therethrough. The oblong hole 60 is particularly suitable for some models of lawn trimmers, particularly earlier versions incorporating a housing 62 including a base which is oblong in profile. In the embodiment of FIGS. 7 and 8, the oblong hole 60 permits the spool and line housing 14 to be advanced through the opening 60 and the housing 62 lowered relative to the base plate 22 so that the nose portion thereof is received in the bracket 38. The oblong hole 60 permits the spool and line housing 14 to be moved vertically relative to the base plate 22 enabling the line trimmer attachment to be mounted to the base of housing 62. As in the embodiment of FIGS. 1-4, a hole drilled through the upper portion of the base of the housing 62 for receiving a bolt 49 therethrough to anchor the lawn trimmer attachment to the base of the housing 62 upon threading a wing nut 47 onto the bolt 49.
In use, the lawn trimmer is positioned so that the edge guide 34 extends into the trench 35 separating the sidewalk and lawn. The wheels 40 are sized so that the trimmer housing 10 and bracket 38 clear the surface of the sidewalk and do not drag therealong. If the nylon cord 64 is too long, it is cut off by the cord cutter 30 so that a substantially uniform depth is edged as the lawn trimmer is guided along the sidewalk. This results in a uniform and straight edge being cut. In addition, the nylon cord 64 lasts much longer since it does not strike the concrete sidewalk or curb.
While the foregoing is directed to the preferred embodiments of the present invention, other and further embodiments of the invention may be devised without departing from the basic scope thereof, and the scope thereof is determined by the claims which follow. | An attachment for temporarily converting a flexible cord-type lawn trimmer to a lawn edger is disclosed. The attachment comprises a base plate for mounting to the housing of the lawn trimmer. The attachment includes an edge guide, a deflection shield, a bracket and wheels mounted to the base plate. The bracket supports a portion of the lawn trimmer housing upon securing the base plate to the lawn trimmer. | 0 |
CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims the benefit of U.S. Provisional Application No. 60/191,780 filing date Mar. 24, 2000, which provisional application is incorporated herein by reference.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
Not Applicable.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a bedside book holding apparatus. The invention includes a support frame for a book, magazine or the like, a lamp, angle adjusting means, a swivel arm, an upright support and clamping means for connecting the apparatus to a bed.
2. Description of the Related Art
Typically individuals simply hold a book or magazine on their chest when reading in bed. Light is provided by a bedside lamp or an overhead light in the room where the bed is located. There are, however, several devices which provide book support or lighting for use in bed or chairs, obviating the need to hold a book or magazine and easing provision of light for reading.
U.S. Pat. No. 5,709,365 to Howard teaches an adjustable book support for use in conjunction with the backboard of a bed. The Howard device includes lamps located on the bottom of the book supporting platform and is connected to the backboard of the bed by twin arm assemblies, one on each side of the book supporting platform.
U.S. Pat. No. 4,021,013 to Wiersma teaches a book holding device which also is used in conjunction with the backboard of a bed. Like the Howard device, the Wiersma device includes a lamp, though it is located at the top of the plate-like support member for the book, and is connected to the backboard of the bed by mounting means shown as two arms, one on each side of the plate-like support member for the book.
The problem with using one's hands to hold a book is that the hands can become tired by such action. The problem with using a bedside lamp or overhead light is that it may be necessary to leave the bed or to reach a great distance to turn such lamp or light off.
These problems are eliminated by both Howard and Wiersma. Unfortunately such devices present other problems. Both Howard and Wiersma disclose devices which must be attached to a backboard of a bed. Not all beds have a backboard. Thus these devices are not usable by all potential users of a bedside book holding apparatus. Secondly the Howard and Wiersma devices as disclosed both require twin arms for support by the backboard. As a result the user is surrounded by the devices when the devices are being used, having the arms on either side of the user's head and the book support in front of the user. This configuration increases the likelihood that the user might accidentally hit the device as the user moves about which at a minimum would be disconcerting and could cause dislodgment of the book from the device or even injury to the user. Additionally the resulting encapsuling of the user within the device might create a claustrophobic discomfort. Finally the Howard and Wiersma devices cannot be swiveled over to either side of the bed, but instead can only be adjusted vertically. As a result they disturb the aesthetic appearance of the bed backboard and create, even when not in use, a structure which might be in the way of the user's non-reading use of the bed. Since the devices cannot be removed from the bed backboard when not in use, the potential exists for the user to hit the devices when not in use, leading to dislodgment of the devices from the bed backboard, possible damage to the bed backboard itself and possible injury to the user.
BRIEF SUMMARY OF THE INVENTION
It is the object of the present invention to provide a bedside book holding apparatus which eliminates the problems outlined above regarding the existing art. The manner in which each of the shortcomings of the existing art is overcome is set forth hereinafter.
The present invention overcomes the problem presented of requiring the use of a bed backboard by being designed to be attached to the bed frame instead. While not all beds have a backboard, all beds have a frame. Thus the present invention may be used by a wider number of potential users than existing art.
The problem of potential user contact with a device which in effect encircles the user is eliminated by designing the present invention to have only one swivel arm. As a result the user has one side open at all times reducing by at least one-half the potential for accidental user contact with the apparatus. Obviously by leaving at least one side open, the user no longer must face the potential claustrophobic effect of the encircling configuration of the existing art.
Finally the problem of existing art being stored when not in use on the bed backboard is addressed in the present invention by designing the invention to swivel to the side and by designing the invention to attach, not to the bed backboard, but to the bed frame on the side. Attaching the present invention to the bed frame means that there can be no damage to the bed backboard even if there is accidental contact with the apparatus when it is not in use. Obviously the placement of the present invention to the side of the bed means that, unlike with existing art, there is no unsightly contraption attached to the bed backboard when not in use disturbing the aesthetics of the bed backboard and other furniture in the room.
The objects and features of the invention may be further understood with reference to the following detailed description of an illustrative embodiment of the invention taken together with the accompanying drawings in which:
FIG. 1 shows an isometric view of the device attached to a bed;
FIG. 2 shows a side view of the upper member of the support frame with the support plate attached, each side view of the members of the support frame being roughly identical to this view with the sole exception of the length dimension;
FIG. 3 shows a detail of the angle adjusting means;
FIG. 4 shows a detail of the connection of the swivel arm to the upright support;
FIG. 5 shows a detail of the clamping means; and
FIGS. 6-A and 6 -B show the lamp with alternative power sources.
DETAILED DESCRIPTION OF THE INVENTION
Turning now descriptively to the drawings in which similar reference characters denote similar elements throughout the several views, FIG. 1 shows the support frame 1 of the invention attached to the support plate 2 . The support frame 1 is attached to the swivel arm 4 via an angle adjusting means 3 . The angle adjusting means 3 allows the support frame 1 to be rotated so as to adjust the angle at which any book placed upon the support frame 1 is held for the user's comfort and ease of viewing. The swivel arm 4 is then connected swivelly to the upright support 5 . This connection of the swivel arm 4 to the upright support 5 allows the user to swivel the support frame 1 away from the user when the invention is not in use. The upright support 5 is then attached to a clamping means 6 which allows the upright support 5 to be clamped to a bed frame 8 upon which rests a mattress 9 .
FIG. 2 shows a how the support plate 2 attaches to the bottom of the support frame 1 .
FIG. 3 shows at least one embodiment of the angle adjusting means 3 , which does not employ screws. Here there is attached to a first end of the swivel arm 4 an adjusting elbow member 10 . From the end of the adjusting elbow member 10 opposite the end attached to the swivel arm 4 there is attached a pin 11 . The pin 11 fits snugly into a cup 12 , which is attached to the upper member of the support frame 1 .
FIG. 4 shows the connection of the upright support 5 to the swivel arm 4 via an arm elbow member 13 . The upper end of the upright support 5 is inserted into a cavity defined in the end of the arm elbow member 13 . A second end of the swivel arm 4 is attached to the other end of said arm elbow member 13 . The swivel arm 4 is swiveled in any needed direction by the user by rotation of the arm elbow member 13 around the upper end of the upright support 5 .
FIG. 5 shows one embodiment of the clamping means 6 . Here the lower end of the upright support 5 is attached to a channel formed by a top 15 , a back 14 and a front 16 . The upright support 5 is attached to the top 15 . A bed frame may be placed within the channel formed by the top 15 , back 14 and front 16 . Into the front 16 are defined one or more threaded holes into which may be screwed one or more bolts 17 , here shown two in number.
FIG. 6-A shows a lamp 7 attached to the support frame 1 at its upper member. Also shown is the power source 18 for the lamp 7 which is a cord attached to a standard wall plug 19 . FIG. 6-B shows an alternative power source 20 , which is a receptacle for a battery.
While I have described and illustrated certain embodiments of my invention, it is to be understood that further modifications and improvements are contemplated and may be practiced without departing in any way from the spirit of the invention, for the limits of which reference must be had to the appended claims. | The present invention relates to a bedside book holding apparatus. The invention includes a support frame for a book, magazine or the like, a lamp, angle adjusting means, a swivel arm, an upright support and clamping means for connecting the apparatus to a bed. | 0 |
TECHNICAL FIELD OF THE INVENTION
This invention relates to a novel formulation for fat-soluble drugs (including tocotrienols, tocopherols, vitamin A, D and β-carotene) which self-emulsify in the presence of an aqueous medium with little agitation. More specifically, the invention is concerned with the formulation of a new dosage form for fat-soluble drugs in the form of a soft-gelatin capsule which forms emulsion instantly when the contents are released and mixed with our gastrointestinal fluid. Since emulsions are known to increase absorption of fat-soluble drugs, the dosage form thus provides higher and more consistent drug absorption. The success of the invention lies in its ability to self-emulsify in the gastrointestinal tract and comprised a suitable mixture of the drug with an appropriate oil and an appropriate surfactant system.
BACKGROUND OF THE INVENTION
Fat-soluble drugs such as tocotrienols and tocopherols are absorbed in the same pathway as other nonpolar lipids such as triglycerides and cholesterol (Kayden and Traber, 1993, J. Lipid Res., 34:343-358). Liver produces bile to emulsify the tocopherols incorporating them into micelles along with other fat-soluble compounds to facilitate absorption. Therefore, dietary fat, which promotes production of lipases and bile, is essential for absorption of vitamin E. However, if dietary fat is insufficient to stimulate adequate bile secretion, or bile secretion is affected by some pathological conditions such as biliary obstruction, then absorption of the fat-soluble drugs will be erratic and low. Also, it is known that absorption of fat-soluble drugs tend to be erratic and low when taken fasted or on an empty stomach.
Emulsions have been known to improve absorption of oil soluble drugs. However, conventional emulsions are not a preferred dosage form since they are bulky, have shorter shelf life due to stability problem and are less palatable. In recent years, there is a great interest in self-emulsifying drug delivery systems (SEDDS) due to the many advantages offered by these kind of systems which include enhanced bioavailability, improved reproducibility of plasma profiles and reduced inter- and intra-subject variability. SEDDS are formulated in the absence of water by mixing oil with one or more suitable non-ionic surfactants. Drugs, which have adequate solubility in the oil/surfactant blend, can be incorporated into the systems. Upon dilution or in vivo administration they form fine oil in water emulsions spontaneously with gentle agitation.
In the present studies it is discovered that the bioavailability of δ-, γ- and α-tocotrienols in palm olein and soybean oil mixtures were approximately 2.7, 2.8, 1.9 times and 2.2, 2.1, 1.6 times that of tocotrienols in medium chain triglyceride mixtures in rats respectively. This could be attributed to the long chain fatty acid of palm olein and soybean oil, which promote the absorption of tocotrienols into the lymph. A number of studies (Sieber et al, 1974, Xenobiotica 4, 265-284 and Palin et al, 1984, J. Pharm. Pharmacol. 36, 641-643) have shown that long chain fatty acids (>C14) (which are present in the palm oil and soybean oil), tend to increase absorption of oil soluble drug through the lymphatic system.
The present studies led to the discovery of a novel formulation by suitably blending palm olein or soybean oil with an appropriate surfactant mixture of Labrasol (caprylocaproyl macrogolglycerides) and Tween 80. The Labrasol to Tween 80 ratio was between 9:1 and 7:3. The above system could self-emulsify easily in water with gentle agitation (such as movement of stomach/small intestine). Therefore, the formulation need not be prepared like a usual emulsion, which is bulky and not palatable. Instead, the mixture is filled in a soft gelatin capsule. In stomach, the capsule wall dissolves and disintegrates and releases the contents, which will readily form an emulsion. Emulsions will give a bigger surface area for absorption and subsequently increased the absorption of fat-soluble drugs like tocotrienols. It was also demonstrated that the self-emulsifying system comprising the palm olein or soybean oil blended with the surfactant mixture could self-emulsify readily with water, when incorporated with fat soluble drugs including tocotrienols, tocopherols, vitamin A, vitamin D and β-carotene. In addition, the novel formulation could increase the absorption of δ-, γ- and α-tocotrienols by approximately 2 to 3 times that of the normal conventional soft gelatin capsule formulation when evaluated using twelve healthy human volunteers. The ratio of the surfactants to the oil and drug mixture was also demonstrated to be very important for enhanced drug absorption. For example, it was demonstrated that equal proportions of surfactant to the drug and oil mixture gave poor absorption whereas one part of surfactants to five parts of drug and oil mixture produced not only good self-emulsifying properties but also optionally enhanced drug absorption.
In conclusion, the studies had optimized three important formulation variables to achieve a superior product with enhanced bioavailability/absorption, namely
(i) use of palm olein and soybean oil as the vehicle for fat-soluble drugs like tocotrienols, which help to enhance absorption;
(ii) addition of a suitable combination of Labrasol and Tween 80 into the drug/oil mixture to promote self-emulsification and thus help to further increase the absorption of tocotrienols; and
(iii) a suitable combination of surfactant system (Labrasol and Tween 80) with the oil/drug mixture to optimize drug absorption.
SUMMARY OF THE INVENTION
Accordingly, it is the object of the present invention to provide a novel formulation for fat-soluble drugs that can self-emulsify in aqueous medium with little agitation.
This objective is accomplished by providing,
A pharmaceutical formulation for oral administration which comprises:
(i) a fat-soluble drug;
(ii) an appropriate oil; and
(iii) an appropriate surfactant system;
the resulting formulation which self-emulsifies under gentle agitation in the presence of an aqueous medium.
According to the present invention, there is provided a new formulation of tocotrienols, in which the tocotrienols are incorporated into a palm olein-surfactant system to form a self-emulsifying system. This formulation is made into soft gelatin capsule and in stomach, the contents are released, resulting in the formation of emulsion and therefore increased absorption.
The formulation of tocotrienols in the present invention has an improved bioavailability when compared with the conventional preparation.
DETAILED DESCRIPTION OF THE INVENTION
Tocotrienols, as Tocomin® 50%, contains a minimum of 50.0% of phyto-tocotrienol/tocopherol complex, was obtained commercially from Carotech (Ipoh, Malaysia).
In the first part of the study, three different oil vehicles were compared concerning the influence of the different oils on the absorption of tocotrienols. The oil vehicles studied were as follows:
(i) palm olein (triglycerides of palmitic acid 46.5%, oleic acid 37.1% and linoleic acid 9.9%);
(ii) soybean oil (glycerides of linoleic acid 50-57%; linolenic acid 5-10%, oleic acid 17-26%; palmitic acid 9-13% and stearic acid 3-6%); and
(iii) trycaprylin (not less than 95% are triglycerides of the saturated fatty acids octanoic (caprylic) acid and decanoic (capric) acid.
10% of Tocomin® 50% were then dissolved in these three oil vehicles and the same dose level (10 mg) were given to 9 rats in a 3 period, 3 sequence crossover study. The nine rats were randomly divided into 3 groups of 3 in each, and administered the preparations according to the schedule shown below:
Period
Group
I
II
III
1
Palm olein
Soybean oil
Tricaprylin
2
Tricaprylin
Palm olein
Soybean oil
3
Soybean oil
Tricaprylin
Palm olein
The animals were fasted for 12-hr prior to, and for a 12-hr period subsequent to, the initiation of the absorption experiments. However, they were allowed free access to water throughout the experiment. The animals were subsequently placed in restraining cages, and approximately 0.5 ml blood samples were collected from the tail vein into heparinized tubes at 1, 2, 3, 4, 6, 8 and 12 hr, post-administration. The blood samples were then centrifuged for 10 min at 12800G, and 0.2-0.3ml aliquot of plasma obtained was transferred into a new Eppendorf tube. All plasma samples were immediately frozen at −20° C. until analysis.
Plasma α-, δ- and γ-tocotrienols were determined by high-performance liquid chromatography (HPLC) using a method reported by Yap et al, 1999, (Journal of Chromatography B, 735:279-283) with slight modification.
The mean plasma concentration versus time profiles of α-, δ- and γ-tocotrienols obtained with Tocomin® 50% in three oil bases, namely palm olein, soybean oil and medium chain triglyceride are shown in FIGS. 1 a , 1 b and 1 c . It was apparent from the plots and the results that the absorption of α-, δ- and γ-tocotrienols from Tocomin® 50% in palm olein were the highest follow by Tocomin® 50% in soybean oil and Tocomin® 50% in Tricaprylin gave the lowest absorption. The difference in bioavailability of the three homologues of tocotrienols for the different oil vehicles was statistically significant.
From the 90% confidence interval for the ratio of the logarithmic transformed AUC 0-∝ values, it appeared that Tocomin® 50% in palm olein and soybean oil achieved a higher extent of absorption compared to Tricaprylin, which was about 2.7 times, 2.8 times 1.9 times and 2.2, 2.1, 1.6 that of Tocomin® 50% in Tricaprylin for δ-, γ- and α-tocotrienols. Thus, in this part of the study, it is clearly shown that palm olein and soybean oil as a vehicle for tocotrienols can increase their absorption significantly.
In the second part of the study, different surfactant systems at various ratio were tried out to get a self-emulsifying drug delivery system (SEDDS). The aim of this part of the study is to incorporate tocotrienols into a suitable surfactant system that will cause the preparation (tocotrienols in oil vehicles) to self-emulsify/form an emulsion easily with gentle agitation, such as movement of the stomach/intestine. Different types of SEDDS which were tried out include the following system
(i) Tween 85—Medium chain triglycerides (MCT)
(ii) Tween 80—Span 80—Palm olein
(iii) Labrasol—Tween 80—Palm olein/Soybean oil
SEDDS are formulated in the absence of water by mixing oil with a non-ionic surfactant, a lipid base and a lipid soluble drug, in this case tocotrienols to form an isotropic oily solution. Upon dilution with water or in vivo administration, they formed fine oil in water emulsions. Labrasol-Tween 80-Palm olein/Soybean oil was found to be the best system due to the following reason:
(i) it can it can incorporate a bigger amount of tocotrienols without compensating the emulsification properties compared to the other two systems;
(ii) from the first part of the study, it was found that the absorption of tocotrienols from medium chain triglycerides was less than that of palm olein. Thus, the usage of Tween 85-medium chain triglycerides was not desirable; and
(iii) between Tween 80-Span 80-Palm olein and Labrasol-Tween 80-Palm olein, the latter has a faster rate of emulsification and stability.
In accord with the present invention, the final master formulation is as follows:
Ingredients
Weight per capsule (mg)
Tocomin ®50%
148.66
Palm olein/soybean oil
351.34
Labrasol
87.00
Tween 80
13.00
Total weight
600.00
The range of the oil to surfactant ratio were ±10% of the final formula. The ratio of the oil to surfactant was kept at 5 to 1 to avoid solubilization. Above the critical micellar concentration of a surfactant system, micellar complexation of tocotrienols might occur. It has been known that absorption of a drug incorporated in the micelle is negligible. Since the drug in the micellar phase.is unavailable for.absorption, the effective concentration of the drug is less than the apparent concentration, and a decreased absorption rate is observed (Gibaldi and Feldman, 1970, J. Pharm. Sci., 59:579-589).
Tocomin® 50% is mixed with palm olein and Labrasol is mixed with Tween 80 until homogenus. The mixing of the surfactant mixtures and the oil mixtures follows this. The final mixture was mixed until homogenous before filling it in soft gelatin capsules.
In the third part, a comparative in vivo bioavailability study was conducted to investigate the bioavailability of tocotrienols in the novel formulation with that of the conventional preparation at the dosage level of 200 mg tocotrienols. The novel formulation comprised Tocotrienols, Palm olein, Labrasol and Tween 80 at the ratio stated above in the master formula. The normal conventional preparation comprised tocotrienols and soybean oil. Both products are in the form of soft gelatin capsule.
Twelve (12) healthy adult male volunteers participated in a standard 2 period, 2-sequence crossover study after providing written informed consent. The volunteers were randomly divided into 2 groups of 6 each, and administered the preparations according to the schedule shown below:
Period
Group
I
II
1
Conventional formulation
Novel formulation(X)
2
Novel formulation(X)
Conventional formulation
On the first trial period, each volunteer in group 1 was given 4 capsules of conventional formulation (Y), while those of group 2, 4 capsules of novel formulation (X) containing an equivalent dose of tocotrienols. After a washout period of one week, each volunteer then received the alternate product. All products were administered in the morning (10:00 am) after an overnight fast with 240 ml of water. Food and drinks were withheld for at least 4 hours after dosing and plain water was given ad. libitum. Lunch and dinner comprising chicken with rice were served at 4 hours and 10 hours after dosing. Blood samples of 5-ml volume were collected in vacutainers (containing sodium heparin as anticoagulant) at 0 (before dosing), 1, 2, 3, 4, 5, 6, 7, 8, 10, 12, 14, 18, 24 hours after dosing via an in-dwelling cannula placed in the forearm. The blood samples were centrifuged for 15 min at 2000 G and the plasma transferred to separate glass containers to be kept frozen until analysis.
The protocol for the study was approved by a joint School of Pharmaceutical Sciences, USM-General Hospital Penang Committee on Bioavailability Studies. Volunteers were given information of the drug and nature of the study in advance of the trial.
Plasma levels of α-, γ- and δ-tocotrienols were analysed using a reversed-phase high performance liquid chromatography method reported by Yap et al (1999, Journal of Chromatography B, 735: 279-283).
The mean plasma δ-, γ- and α-tocotrienols concentration versus time profiles of the conventional preparation and the novel formulation are shown in FIGS. 2 a , 2 b and 2 c . It is apparent from the plots that the profiles of the novel formulation were markedly higher than those of the conventional preparation for the three homologues of tocotrienols. Also, absorption from the novel formulation appeared to commence earlier than the conventional preparation. In addition, δ- and γ-tocotrienols were not detected in a number of individuals given the conventional preparation (3 subjects for δ-tocotrienol and 1 subject for γ-tocotrienol). In comparison, both tocotrienols were detectable in all subjects give the novel formulation, indicating better absorption from this formulation.
There was a statistically significant difference between the logarithmic transformed AUC 0-∝ (p<0.01), as well as the logarithmic transformed C max (p<0.01) values for all the homologues of the two preparations.
In addition, from the 90% confidence interval for the ratio of the logarithmic transformed AUC 0-∞ values, it was estimated that the average extent of the novel formulation (X) was 2.6, 2.9 and 3.0 times that of the conventional preparation (Y) for δ-, γ- and α-tocotrienols respectively. In the case of the parameter T max , the novel formulation has smaller numerical values compared to the conventional preparation suggesting that the former had a more rapid onset/rate of drug absorption. There was a statistically significant difference between the T max values of the two preparations (p<0.05).
Based on the results of the above studies, it is concluded that the novel formulation achieved a marked increase in the extent of absorption of tocotrienols compared to the conventional preparation. Additionally, the novel formulation also showed a more rapid onset or rate of absorption.
While the preferred embodiments of the present invention have been described, it should be understood that various changes, adaptations and modifications may be made thereto. It should be understood, therefore, that the invention is not limited to details of the invention and that variations in such minor details will be apparent to one skilled in the art. | This invention relates to a novel formulation for fat-soluble drugs which self-emulsify in the presence of an aqueous medium with little agitation. More specifically, the invention is concerned with the formulation of a new dosage form for fat-soluble drugs in the form of a soft-gelatin capsule which forms emulsion instantly when the contents are released and mixed with gastrointestinal fluid. The formulation comprises a suitable mixture of drug with an appropriate oil and an appropriate surfactant system. | 0 |
RELATED APPLICATIONS
[0001] The present application claims benefit of priority to U.S. provisional patent application Ser. No. 61/210,892, filed Mar. 23, 2009, which is incorporated by reference herein in its entirety.
FIELD OF INVENTION
[0002] The present invention relates generally to the field of vital signs monitors, and particularly to a device and system for wireless monitoring of the vital signs of a plurality of patients automatically and simultaneously, e.g., far forward to the point of wounding and/or injury.
BACKGROUND OF THE INVENTION
[0003] Monitoring of vital signs of a patient is routinely performed by health care professionals, especially emergency health care professionals for detecting and anticipating medical problems. Vital signs can be measured and monitored in a wide variety of medical settings including at the site of a medical emergency, disaster site, in a combat zone, at the point of injury, in route to further treatment, during treatment at a care facility, or during perioperative or rehabilitation of patients. Vital signs are measurements of the body's most basic physiological and performance functions. Ongoing changes in those vital signs is considered by health care professionals to be as, or more, important than the actual value at any moment. The main vital signs routinely monitored by medical professionals and healthcare providers include body temperature, pulse rate, blood oxygen level, respiration rate, and blood pressure. Depending of the circumstance and status of a patient, other vital signs may be measured or monitored by health care professionals such as the electrical activity of the heart by an electrocardiogram, pulse integrity, skin humidity, the Glascoe Coma Score (GCS), and level of carbon dioxide in expired gases at the end of a respiration cycle (end tidal CO2). All of these vital signs can be observed, measured, and monitored. Still further, more advanced vital signs would include deriving combined measures such as shock index, pulse pressure, pulse integrity, cardiac cycle complexity or heart rate variability, and a host of evolving indices of multi-parameter statistical representations of the composite set of data obtained. These data will enable the assessment of the level at which an individual is currently functioning. Normal ranges of measurements of vital signs change with age and medical condition. To exacerbate the issue, injured patients characteristically change their vital signs as they either improve or degrade so the change and the rate of change in those parameters over time are sometimes more indicative of that patients overall condition than the parameters measured alone. Often the combination of the current characteristics are combined with the characteristic's historical trendlines to obtain a full understanding of the patients state.
[0004] The purpose of recording vital signs historically is to establish a baseline on admission to a hospital, clinic, professional office, or other encounter with a health care provider. Vital signs may be recorded by a nurse, physician, physician's assistant, or other health care professional. A significant amount of data now suggests that the earlier these vital signs are taken, out to as close as possible to the time and place of wounding or injury, and the more information that is recorded about what treatments have already been provided, the better that attending medical personnel will be able to deduce and conclude the proper response or treatment for the injured person. The health care professional has the responsibility of interpreting data and identifying any abnormalities from a person's normal state, and of establishing if current treatment or medications are having the desired effect. Being able to understand the changes in the parameters therefore, and the trending at any moment is significantly better than only a single “upon admission” measure.
[0005] Vital signs are usually recorded from once hourly to four times hourly after admission, as required by a person's condition. Or, they are taken by attending EMS or medics at the site of injury and relayed back manually or verbally further along in the treatment chain. Vital signs taken manually by similarly trained professionals and with nearly equivalent experience have been shown to vary significantly on a single patient. Similarly these individuals will likely triage the same patient differently based on manual assessment. The vital signs are recorded and compared with normal ranges for a person's age and medical condition if available. Based on these results, a decision is made regarding further actions to be taken. The gap between the records can be excessive and errors in timing and trends may be overlooked.
[0006] Typically, continual vital signs monitoring requires either hands-on human attention or bulky, heavy, complicated, and expensive equipment which typically is impossible to have on hand when and where it is needed. Furthermore, in most hospitals, medical emergency situations, disaster sites, and combat zones, care for numerous patients can be difficult for a finite number of clinicians or medically trained care providers to monitor multiple patients on a continuous basis. Commercially available vital signs monitoring equipment may be helpful in these settings, however, the availability and use of such equipment in emergency situations, or in those instances where a plurality of subjects must be monitored, and decisions based on numerous casualties are made, is rarely feasible or possible with today's medical monitors. While there has been a trend to miniaturize vital signs monitoring equipment that are more effective and helpful to medical emergency personnel on site, further improvements in the effectiveness, portability, and ease of use of vital signs monitoring equipment, as well as the simplicity of wireless connectivity of the equipment is desirable, and the devices and systems for wireless monitoring of patients' vital signs of the present invention addresses the existing problems and provides related solutions and benefits.
SUMMARY OF THE INVENTION
[0007] The present invention relates generally to the field of vital signs monitors, and particularly to a highly mobile device and system for wireless monitoring of the vital signs of a plurality of patients simultaneously. The present invention is particularly adaptable for use by medical emergency personnel in any setting, such as road or industrial accidents, disaster sites, combat zones, battlefield aid stations, or hospitals. The systems and methods of the present invention allows the monitoring of a plurality of patients by a single health care professional providing more effective monitoring, better care, wireless tracking by mobile platforms not on the patient, and care for a large number of patients at any one time from anywhere at any time.
[0008] The present invention recognizes that patient care and continuous vital signs monitoring of patients, in particular in disaster areas and combat zones where a large number of injured people with widely variable and dynamic injuries have to be cared for simultaneously, can be made more effective and feasible in a more timely manner by providing patient mounted vital signs monitors to the patients that wirelessly communicate and send data to displays mounted on or carried by emergency medical personnel, sometimes referred to as “user(s)”, such that a plurality of patient mounted monitors can wirelessly communicate with one or more user mounted vital signs systems with or without displays. With such a system, users can monitor the vital signs of a plurality of patients by way of the patient mounted vital signs monitor or by way of the user mounted display allowing a fewer number of emergency medical personnel to care for and continuously monitor a large number of patients. This allows the feasibility of non-medically trained personnel, and those with minimum experience to assess patient's vitals automatically until further medical providers arrive on scene. With such a system the care providers, via wireless connectivity, need not even be within range of the location of the patients yet interact with the care of and disposition of the plurality of patients in near real time from a remote location. This allows for a remote expert to consult in patient disposition across the full list of casualties in near real time without the need to be at or near the site.
[0009] One aspect of the present invention includes an apparatus for wireless monitoring of the vital signs of a patient, including a plurality of patient mounted vital signs monitors, each having a plurality of sensors for detecting and measuring the vital signs of a patient; a first display for displaying the patient's vital signs, the display being operatively connected to the plurality of sensors, wherein the display can receive and display the patient vital signs; a first transceiver operatively connected to the patient mounted vital signs monitor, and operable to transmit the patient's vital signs data to a remote transceiver; and a first processing means for processing the detected or measured vital signs and for controlling the operation of at least the first display and the first transceiver; a user mounted processing system and monitor including a second transceiver for wireless connection to the first transceivers of the plurality of the patient mounted vital signs monitors; a second display configured to separately display each of the patients' vital signs data received from the plurality of the patient mounted vital signs monitors; and a second processing means for processing the received vital signs data from the plurality of the patient mounted vital signs monitors and for controlling the operation of at least the second display and the second transceiver; whereby, users can monitor the vital signs of a plurality of patients by way of the patient mounted vital signs monitor or by way of the user mounted display.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] FIG. 1 shows a schematic diagram outlining the main system schematic and connections of an exemplary embodiment of the wireless vital signs monitor.
[0011] FIG. 2 shows a schematic diagram of an exemplary embodiment of a non-invasive blood pressure module connectivity.
[0012] FIG. 3 shows a schematic diagram of an exemplary embodiment of a wireless vital signs monitor digital signal processing connections and routing for the unit.
[0013] FIG. 4 a shows a schematic diagram of an exemplary embodiment of an analog electrocardiographic circuit integrated into the device.
[0014] FIG. 4 b shows a schematic diagram of an exemplary embodiment of an electrocardiographic isolated power and analog to digital conversion integrated into the device.
[0015] FIG. 5 shows a schematic diagram of an exemplary embodiment of an internal device memory design of the wireless vital signs monitor.
[0016] FIG. 6 shows a schematic diagram of an exemplary embodiment of a membrane switch layout of the wireless vital signs monitor.
[0017] FIG. 7 shows a schematic diagram of an exemplary embodiment of a blood oxygen pulse oximetry design of the wireless vital signs monitor.
[0018] FIG. 8 shows a schematic diagram of an exemplary embodiment of an organic light emitting diode (OLED) design integrated into the wireless vital signs monitor.
[0019] FIG. 9 shows a schematic diagram of an exemplary embodiment of the main power interface for the wireless vital signs monitor.
[0020] FIG. 10 shows a schematic diagram of an exemplary embodiment of a PIC24 interface for the wireless vital signs monitor.
[0021] FIG. 11 shows a schematic diagram of an exemplary embodiment of a WiFi and buzzer interface for the wireless vital signs monitor.
[0022] FIG. 12 shows a schematic diagram of an exemplary embodiment of a main power board battery charger for the wireless vital signs monitor.
[0023] FIG. 13 a shows a schematic diagram of an exemplary embodiment of a programming, AUX, and DATA ports schematics for the wireless vital signs monitor.
[0024] FIG. 13 b shows a schematic diagram of an exemplary embodiment of a battery fuel gage, AUX and DATA ports, and low voltage power schematics for the wireless vital signs monitor.
[0025] FIG. 14 shows a schematic diagram of an exemplary embodiment of a graphical user interface (GUI) for remote transceiver units showing how multiple patients can be linked to a single screen for all patients. GUI may include color coding based on user selection of alarm limits.
[0026] FIG. 15 a shows a schematic diagram of an exemplary embodiment of an OLED display interface.
[0027] FIG. 15 b shows a schematic diagram of an exemplary embodiment of an OLED board interface.
[0028] FIG. 16 shows a schematic diagram of an exemplary embodiment of an OLED 12V power supply for the wireless vital signs monitor.
[0029] FIG. 17 shows a schematic diagram of an exemplary embodiment of a membrane switch user interface showing simple intuitive control and GUI for the wireless vital signs monitor.
[0030] FIG. 18 shows a schematic diagram of an exemplary embodiment of a graphical user interface and membrane switch showing simplicity of functionality and color coded vital signs values based on user selectable alarm limits.
[0031] FIG. 19 shows a schematic diagram of an exemplary embodiment of a GUI for trend analysis of the wireless vital signs monitor transceiver unit showing scrolling window for care giver to search trends of individual vital signs.
[0032] FIG. 20 shows a schematic diagram of an exemplary embodiment of a GUI for transceiver unit showing individual wireless vital signs for the selected patient and interface switches for interfacing with casualty remotely.
DETAILED DESCRIPTION OF THE INVENTION
[0033] Further objectives and advantages of the present invention will become apparent as the description proceeds and when taken in conjunction with the accompanying drawings. To gain a full appreciation of the scope of the present invention, it will be further recognized that various aspects of the present invention can be combined to make desirable embodiments of the invention. Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. Where a term is provided in the singular, the inventor also contemplates the plural of that term. The nomenclature used herein and the procedures described below are those well known and commonly employed in the art.
I. Device and System for Wireless Monitoring of the Vital Signs of Patients
[0034] One embodiment of the present invention includes an apparatus for wireless monitoring of the vital signs of a patient, including a plurality of patient mounted vital signs monitors, each having a plurality of sensors for detecting and measuring the vital signs of a patient. The present invention can provide a system whereby health care providers can maintain patient longitudinal situational awareness of data across the spectrum of health care providers. The sensors of the patient mounted vital signs monitors may include any desired and suitable sensor for the purpose the present invention and is contemplated for use. For example, the detecting and/or measuring sensors may include pulse waveform, skin temperature, skin humidity, multiple lead electrocardiograms, non-invasive blood pressure (NIBP), and saturation of blood oxygen. In addition the sensors may allow a specific and detailed calculation of multiple derived parameters through combinations and trends of current vital sign measures, for example, the plurality of sensor data may be processed to calculate additional vital signs data such as shock index, pulse wave delay as an indicator of changes in non-invasive blood pressure, heart rate complexity, and a summary alarm feature that indicates dynamically changing and overall vital signs state of the patient (called “Murphy Factor” or Life Saving Intervention (LSI) Probability).
[0035] The patient mounted vital signs monitor of the present invention also includes a first display for displaying the patient's vital signs, the display being operatively connected to the plurality of sensors, wherein the display can receive and display the patient vital signs. In such a configuration the patient mounted vital signs monitor may act as a stand alone display monitor for the vital signs of a patient, or not have any display and simply send the obtained data to the remote display to be observed, or both. The present invention can also transmit the patient's vital signs, for example by way of a transceiver, to remote locations, such as to emergency personnel that are on the scene tending to multiple patients, or to remote personnel able to connect into the wireless protocols available and linked to the system. As used herein, a “transceiver” is contemplated and may include a device that has both a transmitter and a receiver which are combined and share common circuitry or a single housing, and/or also may include a trans-receiver such as a device that no circuitry is common between transmit and receive functions. In such a configuration, the patient mounted vital signs monitor also includes a first transceiver operatively connected to the patient mounted vital signs monitor, and operable to transmit the patient's vital signs data to a remote transceiver by way of a first processing means for processing the detected or measured vital signs and for controlling the operation of at least the first display and the first transceiver automatically and autonomously. Such systems may include, for example, standard Wi-Fi® or Bluetooth® wireless communications hardware, and may use, for example, IEEE 802.11 or Bluetooth® chipsets. The transceivers of the present invention may include a combination transmitter/receiver in a single package, and may include full duplex capability which allows reception of signals during transmission periods.
[0036] In circumstances where the patient's vital signs are transmitted to a remote location or to emergency personnel on the scene, the present invention also includes a user mounted processing system and monitor platform having a second transceiver for wireless connection to the first transceivers of the plurality of the patient mounted vital signs monitors, and also a second display configured to separately display each of the patients' vital signs data received from the plurality of the patient mounted vital signs monitors by way of a second processing means for processing the received vital signs data from the plurality of the patient mounted vital signs monitors and for controlling the operation of at least the second display and the second transceiver. In such a configuration of the present invention, the user, which can be an emergency personnel, may remotely monitor the vital signs of multiple patients via the user mounted processing system and monitor, where as other emergency personnel without a user mounted processing system and monitor can monitor the patient's vital signs values, trend history, and status, for example, via a color coded (e.g., green-normal, yellow-caution, and red-serious) visual display by way of the patient mounted vital signs monitor. This configuration can be very efficient and effective in situations where a large number of injured patients are being treated by a small number of emergency personnel such as in the case of a disaster site or in a combat zone. Such an embodiment can allow for rapid triage based on the parameters shown using similar triage scoring of green, yellow, and red.
[0037] The present invention can be configured to send the vital signs of the patients (e.g., encrypted format) from the scene to other remote locations such as a nearby hospital or anywhere in the world providing that the receiving unit has, for example, internet connectivity and the system software. In such a configuration, the present invention may include a communications module that can be configured to be co-operable with at least one or more of the user mounted processing system and monitors, wherein the user mounted processing system and monitor can transmit the vital signs of the patients and the communication module can be configured to receive the vital signs data and be operable to transmit the vital signs data to a remote location anywhere in the world, for example using existing communications infrastructures automatically. For example, the user mounted processing system and monitor and/or the communication module may be provided with internet connectivity, and this connectivity can be used to transmit the data to any receiving station with internet connectivity via standard internet protocols.
[0038] In the present invention, the first display of the patient mounted vital signs monitor can be any suitable display for this purpose. In some embodiments of the present invention, it is preferable for the display of the patient mounted vital signs monitor to be comprised of a flexible display and/or modified sensor system that is configured to be placed on a patient and flex with the patient's body. In such configuration, depending on the contours of the patient's body or the location of the attachment of the monitor, the display can flex and bend accordingly.
[0039] The transceivers of the present invention can be any suitable transceivers that are suited for their desired purpose and the distances involved for transmitting and/or receiving the vital signs data and information. For example, the transceivers of the patient mounted vital signs monitor and the user mounted processing system and monitor can be configured to wirelessly communicate by way of IEEE 802.11b, 802.11g, Zigbee® 802.15.4, Bluetooth® 802.15.1, or standard off the shelf smart phones.
[0040] The monitors of the present invention may include other components and systems, for example, the display of the user mounted processing system and monitor may be configured to measure and display the range to the patient mounted vital signs monitors and producing one or more alarm when the patient mounted vital signs monitor is out of range of the user mounted second display, for example the alarms may be color coded to represent preset user alarm conditions and produce both visual and auditory alarms based on parameters, derived parameters, and trend-lines. An option to allow for vibration the hand held display units can also be embedded to alert the user to changes in patient status. Furthermore, in situations where a larger numbers of injured patients are being treated and monitored at the scene, the present invention can be configured to handle large numbers of patients, for example up to about 250 patient mounted vital signs monitors, but preferably between about 5 up to about 25 can be in wireless communication with the user mounted processing system and monitor. In addition, the user mounted processing system and monitor can further include a kill switch that can be configured to turn on and off the wireless communication to a particular patient mounted vital signs monitor. In some embodiments, the user mounted processing system and monitor can further include a patient locator which can be configured to transmit a pulsing display command to one particular or all patient mounted vital signs monitors that are in range. In other embodiments, all the patient data may be autonomously and wirelessly transferred from the patient mounted monitor to a base system, for example a hospital, once the patient is in range of the base system for storage and display of vital signs data. Furthermore, the hospital system can be configured to display all vital signs data and trending, and also further process vital signs data and calculate more complex derived vital signs, for example, a laptop or computer base system can generate the display of data and be configured to generate additional derived vital signs data such as predicting the need for a life saving intervention and heart rate variability, and/or display all of the vital signs data (sensor parameters and calculated vital signs) as well as data trends all on one display.
[0041] It is an important aspect of the present invention that, for example, all of the patient's data may be stored only on the patient mounted vital signs monitor and no long term data may be stored on the user mounted processing system and monitor. The data is stored on the patient mounted vital signs monitor, such as by utilizing non-volatile memory, and such data can be retrieved, for example, by using a wireless or wired serial connection to a PC with related software.
EXAMPLES
Example I
Device and System for Wireless Monitoring of the Vital Signs of a Patient
[0042] One example of the wireless vital signs monitor (WVSM) is a highly mobile, patient-worn medical monitoring system using wireless Wi-Fi® 802.11b/g technology and standard off-the-shelf Windows® based software and hardware; it connects to multiple PCs, smart phones, and PDAs. WVSM allows medical personnel to be in touch with remote or on-site monitoring.
[0043] The WVSM is designed to attach directly onto the patient via standard blood pressure arm cuff for both sedentary and mobile patients. It integrates standard medical technologies such as the Nonin® SpO2 sensor, standard arm cuff NIBP, and multiple ECG configurations and connectors already on the market—thereby minimizing product acquisition and support costs. WVSM acquires motion tolerant electrocardiograms (at 230 Hz), SpO2, pulse rate and NIBP with selectable alarm limits and data rate capability. WVSM may be configured to process up to 254 simultaneous patients and can be embedded with algorithms to track real-time heart rate variability (rt-HRV), shock index, pulse wave delay (PWD), and pulse pressure in all patients.
[0044] All WVSMs use an on board OLED low power, full color, 128×128 resolution display showing patient HR, SpO2, and NIBP. User interface includes selectable press-and-release switches for starting/stopping NIBP, turning on and off the wife, and turning the unit on and off.
[0045] The WVSM can be configured to run wirelessly. PC and PDA enabling software is provided for full control of the WVSM within existing IT platforms, with no additional or hidden mandatory software purchases needed to implement. Additional vital signs can be manually entered such as the patients Glascoe Coma Score or GCS and patient respiration rate. Numerous WVSM-enabled patients can be linked together and displayed on common platforms. The WVSM is essentially a plug and play device requiring less than a minute to implement effectively in any environment at any time.
[0046] The WVSM basic monitoring system is comprised of the medical monitor WVSM unit, a non-invasive blood pressure cuff (NIBP) and lines, SpO2 sensor and connectors, and ECG leads and connectors. On the top of the WVSM are three standard plug-in leads that are color coded according to where on the body the lead sensors (stick-on) are placed. Red is left leg (LL), black is left arm (LA), and white is right arm (RA).
[0047] Manufacturer directions should be followed when placing the ECG leads on the body. The SpO2 connector (female) is on the front side of the WVSM. This connector is designed to accommodate the Nonin® SpO2 sensor and the attached finger clip as well as stick on sensors and reflectance forehead sensors. The NIBP connector is at the end of an approximate 6 inch pneumatic line from inside the WVSM device. The quick connector attaches firmly to a standard NIBP cuff with a quick insertion and snap turn.
[0048] The WVSM is a DC powered device and the Li-Polymer battery is internal to the device, and is accessible device only by disassembly of the device. The batteries do not need to be removed from the unit to be recharged.
[0049] The WVSM Unit can be operated by the following exemplary steps:
[0050] Step 1—Connect all applicable leads and sensors as needed on the unit and on the patient. Turn “ON” WVSM: The ON/OFF switch is located on the front face of the unit as it faces the user. Upon turning on the unit the green Power LED located on the front face will indicate that the unit is powered. The blue LED indicates WLAN activity and that the unit is automatically searching for a WLAN (802.11b/g) connection enabled with WVSM software. In addition, the display located in the center of the front surface of the WVSM unit indicates the vital signs SpO2, HR (heart rate), and BP (mm Hg) (Non-invasive Blood Pressure or NIBP in milliliters of mercury or mm Hg). The display will show dashed lines indicating no signal upon power up and then switch automatically to patient data as it begins to be obtained.
[0051] Step 2—The WVSM is set up to automatically take blood pressure every 15 minutes. To initiate an immediate blood pressure reading, simply press the BP button. To terminate a BP reading in progress, press the BP button.
[0052] The PDA can be operated by the following exemplary steps:
[0053] Step 1—Note: In order to communicate with the WVSM the PDA needs to be setup to operate on the same network. The units sent by the manufacturer are already configured properly. New systems should be set up by the user.
[0054] Step 2—Upon power up the screen on the PDA should present the display in standard MS Windows® format. It is now possible to engage WVSM transmittance into the PDA (or other device). Note: some PDAs and other mobile devices may vary in startup menus and icons.
[0055] Step 3—Touch Start on the Home Screen. The PDA will display typical menu icons. Find the File Explorer icon. Navigate to My Device\WVSM using the “Down” arrow in the upper left hand corner.
[0056] Step 4—Under My Device, Select “WVSM”.
[0057] Step 5—Select “WVSM.exe” program.
[0058] Step 6—The Main Screen appears. The software in the product allows registration of patients and selected functionality by attending medical personnel. Select “OK” to go directly to the monitoring screen.
[0059] Step 7—WVSM Patient List The WVSM software in the PDA automatically searches for and logs in the patient monitor when in range of the PDA. Typical indoor ranges are about 100 yards and 300 yards line of sight with substantial structure and reinforced concrete limiting wireless transmissions. All patients in range will produce patient icons displayed on the PDA. Verification is shown by the appearance of the patient ID (# of the WVSM unit, e.g., #W5) on the PDA patient list screen and vital signs for that patient. In this display all patients and data can be viewed simultaneously and reviewed. Users can access any of the registered patients by touching the patient number and data line to display that subjects' data in more detail and/or to affect alarm settings.
[0060] Each active WVSM monitor is displayed on the PDA screen in the order in which it was powered “ON” and subsequently connected, received, or “seen” wirelessly by the PDA. All patients connected to an active monitor will transmit patient data in color coded formats based on the vital signs alarm settings used (default values are pre-installed but can be adjusted in the alarm settings). Patient vital sign data within normal ranges, as set in the PDA, will display green highlighted data. When vital signs are either approaching or are out of line with alarm limits, the color changes from green to yellow to red highlights. In one application, if the unit is on, but no vital signs are connected to it, all data shows as Out of Track.
[0061] Step 8—WVSM Patient data-Main Patient Screen touching or tapping anywhere on the data line of a patient on the patient list screen will display specific vital signs for that patient as shown here. This same display reflects the previous step's “patient data” but adds full ECG waveform.
[0062] Each patient would display data here. The patient's registered unit is shown in the lower right corner, and last BP recorded (121/81), Heart Rate (76), SpO2 (96) and the lead 2 ECG are shown in real time based on sensor inputs.
[0063] Specifications for this WVSM system include:
Microprocessor
[0064] High performance 40 MIPS DSP and MCU core
[0065] 128K program memory, 16 KB RAM, and 64 KB Flash
[0066] 16-bit ADC producing up to 1 KHz sampling rates
Analog Features
[0067] Patient and system electrical isolation
[0068] High performance biomedical instrumentation amplifier
On Board Display
[0069] Low power, passive matrix OLED
[0070] 128×128 resolution with 16 bit color
[0071] 25×25 mm viewing area
Power Management
[0072] Standard 7 hours battery life
[0073] Auto-sleep for power conservation
Wireless
[0074] Network Interface Wireless 802.11b/g; 328 foot range indoors, 900 ft+range LOS
[0075] Multiple protocols supported in 802.11b/g (ARP, UDP, TCP, Telnet, ICMP, SNMP, DHCP, BOOTTP, Auto IP)
[0076] Media Access Control CSMA/CA with ACK
[0077] Security Password protection with locking features, 64/128 bit WEP, TKIP
Sensors
[0078] ECG at 230 Hz, Channel-user selectable time window with embedded software digital filtering and high GAIN
[0079] SpO2/HR via Nonin® OEM III module
[0080] Oxygen Saturation Range 0 to 100%
[0081] Pulse Rate Range 18 to 300 pulses per minute
[0082] Rate Accuracy 3%±1
[0083] Blood pressure, NIBP; Common Cuff, Range: Systolic: 40 mmHg to 260 mmHg, Diastolic: 20 mmHg to 200 mmHg, heart rate range: 40 BPM to 200 BPM and Serial Output
Graphical User Interface/Software Compatibility
[0084] All connectivity software included
[0085] User selectable and auto peer-to-peer or multiple access point connectivity
[0086] Compatible with Windows® XP
[0087] Wi-Fi® enabled (fixed and mobile devices)
[0088] User ID, patient ID utilizing selectable patient alarms, data storage with post processing pulse pressure, heart rate variability (from R wave), and shock index.
[0089] Across entire patient database from remote positions. Software installed for remote consult data capture on patient records.
[0090] Architecture allows interfacing to peripheral devices in both I/O configurations via serial interface or other wireless protocols.
[0091] All headings are for the convenience of the reader and should not be used to limit the meaning of the text that follows the heading, unless so specified. Various changes and departures may be made to the present invention without departing from the spirit and scope thereof. Accordingly, it is not intended that the invention be limited to that specifically described in the specification or as illustrated in the drawings, but only as set forth in the claims. Although the invention has been described and illustrated with respect to exemplary embodiments thereof, it should be understood by those skilled in the art that the foregoing and various other changes, omissions, and additions may be made therein and thereto, without parting from the spirit and scope of the present invention. | The present invention relates generally to the field of vital signs monitors, and particularly to a device and system for wireless monitoring of the vital signs of a plurality of patients simultaneously yet independently. The present invention is particularly adaptable for use by medical emergency personnel or medics in any setting, such as road accident, disaster sites, combat zones, or hospitals. The systems and methods of the present invention allows the monitoring of a plurality of patients by a single health care professional providing more effective monitoring and care for a large number of patients at any one time, and retaining all the information for more effective later triage and decision making by health care providers. | 0 |
GOVERNMENTAL INTEREST
The invention described herein may be manufactured, used and licensed by or for the Government for Governmental purposes without the payment to me of any royalties thereon.
BACKGROUND OF THE INVENTION
The present invention relates to electronic velocimeters and in particular to velocimeters employed to measure the muzzle velocity of a projectile.
The muzzle velocity of a projectile is a significant operating parameter of a weapon. Knowing the angle of elevation and muzzle velocity, the trajectory of a shell can be readily computed. A measurement of muzzle velocity can also be dispatched to an automatic gun control system to adjust gun elevation in response to variations in the muzzle velocity. In addition, a measurement of muzzle velocity can be a useful diagnostic tool for assessing barrel wear or projectile quality.
Known velocimeters have employed a magnetized projectile which is fired through a pair of spaced coils. Besides the special projectile which is required, the spacing between coils enlarges the device, making it cumbersome. Other known velocimeters substitute a light source and photocell for each of the above mentioned coils. While the latter system does not require a special projectile, the requisite spacing between photocells is still cumbersome. Microwave interferometers may be employed to measure muzzle velocity, however, such systems are relatively complicated and costly. In addition care must be taken to direct a microwave beam axially into the gun tube. This approach requires a system of reflectors and its performance is degraded by pointed projectiles which do not reflect microwave energy well. Another known velocimeter employs a spaced pair of strain or pressure gauges mounted on the gun tube which sense the strain caused by the passing projectile. This system is prone to false readings caused by acoustical or vibrational shock waves caused at the instant of firing. Also the strain on the gun tube lags the passage of the projectile to an extent which degrades accuracy.
The present invention measures velocity by measuring the transit time of a projectile through a coil. Since a pair of spaced coils is not required a simple and compact measurement system is provided which may be conveniently mounted on the muzzle, in some embodiments.
SUMMARY OF THE INVENTION
In accordance with illustrative embodiments demonstrating features and advantages of the present invention, there is provided in an electronic velocimeter for measuring the muzzle velocity of a projectile exiting from the muzzle of a weapon along a given trajectory, a sensor means. The sensor means includes an annular conductive shield mounted alongside and spaced from the muzzle. Also included is a conductive coil insulated from and mounted between the muzzle and the shield. The shield and the coil each encircle the trajectory of the projectile. The sensor means also includes an oscillator means for generating an oscillator signal. The oscillator means is coupled to the conductive coil and is responsive to passage of the projectile therethrough along a predetermined interval of the trajectory. Also included is a timing means responsive to the oscillator signal and operative to produce a timing signal. The timing signal represents the transit time for the projectile to traverse the predetermined interval of the trajectory. Thus the timing signal represents a quantity inversely proportional to the muzzle velocity.
BRIEF DESCRIPTION OF THE DRAWINGS
The above brief description as well as further objects, features and advantages of the present invention will be more fully appreciated by reference to the following detailed description of presently preferred but nonetheless illustrative embodiments in accordance with the present invention when taken in conjunction with the accompanying drawings wherein:
FIG. 1 is an elevational view in section showing the mechanical mounting of components of the instant invention;
FIG. 2 is a perspective view of parts illustrated in FIG. 1;
FIG. 3 is a partial schematic representation of an oscillator means in accordance with the instant invention;
FIGS. 4A and 4B are elevational views of a projectile and its corresponding spatial signature;
FIG. 5 is a block diagram of an oscillator means and a timing means in accordance with the instant invention; and
FIG. 6 is a series of timing diagrams showing signals at various terminals in FIG. 5.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now specifically to the drawings, in FIG. 1, the barrel 10 of a weapon is shown in section and broken on the right. The muzzle 12 of barrel 10 has alongside it a conductive coil which is shown herein as annular conductive sheet 14 which is laminated onto an annular insulator 16. Coil 14 and insulator 16 are a convential printed circuit board composed of a fiberglass substrate with a copper laminate. It is understood that the thickness of coil 14 is exaggerated to clarify the illustration. Obviously many other arrangements are possible for coil 14 and insulator 16 such as a teflon annulus having a concentric groove on its side into which a wire or bus bar is embedded. Also, while coil 14 is shown herein as a single turn of conductive material, other embodiments may employ multi-turn coils.
Disposed alongside coil 14 is an annular conductive shield shown herein as an annular conductive sheet 18 adjacent to an annular insulating layer 20. Sheet 18 and layer 20 are fabricated from printed circuit board material consisting of copper-clad fiberglass. Copper sheet 18 provides an electrostatic shield for coil 14 although obviously many other conductive annular arrangements can provide shielding. Moreover, such shielding could be provided by a plurality of annularly disposed conductive elements in which adjacent elements are electrically isolated. Also for some embodiments a separate shield may not be employed and instead the mounting hardware may provide electrostatic shielding. In the embodiment shown herein a conductive tube 22 having an inwardly projecting shoulder 24 provides shielding and functions as mounting hardware. Shoulder 24 bears against the two printed circuit boards 18, 20 and 14, 16 and compresses them and annular gasket 26 onto muzzle 12. Gasket 26 prevents the leakage of high pressure gun gas which could damage or dislodge coil 14 or shield 18. Tube 22 is clamped onto muzzle 12 by means of split collar 28 which engages ridge 30. Split Collar 28 is a annulus formed of two complimentary semi-circular sections which draw tube 22 backwards by means of bolts 32.
Electrical leads 34 connect to coil 14 and pass through insulating bushing 38 into junction box 36. Bushing 38 is fitted into an aperture in tube 22. The contents of junction box 36 have not been illustrated for simplification purposes. In this embodiment an oscillator means is contained in box 36 and the balance of supporting circuitry is connected thereto by multi-pin connector 40. It is apparent, however, that the partitioning of circuitry within and without box 36 is a designer's choice.
In this embodiment barrel 10, tube 22, shoulder 24, shield 18, coil 14 and insulators 20, 16 and 26 are all coaxially mounted. Their axis coincides with trajectory 42 of the projectile (illustrated elsewhere). While this mounting is preferred it is contemplated other mounting arrangements may be employed.
Referring to FIG. 2, an exploded view of some of the components mounted in front of muzzle 12 of FIG. 1 are shown in perspective. The shield is shown herein as an annular substrate of fiberglass 20 having a copper sheet 18 laminated thereupon. As previously mentioned sheet 18 and substrate 20 are fabricated from conventional printed circuit board material. Similarly fabricated from printed circuit board material is coil 14 and insulator 16. Coil 14 is split and electrical leads 34A and 34B are soldered to different ends of coil 14 at this split. Such splitting may be accomplished by etching or by grinding coil 14. Leads 34A and 34B correspond to the leads designated as leads 34 in FIG. 1. Leads 34A and 34B may be formed of thin buss bar material.
Referring to FIG. 3, an oscillator means is shown as a Hartley oscillator employing NPN transistor Q2. Obviously many other sources of an oscillating signal may be used instead. Coil 14, which was illustrated in FIGS. 1 and 2 is shown schematically herein as coil 14. Coils 14 and L2 are connected together to a reference potential. While this reference potential is illustrated as ground, a fixed bias point differing in potential from other grounded terminals may be substituted here and elsewere. Connected to the ungrounded terminal of coil 14 is the collector of transistor Q2 and one terminal of capacitor C2, its other terminal being connected to the junction of the ungrounded terminal of coil L2 and one terminal of feedback capacitor C4. The other terminal of capacitor C4 is connected to the junction of the base of transistor Q2 and one terminal of bias resistor R2, whose other terminal is grounded. Emitter resistor R4 is connected to a negative supply potential at terminal -V. Capacitor C6 shunts oscillating signals across resistor R4. Supply filter capacitor C8 is connected between terminal -V and ground. Arranged in this fashion a 12 MHz signal is provided across coil L2 whose amplitude varies with the losses of coil 14. The losses of coil 14 increase as a projectile approaches and loads coil 14. Accordingly, the amplitude of oscillation across coil L2 decreases as a projectile passes through coil 14.
This amplitude modulated signal is fed to an amplitude detector shown herein as serially connected diode CR2 and capacitor C10, serially connected between ground and the junction of capacitor C2 and L2. Resistor R6 and capacitor C10 are connected in parallel between ground and the cathode of diode CR2. In operation, capacitor C10 is charged to a voltage corresponding to the amplitude of oscillation across coil L2.
The detected voltage is capacitively coupled to an emitter follower amplifier by capacitor C12. This amplifier comprising NPN transistor Q4, has its base resistively coupled (resistor R8) to the junction of biasing resistor R10 and biasing diode CR4 which are serially connected between the positive supply potential at terminal +E and ground. Diode CR4 has its cathode grounded and its anode connected to the junction of capacitor C12 and resistors R8 and R10. Transistor Q4, whose collector is connected to supply terminal +E and supply filter capacitor C14, employs grounded emitter resistor R12. The output at terminal 44 is connected to the emitter of transistor Q4.
It is appreciated that the output signal on terminal 44 is a voltage that varies as a function of the position of a projectile with respect to coil 14. Referring to FIG. 4A, projectile 46 is shown with its axis parallel to the abscissa S of a graph. This graph displays the voltage on terminal 44 (FIG. 3) as ordinate V44. The abscissa S represents the axial position of projectile 46 which is encircled by coil 14 (FIG. 1). Abscissa S is scaled to coincide with the illustrated projectile 46 such that lines parallel to ordinate V44 intercept an axial position on projectile 46 and its corresponding coordinate on abscissa S. The plot of FIG. 4A is referred to as the signature of projectile 46.
The specific signature produced will depend upon the diametric and compositional variations occurring along the axis of a projectile. Projectile 46 is relatively blunt so that its signature has a steep rise and fall. Referring to FIG. 4B, projectile 48 has a pointed forward end which causes a comparatively gentle rise in the signature. The signature of projectile 48 is plotted against abscissa S and ordinate V44, which are arranged and scaled in the same manner as the graph of FIG. 4A.
Referring to FIG. 5, a block diagram is shown of a timing means coupled to an oscillator means 50. In this embodiment oscillator 50 is identical to the circuit shown in FIG. 3. The timing means includes peak means 52 which drives a threshold means 54. As will become clear peak means 52 need not be employed in all embodiments but is useful for processing the signature of a pointed projectile. Peak means 52 provides a signal responsive to the magnitude of the output of oscillator 50 exceeding its prior peak value. While other known arrangements can provide such a function, peak means 52 employs a unidirectional conducting device CR6 serially connected with a capacitive element C16.
The output of oscillator 50 is coupled to diode CR6 by a coupling means shown herein as amplifier 56. Amplifier 56 is cascaded with amplifier 58. The non-inverting inputs of amplifiers 56 and 58 are separately connected to the outputs of oscillator 50 and amplifier 56, respectively. Amplifier 56 has a negative feedback resistor R14 connected around it to establish a stable and moderate gain. Capacitor C16 has one terminal grounded and its other terminal connected to the junction of the cathode of diode CR6 and the inverting input of amplifier 58. The output of amplifier 58 is connected to the anode of diode CR6.
In operation, amplifier 58 will forward bias diode CR6 and charge capacitor C16 if the charge thereon does not exceed the voltage applied to the non-inverting terminal of amplifier 58. Accordingly, capacitor C16 operates as a peak detector. The output of amplifier 58 will rise whenever capacitor C16 is charging and will fall otherwise. In effect the output of amplifier 58 will fall whenever the rate of change of the output of amplifier 56 is zero or negative.
Threshold means 54 is a device which produces a high or a low signal depending upon whether or not its input exceeds a predetermined threshold value. In a constructed embodiment, threshold device 54 employed a bistable multivibrator, although obviously circuits such as a comparator or a schmitt trigger may be employed instead.
The output of devive 54 drives a logic means and a hold means shown herein as monostable multivibrators 62 and 64, respectively. The output T4 of device 54 is connected to the input of inverter 60 and the reset input of monostable multivibrator 62. The output of inverter 60 is coupled through capacitor C18 to the trigger input of monostable multivibrator 62. Multivibrator 62 has two outputs P1 and P2 which are in phase. Output P1 is coupled through capacitor C20 to the trigger input of multivibrator 64, whose output is connected to the output of inverter 60 through resistor R16. The durations of the unstable high states of multivibrators 62 and 64 are relatively long in comparison to the time required for a projectile to pass through coil 14 (FIG. 1). The output P2 is connected to output terminal T7 and the junction of resistors R18 and R20. Resistor R20, being connected between output P2 and the inverting input of amplifier 56, can reduce the system sensitivity to the signal on line T1, as explained hereinafter. Diode CR8, having its cathode connected to the inverting input of amplifier 58, provides a form of positive feedback. Diode CR8 and resistor R18 are serially connected between terminal T7 and the inverting input of amplifier 58.
To facilitate an understanding of the foregoing equipment, its operation will be briefly described as a projectile such as projectile 48 (FIG. 4B) is fired past coil 14 (FIG. 1). Prior to entry of a projectile into coil 14 (FIG. 1) oscillator 50 (FIG. 5) produces a constant low (zero volts) signal which is transferred from line T1 to T3. In this quiescent condition monostable multivibrator 62 is in its stable state and produces a low signal on terminal T7. As projectile 48 (FIG. 4B) approaches coil 14 (FIG. 1) the output of oscillator 50 (FIG. 5) begins increasing, causing a positive voltage to appear at the output of amplifier 58, for the reasons previously given. In response, threshold device 54 produces a low signal which causes inverter 60 to produce a high (5 volts) signal. Also, the positive voltage on line T3 forward biases diode CR6 and charges capacitor C16.
The output of oscillator 50 continues to rise as shown in the timing diagram 6A (FIG. 6) until at time ta it reaches a plateau. Since at time ta the voltage on lines T1 and T2 stops increasing, the output of amplifier 58 (FIG. 5) falls to zero. This event corresponds to the constant diameter portion of projectile 48 (FIG. 4B) entering within coil 14 (FIG. 1). The falling voltage on line T3 causes threshold device 54 to produce a high signal on line T4 and an inverted low signal on line T5. These signals on lines T3, T4 and T5 are shown in timing diagrams 6C, 6D and 6E (FIG. 6), respectively. The voltage fall on line T5 couples a negative-going trigger through capacitor C18 to multivibrator 62, causing it to produce on its outputs P1 and P2 and on terminal T7 a high signal. The waveforms appearing on lines T6 and T7 are shown in timing diagrams 6F and 6G (FIG. 6), respectively. The foregoing conditions persist as the constant diameter portion of the projectile 48 (FIG. 4B) passes through coil 14 (FIG. 1).
As the rear of projectile 48 (FIG. 4B) enters coil 14 (FIG. 1) a diametrically larger portion is presented to the coil. As a result, the output of oscillator 50 (FIG. 5) rapidly increases. This rapid increase is shown occurring around time tb in timing diagram 6A (FIG. 6). This increase causes amplifier 58 to produce a positive signal which drives threshold device 54 so it produces a low signal on line T4. The low signal on line T4 prematurely resets monostable multivibrator 62 causing it to produce a low signal at terminal T7. Also the in-phase output P1 couples a negative going pulse to monostable multivibrator 64 causing it to produce a high signal on line T8 as shown in timing diagram 6H (FIG. 6). The high signal on line T8 biases line T5 for a predetermined interval so that subsequent transients do not retrigger multivibrator 62. Such transients can be produced as a result of the output of amplifier 58 returning to zero or from ionized gun gas escaping past coil 14 (FIG. 1) after projectile 48 is launched.
It is apparent that the pulse produced on terminal T7 by the foregoing process has a duration equivalent to the time elapsing as a predetermined projectile length passes a fixed station at the muzzle. This predetermined projectile length is illustrated as dimension D2 in FIG. 4B. Muzzle velocity is the ratio of dimension D2 to the pulse duration at terminal T7. Accordingly this pulse duration is a quantity that is inversely proportional to muzzle velocity. The signal at terminal T7 may be dispatched to well-known computing circuitry to provide a direct display of muzzle velocity.
It is also apparent that peak means 52 (FIG. 5) will respond to the constant diameter portion of a projectile so that accurate velocity readings may be obtained from blunt or pointed projectile. So long as the time of passage of the constant diameter portion of the projectile does not exceed the free running time of the multivibrator (62), projectiles of different lengths and configurations may be fired without any circuit changes. Only a change in the baseline length for different length projectiles would have to be considered in the computation of muzzle velocity.
Overall accuracy will be a function of the interspacing of muzzle 12, coil 14 and shield 18 (FIG. 1). If they are relatively close, the accuracy will be correspondingly high.
To prevent false triggering, the positive output on terminal T7 is fed back to amplifiers 56 and 58. This positive output applied to the inverting input of amplifier 56 reduces its output during the constant diameter phase of operation. This renders the system relatively insensitive to noise and allows the system to respond to a large rise in voltage such as that occurring at time tb, as shown in timing diagram 6A (FIG. 6). This reduction in sensitivity is manifested by the voltage depression on line T2 of FIG. 5 as shown in timing diagram 6B (FIG. 6). This effect is further enhanced by the positive voltage fed to capacitor C16 (FIG. 5) by diode CR8. This cuts off amplifier 58 further so it responds only to a substantial rise in the voltage at line T2.
It is also appreciated that after firing of a projectile capacitor C16 will retain a residual charge which will inherently dissipate at a rate depending on the dielectric and insulating qualities of that capacitor and the time constant of the parallel circuit. In some embodiments in which a weapon is rapidly fired it may be necessary to directly discharge capacitor C16 by means of a transistor switch or other suitable device. Such details and variations are clearly within the skill of this art.
The foregoing embodiments may also be varied dimensionally to satisfy the accuracy and noise immunity requirements of a specific installation. Moreover, many alternate circuits may be devised to provide the functions needed to measure muzzle velocity. Obviously many other 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. | An electronic velocimeter for measuring the muzzle velocity of a projectilemploys a conductive coil mounted between the muzzle and an annular conductive shield. The shield and coil are insulated from each other and encircle the trajectory of the projectile. An oscillator means for generating an oscillator signal is coupled to the coil. This oscillator means is responsive to the projectile passing through the coil. A timing means responds to the oscillator to produce a timing signal. This timing signal represents the transit time for the projectile to traverse a predetermined interval of the trajectory of the projectile. Knowing this transit time the velocity is readily obtained. | 6 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to apparatus for separating a food product from a tray, and more particularly separation from a tray having apertures defining a supporting lattice to which the food product is adhered.
2. Description of Related Art
Certain food products tend to adhere to the surfaces supporting them during food processing. As explained in more detail in my U.S. Pat. No. 4,645,404, separation of the food product from supporting trays is difficult where the food product is in thin strip form, as is the case with the long strips of meat jerky for human or animal consumption.
In preparing jerky, a meat containing mixture is extruded to form thin elongated strips which are arranged on a tray having apertures defining a supporting lattice. The apertures permit air circulation during drying of the product, but the nature of jerky material is such that the strips stick to the ribs or lattice of the tray during drying. The problem is made worse because the strips of meat tend to sag into the apertures as the meat dries.
The long strips of jerky must be separated intact, without breaking, so that they can be cut into predetermined short lengths for packaging. Any broken pieces cannot readily be packaged and must be discarded.
The apparatus of my U.S. Pat. No. 4,645,404 provided reasonably satisfactory separation of the strips of meat jerky from the tray lattice. However, the apparatus involved a two step procedure to effect separation, and a significant number of long strips were still broken into commercially unusable short pieces. In that apparatus a pair of conveyor belts were arranged in spaced apart end-to-end relation to define a gap across which the food product tray was carried. Preliminary separation of the jerky strips lying on top of the tray lattice was accomplished by one or more separating rollers located below the tray. Radially directed fingers of the tray were arranged to project upwardly through the tray apertures and into engagement with the food product. At least two backup rollers were located above the tray opposite each separating roller. These engaged both the food product and the tray, allowing the food product between the rollers to be moved up from the tray by the roller fingers, but keeping the tray from also moving upwardly.
Some portions of the jerky strips still stuck to the tray at various points along their lengths. Final separation was achieved by transferring the trays onto a third conveyor belt disposed at right angles to the first pair of conveyors. In making the transfer, each tray was inverted so that the already loosened jerky strips hung down in loose loops. A stripper plate above the third belt was arranged to lie within the space between the tray and the sagging strips as they moved along the belt. The partically separated strips were then pulled away from the tray by the plate and transported to a collection station. Some of the strips still adhered sufficiently tenaciously that this pulling action resulted in their breakage.
SUMMARY OF THE INVENTION
According to the present invention, all food product separation occurs in a substantially continuous process on the same conveyor belt that supports the food product trays.
The trays are inverted on the conveyor belt, and the belt is moved past a first row of roller bands located above the belt and a row of supports located below the belt. The supports are rigid and transversely spaced apart for slidable engagement with the under side of the belt. The belt is sufficiently flexible that it sags between the supports in a catenary-like configuration.
The roller bands are located between the supports, and radially directed fingers of the roller bands project downwardly through apertures in the tray and press the food product into the spaces between the food product and the sagged portions of the belt. Thus, the food product can be pushed downwardly by the roller belt fingers onto the conveyor belt despite the fact that the same belt is providing support for the tray.
The tray is preferably made of a resiliently deformable material so that it is flexed between the roller bands and supports to facilitate food product separation.
Portions of the food product overlying the first row of supports are not easily reached by the fingers of the first row of roller bands. Accordingly, a second row of roller bands and supports are located behind or beyond the first row of roller bands and supports, in staggered or laterally offset relation to the first row so as to operate on the portions of the food strips that were not acted upon by the first row of roller bands and supports.
Tray separation from the conveyor belt is accomplished by a transfer plate spaced slightly above the conveyor belt to intercept and move each tray upwardly where it can be engaged by conveyor rollers which move it up a ramp to a tray collection station.
The apparatus of the present invention thus eliminates two step strip separation, accomplishing all separation by roller belt fingers projecting downwardly through the trays for strip separation onto the same conveyor belt which provides support for the trays.
Other objects and features of the invention will become apparent from consideration of the following description taken in connection with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a diagrammatic perspective view of the present apparatus, and particularly the conveyor belt and overlying roller bands;
FIG. 2 is a top plan view of a tray supporting a plurality of jerky strips;
FIG. 3 is an enlarged view of the section indicated by the numeral 3 in FIG. 2;
FIG. 4 is an enlarged view taken along the line 4--4 of FIG. 3;
FIG. 5 is a top plan view of the present apparatus;
FIG. 6 is a view taken along the line 6--6 of FIG. 5;
FIG. 7 is a diagrammatic side elevational view of the drive means for the roller bands and conveyors of the apparatus;
FIG. 8 is an enlarged view taken along the line 8--8 of FIG. 5;
FIG. 9 is an enlarged view taken along the line 9--9 of FIG. 5;
FIG. 10 is an enlarged view taken along the line 10--10 of FIG. 8;
FIG. 11 is a View taken along the line 11--11 of FIG. 5;
FIG. 12 is a view taken along the line 12--12 of FIG. 5;
FIG. 13 is a diagrammatic side elevational view of the discharge end of the apparatus, illustrating an embodiment utilizing a strip collector belt;
FIG. 14 is a diagrammatic side elevational view of the feed end of the apparatus, illustrating an embodiment employing a conveyor belt to transport inverted trays to the main conveyor belt;
FIG. 15 is a diagrammatic side elevational view similar to FIG. 14 but showing an alternate tray inverting chute.
FIG. 16 is a fragmantary top plane view of an alternate empty-tray engaging roller cosntruction and;
FIG. 17 is a side elevational view taken along line 17--17 of FIG. 16.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The present apparatus relates to the separation of strips of dried meat products from tray support surfaces to which the products are adhered. One such product is a mixture, by weight, of 75% meat by-products, 15% beef, 1% wheat flour, 1% cane molasses, 2% dextrose, 2% salt, 2% water, and 2% spices and preservatives. The mixture is extruded into meat strips 10 approximately 11/4 inch wide, 0.165 inch thick, and 48 inches long, following which the strips are dried, and then cut into lengths of about 41/4 inches for packaging.
FIGS. 2, 3 and 4 illustrate a tray 12 onto which the meat strips 10 are extruded. The tray 12 is typically made of resiliently deformable plastic about 6 inches wide and 48 inches long. Four strips 10 are supported on each tray, as seen in FIG. 4. Each tray 12 includes a plurality of apertures 14 arranged to define a supporting lattice 16 comprised of crosswise and lengthwise ribs. Each aperture 14 is about 3/8 inches wide and 3/4 inches long, making a total of about 544 apertures per tray.
After the strips 10 are extruded onto the surface of the trays, the trays 12 are stacked on racks and placed in a drying oven (not shown) in which air circulates through the apertures 14, drying the meat strips 10 and forming a jerky product. During drying the strips 10 tend to bake onto and stick to the tray lattice 16, the strips also tending to sag into the apertures 14, as seen in FIG. 3. The purpose of the present apparatus is to remove the strips 10 from the trays without breaking the 48 inch long strips into unusable shorter pieces. The separated long strips can then be cut into the desired lengths of about 41/4 inches for packaging. As will be seen, the present apparatus accomplishes such separation through the unique interaction of separating roller bands and support structure located on opposite sides of the tray conveyor belt.
As best seen in FIGS. 1 and 5-7, the present apparatus includes a rigid frame, most of which is omitted for brevity, having a pair of longitudinally extending, transversely spaced apart I-beams or sides 18.
A continuous conveyor belt 24 is trained around rollers carried by a pair of belt shafts 20 and 22 which are rotatable in suitable bearings mounted to the front and rear extremities of the frame sides 18. Another roller, carried by an idler shaft 25 extending between the sides 18, presses upwardly against the conveyor belt 24 to eliminate slack and provide proper tensioning.
The belt 24 is preferably made of a wear resistant, flexible plastic material such as vinyl that can be tensioned longitudinally, but which droops or sags transversely in areas where it is unsupported. As will be seen, this feature is useful in the separating operation to be described.
The belt 24 is supported adjacent the front of the apparatus by a row of four longitudinally oriented, transversely spaced apart pipes or supports 26. The forward and rearward extremity of each support 26 is downwardly curved, as best seen in FIG. 6, to promote smooth engagement and disengagement with the underside of the upper run of the conveyor belt 24. The supports 26 are fixed against vertical movement by attachment to a pair of brackets 28 whose ends are fixed to the frame sides 18.
A second row of longitudinally oriented, transversely spaced apart pipes or supports 30 are located behind or beyond the supports 26. There are five such supports 30, all of which are downwardly curved at their forward and rearward extremities to facilitate sliding engagement with the underside of the upper run of the conveyor belt 24. The middle one of the supports 30 is approximately the same length as each of the forward supports 26, while the other four supports 30 extend from approximately the mid portion of the frame to its rearward extremity. In a manner similar to the mounting of the supports 26, the supports 30 are fixed against vertical movement by transverse brackets 32, two of which are seen in FIG. 6, which are attached at their ends to the frame sides 18.
It is important to note that the supports 30 are transversely offset relative to the supports 26. As will be seen, the flexible belt 24 is designed to hang or sag in a catenary-like configuration between adjacent supports 26, as seen in FIG. 8. As the belt 24 passes beyond the supports 26, the areas of such sagging changes so that the catenary-like sags of the flexible belt are longitudinally aligned with the first row of supports 26, as seen in FIG. 9.
The conveyor belt 24 supports each tray 12 and conveys it in the direction or conveyor path indicated by the arrow in FIG. 6. Each tray is placed across or transversely of the belt, and in an inverted position. The food product or strips 34 located on the underside of the tray thus engage the upper surface of the upper run of the conveyor belt 24, with the long axis of each strip 34 perpendicular to the conveyor path.
As the trays 12 move with the belt 24, separator means are arranged to project downwardly through the tray apertures 14 to engage with the strips 34 and gently separate them from the tray 12 and onto the upper surface of the belt 24.
The separator means comprise a row of five separator or roller bands 36 transversely spaced across and above the conveyor belt 24 adjacent the front end of the apparatus frame. The two outside roller bands 36 are narrower than the three central bands, but each band is characterized by a plurality of projections, protrusions, or fingers 38 made of flexible plastic material or soft rubber. Each finger 38 has a transverse cross-sectional area smaller than that of one of the apertures 14 so that the fingers can pass downwardly through the apertures into contact with the strips 10. As will be seen, the vertical position of the bands 36 can be adjusted so that engagement between the fingers 38 and the strips 10 is firm enough to separate the strips from the tray lattice 16 but not forceful enough to unduly deform and break the strips. This separating action is seen in FIGS. 8 through 10.
The base fabric or material of which the bands 36 is made is commercially available in wide, continuous belts. These are cut into narrow bands to provide the bands 36 with the integral fingers 38. Although the bands 36 could be adhered or otherwise secured to the periphery of large rollers carried on transverse shafts extending above the conveyor belt 24, the bands 36 are preferably adhered in transversely spaced apart relation to one one another on a wide separator belt 37 which extends across and above the belt 24. The belt 37 is supported so that each individual roller band 36 is upwardly inclined at its leading extremity, enabling a tray 12 to easily pass below the front of the roller band. The fingers 38 thereafter come into progressively closer relationship with the strips, and then firmly engage them along a rearward, horizontally disposed extremity of the band 36.
The sagging of the belt 24 between the supports 26 is clearly evident in FIG. 8, as is the projection of the fingers 38 through the tray apertures and into engagement with the strips 10. The sagging or yieldability of the flexible belt 24 between the supports 26 provides a space into which the strips 10 can be moved to separate them from the tray lattice portions between the supports 26. The size of the space is somewhat exaggerated for clarity. In some instances a pre-existing space is not necessary so long as the belt 24 is made sufficiently yieldable that it will move away from the tray with the separated food strips to accommodate their presence on the belt. Although not clearly seen in the drawings, the action of the fingers 38 on the tray also bends or flexes the portions of the tray 12 between the supports 26. This flexing induces relative movement between the adhered food product and the tray, and further facilitates separation of the strips 10 from the tray lattice 16.
FIG. 10 illustrates in detail the action of the fingers 38 in separating the strips 10 from the tray lattice 16 and into the spaces defined by the sagging portions of the conveyor belt 24. However, the portions of the strips 10 located between the roller bands 36 are not reached or engaged by the fingers 38 of the bands, and consequently separation of the strips 10 in these areas is not achieved.
Accordingly, a second row of four roller bands 40 is mounted on a continuous separator belt 41 like the front separator belt 37. The bands 40 are identical in construction and orientation to the bands 36, but are arranged behind the bands 36 and in transversely offset or staggered relation, that is, out of longitudinal alignment with the bands 36 and in longitudinal alignment with the supports 26 between the bands 36. With this arrangement the fingers 42 engage those portions of the food strips 10 not previously acted upon and separated by the fingers 38 of the first roller bands 36. The action of the fingers 42 on the strips 10 is best seen in FIG. 9.
The separated strips 10 pressed onto the conveyor belt 24 by the separating fingers 38 and 42 are carried by the conveyor belt 24 to its discharge end. At that point the belt 24 reverses direction around a belt shaft 22, as seen in FIG. 13. The strips can be collected in a bin (not shown), or a strip collection belt 44 can be located below the belt shaft 22 to catch the strips as they fall off the belt 24. The collection belt 44 preferably includes transverse ridges or ribs forming individual recesses for the strips 10. The collected strips are carried by the collection belt 44 to a station (not shown) where they are cut into shorter lengths and packaged.
The empty trays 12 leaving the rollers belts 40 are engaged adjacent their ends by a pair of rollers 46. These rollers have a continuous band of material adhered to their periphery like the material of the bands 36 and 40, and with the same type of flexible fingers. The rollers 46 engage the tray ends and force it into a horizontal plane, which is necessary for trays which have become warped through continued usage. In a horizontal plane the tray is properly positioned for interception by the pointed end 48 of a tray raising plate 50.
Plate 50 extends across the belt 24 and is secured at its opposite sides to the frame sides 18. As the tray moves toward it the end 48 passes beneath the tray 12 and above the sagging strips 10 and belt 24, as seen in FIG. 11.
The tray portion between the rollers 46 is flexed downwardly to help in completing the separation of the strips 10 from the tray lattice 16.
A pair of rollers 52 identical to the rollers 46 are located beyond and transversely inwardly of the rollers 46 to engage each tray 12 as it leaves the rollers 46, as seen in FIG. 12. The trays raised by plate 50 from the conveyor belt are first driven up the inclined surface of the plate 50 by the rollers 46, and then further driven downwardly by the rollers 52 until the end ones of the trays 12 drop into a pair of collection hangers 54 mounted to the rearward end of the plate 50. From this point the trays can be taken up for reuse in the strip processing operation.
Although the trays 12 can be manually inverted and placed on the belt 24 at the forward or feed end, as seen in FIG. 6, this operation is preferably automated by using a tray feed belt 56, as seen in FIG. 14. Trays coming from the drying oven (not shown) are normally in the upright position seen in FIG. 14, and the belt 56 is operated to bring the upright trays to a point adjacent an end shaft 58 where the direction of travel of the belt 56 reverses. The trays fall off the belt 56 and engage a vertical front plate 60 attached at its ends to the frame sides 18. The plate 60 holds the upper side of the tray against movement with the belt 24 so that the lower side of the tray 12 can be engaged by the belt 24 and carried away from the plate 60. This inverts the tray 12 and locates the food product on the underside of the tray.
The showing in FIG. 7 is exemplary of the means by which the various belts and rollers of the apparatus are driven and adjusted for operation.
The drive means comprises a suitable electric motor 62 which is mounted on the apparatus frame and operated to rotate a sprocketed drive shaft 64. This drives a chain engagable with a pair of sprocketed shafts 66 and 68.
Rotation of the shaft 66 is transmitted by a chain 70 for rotation of a sprocket mounted to the rear conveyor belt shaft 22. The belt roller on the shaft 22 acts upon the conveyor belt 24 to move it along the conveyor path previously described.
Rotation of the other sprocketed shaft 68 adjacent the motor 62 operates a drive chain 72 which rotates a sprocketed shaft 74 which drives the separating belt 41. A chain 76 trained about the sprocket of the shaft 74 also rotates a sprocketed shaft 78 which drives the separating belt 37.
Another chain 80 engages a sprocket of the shaft 68 and drives a sprocketed shaft 82 which is rotatable to drive a shaft 82 carrying the pair of rollers 46. The shaft 86 mounting the rearward pair of rollers 52 is driven by a chain 84 extending between the sprockets of the shafts 82 and 86.
The means for adjusting belt tensions and relative positions of the apparatus components is best seen in FIGS. 7, 13 and 14. The horizontal portion of the lower run of the separator belt 37 is urged downwardly by a pair of transverse rollers mounted to a pair of forwardly located adjustment shafts 88. As seen in FIG. 7, the vertical position of the shafts 88 can be adjusted by tightening or loosening nuts 92 which bear against an upward extension of the frame sides 18 and which operate upon vertical studs to raise and lower the bearing blocks which rotatably carry the shafts 88.
A similar arrangement of nuts 94 acting upon blocks mounting a pair of transverse adjustment shafts 96 raises and lowers the shafts 96 to adjust the vertical position of associated transverse rollers acting upon the horizontal portion of the lower run of the rearward separator belt 41.
The foregoing arrangement enables the degree of separating force exerted by the respective roller band fingers 38 and 42 to be adjusted for firm food strip separation, but without strip breakage.
An adjustment shaft 90 mounts an idler roller engaged upon the rearward portion of the separator belt 37 where it changes direction. The longitudinal position of the idler roller can be adjusted by tightening or loosening a nut 100, which adjusts the tension in the belt 37. Similarly, a nut 102 can be tightened or loosened to adjust the longitudinal position of a shaft 98 which mounts the idler roller engaged upon the separator belt 41, thereby adjusting the tension in the belt 41.
In operation, each tray 12 carrying food product strips 10 is placed in inverted position upon the conveyor belt 24, either manually or by the belt conveyor means of FIG. 14. The trays are carried by the conveyor belt 24 to the first row of roller bands 36, where the separating action illustrated in FIG. 8 occurs. The food product strips 10 are displaced downwardly from the tray 12 by the fingers 38 and into the space which exists by virtue of the cantenary sag of the belt 24 between each pair of adjacent supports 30. As previously indicated, displacement of the strips is not necessarily into existing sag spaces, but may be into spaces formed by downward yielding of the belt 24.
The portions of the food strips 10 not reached by the action of the roller fingers 38 are next acted upon by the fingers 42 of the roller bands 40 as the trays pass along the conveyor path, resulting in the separating action illustrated in FIG. 9.
Finally, the separated food strips are carried onto the strip collection belt 44, while the trays are moved up the inclined plate 50 onto the collection brackets 54 by the successive action of the rollers 46 and 52, as seen in FIG. 13.
The separating action developed by the roller bands 36, followed by the roller bands 40, and finally by the rollers 46, has been found to separate the strips 10 from the trays 12 with insignificant or no strip breakage. Moreover, utilization of the flexible conveyor belt 24, which sags or yields transversely between its underlying supports, makes possible separation of the strips in an essentially single operation, that is, with all separation occurring onto the same conveyor belt which supports and conveys the trays through the apparatus.
Referring now to FIG. 15, there is shown an alternate arrangement for feeding and inverting for the trays 12 onto the conveyor belt 24. Such means includes a vertical chute 110 having an open top 112 through which loaded trays 12 may be fed. The lower end of chute 110 is of reduced aide area and defines a tray discharge opening 114. The front of the discharge opening 114 is defined by a rearwardly and downwardly inclined wall 115 of chute 112. It will be apparent that as lowermost tray 12 enters the lower portion of chute 110, the inclined wall 115 will cause the tray to tilt into a generally, vertically extending position and forward movement of the upper run of the conveyor belt 24 (to the left of FIG. 15) will cause the tray to flip into an inverted position, with the meat strips 10 facing downwardly against the upper surface of the conveyor belt 24.
Referring now to FIGS. 16 and 17, there is shown a modified arrangement of the empty tray-engaging rollers designated 46 and 52 in FIG. 13. In the embodiment of FIG. 16, an extra set of rollers 120 are interposed between rollers 46 and 52 to assist in preventing the empty trays fro being twisted as they pass from plate 50 onto the upper run of conveyor belt 24.
Various modifications and changes may be made with regard to the foregoing detailed description without departing from the spirit of the invention. | An apparatus for separating a food product from a tray having apertures defining a supporting lattice to which the food product is adhered. A conveyor belt carries the tray in an inverted position with the food product on the bottom and engaging the upper surface of the belt. The undersurface of the belt is slidably supported by a first row of fixed, transversely spaced apart supports. A first row of roller bands with radially directed fingers is located above the belt with the roller bands midway between the supports. The fingers project through the tray apertures and move the product away from the tray and toward the conveyor belt. The conveyor belt sags between the supports, providing room for the product to move for separation from the tray. | 1 |
BACKGROUND OF THE INVENTION
Various designs for crochet needles have been in common use and separate cut off devices have also been provided in the past. Alternative use of the crocheting hook and an integral cut off device, however, has not been provided for in a ready and convenient manner. It has been necessary to disengage the crocheting hook, place the needle at rest, then to pick up and to manipulate the separate cut off device in severing the thread, yarn, etc.
SUMMARY OF THE INVENTION
It is the general object of the present invention to provide an improved crochet needle which includes an integral cut off device which may be easily and conveniently employed on a mere reversal of attitude of the needle.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side elevational view of the improved crochet needle of the present invention.
FIG. 2 is a top view of the crochet needle.
FIG. 3 is an enlarged fragmentary side elevational view of a portion of a second needle and illustrating a cut off device in partial section.
FIG. 4 is an enlarged fragmentary side elevational view of a third embodiment of a crochet needle of the present invention.
FIG. 5 is a perspective view of the improved crochet needle of FIGS. 1 and 2 in a cut off operation.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring particularly to FIGS. 1 and 2, it will be observed that a crochet needle indicated generally at 10 has a central body portion 12 which is or may be conventional in form. That is, the body portion 12 is elongated and has a generally smooth arcuate surface for manual gripping and manipulation. As illustrated, the body portion 12 is of circular cross section throughout a major part of its length. Through a region or zone 14, however, there is a somewhat enlarged and flattened section with a finger engaging surface 16 which is substantially flat and which has a complementary surface 18 on an opposite side of the needle. The surfaces 16, 18 may be engaged by fingers or by a finger and thumb of the user for manipulation of the needle in a conventional fashion.
At one end portion of the crochet needle, illustrated at a left-hand end portion thereof in FIGS. 1 and 2, a conventional crocheting hood 20 is formed for engagement with and manipulation of an elongated flexible strand of material which may comprise thread, yarn, string, etc. The hook 20 is formed integrally with the body portion 12 and is bent back upon itself so as to open generally longitudinally toward the central body portion of the needle. That is, the hook 20 has an opening or mount 22 which faces generally longitudinally rightwardly in FIGS. 1 and 2.
As thus far described, it will be apparent that the crochet needle 10 of the present invention is or may be of conventional construction and the material of construction may also take a conventional form. Plastic, bone, and metallic construction is contemplated within the scope of the invention. The needle shown and described may be regarded as formed of anodized aluminum.
In accordance with the present invention, a means for severing a flexible strand of material such as thread, yarn, etc. is provided at an end portion of the crochet needle opposite the aforesaid one or left-hand end portion bearing the conventional hook 20. A severing means is indicated generally by the reference numberal 24 in FIGS. 1 and 2 and it will be observed that a small cutting blade with a sharpened edge is provided at 26. The blade 26 is disposed within a shielding means which serves to prevent the user of the crochet needle from inadvertently injuring her hand or finger.
The shielding means may vary in form, but preferably and as illustrated, a second hook or hook-shaped element 28 is provided. The hook 28 is bent back upon itself in the manner of the hook 20 so as to open generally longitudinally toward the body portion 12 of the needle. Further, the hook 20 is preferably on a side of the needle generally opposite the hook 20 or, the hook 28 may be said to reside approximately 180° from the hook 20. Still further, the hook 28 is preferably formed integrally with the body portion 12 of the crochet needle.
An opening or mouth 30, best illustrated in FIG. 1, and formed by the hook 26 accommodates entry of a flexible strand of material for a cutting operation. The size of the mouth or opening 30, however, is small enough so as to prevent the entry of the finger or other portion of the hand of the user. As will be observed, the edge of the blade 26 is spaced somewhat rightwardly or inwardly from the mouth 30. Further, the edge of the blade 26 is shown extending in a lateral direction or approximately at 90° with respect to the longitudinal center line of the crochet needle.
The blade 26 may approximate a portion of a razor blade in construction and may be fixed in position as shown or, alternatively, provision may be made for removal and replacement thereof. That is, a slot 32 in the hook 28 may be provided so as to frictionally retain the blade in position but to permit lateral sliding movement of the blade on exertion of a predetermined force for removal and replacement.
In use of the improved crochet needle of the present invention, the needle may be readily and conveniently reversed in attitude or, swung through approximately a 180° arc to engage a strand of flexible material and to sever the same. Alternatively, the material may be entered in the mouth 30 as illustrated at 34 in FIG. 5 and thereafter severed with the crochet needle held in the same position or attitude as required for crocheting. In either event, there is no necessity for placing the needle at rest and alternatively grasping and manipulating a second instrument for a cut off operation.
Further in accord with the present invention, and its presently preferred form, an indicator means is provided to prevent the user of the crochet needle from inadvertently reversing the needle and accidentally effecting a cut off operation. Such means may vary widely within the scope of the invention and may comprise merely a visual indicator as in FIGS. 1, 2 and 5. That is, an indicator means may comprise a portion of the needle adjacent the hook 28 which is distinctively different in color from the central and opposite end of the needle which bears the conventional crochet hook 20. A portion 36 of the needle 10 in FIGS. 1, 2 and 5 bears such a distinctive color extending rightwardly from a circumferential dividing line 38.
A second type of indicator means, in accordance with the present invention, may be both visually effective as well as effective to the sense of touch of the user. That is, an indicator means such as illustrated at 40 in FIG. 3 may be employed. The indicator means 40 comprises a series of flat surfaces which extend longitudinally and about the needle in an area adjacent the said opposite end portion or, the end portion bearing a hook 28a and a cut off blade 26a.
A still further form of indicator means is illustrated in FIG. 4 at 42. The indicator means 42 takes the form of a conventional knurled finish which may extend about the crochet needle adjacent a hook 28b which houses and conceals a cut off blade 26b. | A crochet needle having a conventional hook and integral body portion and a cut off device at an end opposite the hook. The cut off device comprises a blade with a sharpened edge which is concealed within a second hook which is displaced 180° from the crocheting hook. The edge of the blade is spaced inwardly from the mouth of the cut off hook so as not to form a hazardous device which might injure the hand or finger of the user. | 3 |
TECHNICAL FIELD OF THE INVENTION
[0001] The present invention relates in general to psychoacoustics, and, in particular, psychoacoustics as related to hearing-assist applications, and specifically to psychoacoustics as related to hearing-assist applications in a large venue.
BACKGROUND OF THE INVENTION
[0002] The population of hearing-impaired and severely hearing-impaired youth and adults is approaching 50 million in the United States and is growing rapidly. The plight of the severely hearing-impaired can be very difficult. The ability to enjoy live theater, a religious service, or even a movie is more important than just for entertainment purposes. For children, it enables critical development and contact with the everyday world. For adults or the elderly it allows enjoyment, mental stimulation, and social contact that is important. However, due to hearing impairment, some youth and adults may no longer be able to obtain these benefits from these activities.
[0003] Hearing-assist systems, as found in venues such as churches, movie theaters, live Broadway theaters, and similar venues attempt to provide amplified sound to the hearing-impaired. Many are legally required to do so. The legal requirements do not go into any significant detail with regard to actually optimizing the sound for a hearing-impaired person. A typical venue operator (and even the sound production staff) is understandably focused on other high priority tasks, and the hearing-assist system is often described as ‘the end of the food chain’, in that minimal effort is made improving the hearing-assist system. Most often, the sound from the hearing-assist system is perceived by the user to be unintelligible and in frustration the user may give up and further retreats from the venue, and even society.
[0004] In an attempt to maintain social contact many hearing-impaired individuals have tried hearing-assist systems in venues such as movie theaters, live Broadway theaters, and churches without success. They have been unable to hear or understand the dialog on typical headset, T-loop, and similar hearing-assist systems and have essentially retreated from these important elements of every day society. The issue or challenge is that typical hearing-assist systems were not optimized or designed for use in these venues.
[0005] More specifically, the poor hearing-assist sound quality as perceived by the hearing-impaired person in such venues results from the fact that most hearing-assist systems appear to be designed for the home, museum, or classroom environment, perhaps because cumulatively these markets may be larger than the venues of interest herein. The hearing-assist sound is typically transmitted to a headset or hearing aid (such as a cochlear implants) by FM, infrared, magnetic, or a similar coupling. It is important to recognize that the hearing-impaired person may still hear all or portions of the venue's ambient (audience) sound directly either through one ear being good, through their natural hearing's frequency response eliminating but some sound frequencies, via a hearing aid system simultaneously picking up ambient sound such as echoes and reverberation, through low-cost headsets not reducing ambient room sound, or even through body and bone conduction of low frequency sound.
[0006] Since there is a time delay between the sound waves propagated through the air and the representations of the sound propagated electronically to a device, as well as the energies in the ambient propagated sound, there may be significant interference between the ambient sound and the hearing assisted electronic sound. This interference can be extremely confusing and is likely to render the ultimate signal actually heard by the hearing-assisted user as gibberish.
[0007] The problem for the hearing-assist user in such venues will be referred to as a psychoacoustic effect. That is, as used herein, psychoacoustics is concerned with how sound is perceived, and a psychoacoustic effect is the psychological and physiological response by a hearing-impaired hearing-assist user to receiving sound in a venue. This sound heard by the hearing-assist user can include a mix of ambient sound as well as electronically transmitted sound.
[0008] As will be discussed in greater detail below, the psychoacoustic effect for a hearing-assist user occurs in any venue where some sound heard by that user is ambient and some sound to be heard by the user is electronically transmitted. In small venues, such as in a home or a classroom or the like, this effect is not significantly affected by differences between ambient sound and electronic sound is and tends to not result in the masking or garbling of effects present in the original sound; however, in large venues such as theaters, concert halls, opera houses, or the like, the effect can be sufficiently significant to noticeably degrade the person's enjoyment of the program in the venue. The prior art has not adequately addressed this issue. Further developments are therefore required.
SUMMARY OF THE INVENTION
[0009] This summary is provided to introduce a selection of concepts that are further described below in the detailed description. This summary is not intended to identify key or essential features of the claimed subject matter, nor is it intended to be used as an aid in limiting the scope of the claimed subject matter.
[0010] It is one objective of this invention to consider the elements that have been overlooked with regard to the user's psychoacoustic conflict between the ambient sound at a venue and the hearing-assisted provided sound.
[0011] It is another object of the invention to provide an economical solution to the above-noted psychoacoustic problem.
[0012] It is yet another object of the invention to provide a system which solves the above-discussed psychoacoustic problem using a system that can be retrofitted to most existing hearing-assist systems or incorporated into new systems.
[0013] The overall objective of this invention is to greatly improve sound intelligibility for the hearing-impaired person whether he/she uses only headsets or a hearing aid system which allows electronic interface to an external sound source.
[0014] A more specific overall objective of the present invention is to bridge the gap between the world of the performing arts theater or movie theater and the needs of the hearing-impaired person in that environment with regard to hearing-assist systems.
[0015] These, and other objects are achieved, by a hearing-assist system for use in a venue in which ambient sounds contain dialogue as well as other components. The hearing-assist system includes circuitry inserted in a signal path between a program source feed in a program occurring in the venue and a hearing-assist unit worn by a user in that venue which reduces psychoacoustic conflict and interference between sound which is ambient in the venue and sound heard by the user via the hearing-assist unit. The system embodying this invention recognizes and corrects the conflict that exists between the hearing-assist sound and the venue's ambient (audience) sound as perceived by the hearing-impaired hearing-assist user. The system embodying the present invention bridges the gap between audiology science and electronics and combines these two disciplines in a manner not achieved by the presently-existing art.
[0016] The system not only customizes the sound so that dialogue is emphasized while other portions of the sound program, such as bass-heavy music, is de-emphasized, or even removed, the system also introduces specific delays so that the electronically customized sound reaches the hearing-impaired hearing-assist user virtually simultaneously with sound that is ambient in the venue. Still further, the system customizes the sound signal so that low amplitude valleys and peak amplitudes are reduced, using reduction/attenuation techniques which reduce the dynamic range and allow amplification of the remaining signal, such as a companding or similar technique, such that the dynamic range of the sound is reduced. Also, the system significantly improves the signal/noise ratio and increases the available clear speech energy by increasing the amplitude of the transmitted signal.
[0017] To mitigate the problems discussed above with regard to the prior art, the following are examples of processing that the inventor has discovered that can be performed on the audio source before it is transmitted by the hearing-assist system, but have not been done by the prior art:
[0018] A. Reduction of low frequencies below approximately 300 Hz by 12 db to 15 db. Although this may appear to be a severe bass cut, the sound typically still sounds rich and balanced to the hearing-assist listener because these frequencies are still received from the house system. This is due to body conduction of low frequencies and the fact that headset isolation still tends to pass ambient low frequencies to a significant degree. By first reducing the high disturbing energy, the rest of the processing can be made more accurate, the signal to noise ratio on a transmitter can be improved, the dialogue output energy in the user's headset can be increased, and the dynamic range after removing the disturbing energy can be improved.
[0019] In the chain of signal processing reducing the undesired frequencies first allows the following processing to work more effectively.
[0020] B. Further improving dialog quality by applying techniques such as Aphex, and/or moderate bandpass filtering to favor the speech band, and/or moderate high frequency emphasis as desired.
[0021] C. Reducing the dynamic range of the remaining signal by increasing low amplitude valleys and reducing peak amplitudes, using “Companding” or a similar technique.
[0022] D. Increasing the amplitude of the transmitted signal based upon the above processing, thereby significantly improving the signal/noise ratio and increasing the available clear speech energy at the headset.
[0023] E. One or more outputs is provided with various delays to the hearing assist signal (s) as required for all or particular segments of a venue to reduce the timing disparity between the rapidly delivered hearing assist signal and the later perceived ambient (audience) sound.
[0024] It is significant to note that in trials conducted by the inventor, the above processing has dramatically improved the ability for severely hearing-impaired persons to enjoy the hearing-assist system, even over the standard headset. There is a perception that the dialog is magnitudes stronger and clearer through the same headsets than previously without the above processing. Previously such users were unable to understand anything through the headset and could only rely upon their special hearing aids with T-loop or other direct input, with mediocre results. Now, many prefer the clear sound through the hearing-assist headsets rather than their own special hearing aids.
[0025] The described enhancements can easily be added to an existing or new hearing-assist system of any type (such as wired, FM, infrared, inductive, wide area, Bluetooth, cell phone) or incorporated in a new system by those skilled in the art. Other variations will also be obvious to those skilled in the art.
[0026] The principles described herein can be applied to special situations to further increase the number of hearing-impaired that can be served in such venues.
[0027] As an example, consider a classroom found in many elementary schools for the severely hearing-impaired. The teacher will speak into a special FM frequency hearing-assist system and the signal is transmitted to special hearing aids worn by the students and equipped with an FM receiver and a microphone as well. For the young students, the microphone is left on at all times to allow them to stay in touch with their environment as they may also be too young to have the agility to turn on and off the microphone. In the small quiet classroom leaving the microphone on is not a negative.
[0028] Assume a venue desires to give hearing-assist service to these children by simulating their classroom environment. As part of this, a transmitter on the proper FM frequency can be installed and served by the signal processing described above. However, it is important to remember that the students' microphone will also be turned on. Therefore, the house ambient sound is injected into the students' ears at a very high and unnatural level. Under these conditions, as previously explained, there is only a very small tolerance of a few milliseconds that can be tolerated between the hearing-assist sound and the house sound. (This is just the opposite of using isolated headsets as previously described to attenuate the undesired house sound.) The inventor has discovered that the solution is to define selected adjacent rows of the theater as “classroom compatible”. In this case the hearing-assist delay for these users must be precisely adjusted to correlate with the ambient sound in the designated rows. Trial results have been quite impressive with students being made capable of hearing for the first time ever in a theater, including those students with cochlear implants
[0029] Therefore, the system embodying the present invention achieves its objectives in several steps: filtering out excessive unwanted energy, for example, the bass and low-mids as the first step for the hearing assist signal path. This now essentially leaves dialog energy (plus a little bass, moderate music and sound effects). The system then effectively applies additional enhancements to the dialog energy unencumbered by the excess bass energy or undesired energy which might ‘fool’ the subsequent processing. Such enhancements may include adding a small mid-high frequency boost in the frequency range common for hearing-impaired loss, adding automatic volume control, and reducing/attenuating the signal, as by companding (compression of high peaks, expansion of soft sounds), or the like (if excessive bass remained, it would overshadow the attempts to enhance the dialog energy), and other speech enhancement techniques as desired. A time delay can also be introduced to the hearing-assist signal so its timing correlates better with the ambient sound which was delayed due to propagation through the air and processing in the main house sound system.
[0030] The resulting vocal sound heard by the hearing-assist user is much louder. The total energy is the same, but the vocal energy is increased due to the lack of bass energy or other undesirable energy in the (hearing assist) signal stream.
[0031] The quality of sound reaching a hearing-assist user is further improved by the system embodying the present invention by modifying earsets which may be used by the user to include isolation elements. These earsets can be connected to the venue system by over-the-air communication or by patch cords as suitable. A cellular telephone might even be used to effect this venue-user connection.
[0032] The system of the present invention is most useful in large concert halls, such as are used for musical concerts, operas and musical plays. However, as those skilled in the art will understand, it can be used in any venue.
[0033] Another growing segment today of the hearing-impaired population has hearing aids which can accept an external input such as a line level audio input or T-loop inductive input. These users can be accommodated by a patch cord assembly or T-loop inductive adapter connected to the hearing-assist receiver in place of the headset previously described. In this case the user receives all the benefits described herein as well as additional customization afforded by his or her own hearing aid.
[0034] While the system embodying the preferred form of the invention is directed to speech as being the preferred component of the overall signal, those skilled in the art will understand that the teaching of this disclosure can be used to filter any signal to emphasize desired components and reduce, or eliminate, other undesired components of the signal. As such, speech as the desired component will be used herein as an example of the preferred form of the system with the understanding that the disclosure and claims associated therewith is intended to cover the situation where certain desired components of the signal are emphasized and undesired components are reduced or eliminated. This will be the situation of music being the desired component and the music component will be optimized, or where certain speech components are desired and other speech components are undesired, and the like as will occur to those skilled in the art based on the teaching of this disclosure. These situations are intended to be encompassed by this disclosure and the claims associated therewith.
[0035] This system allows reduction as much as necessary, such as 500:1, so there is something left so a user can hear the desired components of the overall signal but can also hear some of the undesired components if some portion of those components are desired. For example, this system will allow a user to hear dialog but also hear some music so the overall signal heard by the user is a mix, but a mix which emphasizes dialog so that music does not overpower the dialog and render the signal heard by the user as gibberish.
[0036] Other systems, methods, features, and advantages of the invention will be, or will become, apparent to one with skill in the art upon examination of the following figures and detailed description. It is intended that all such additional systems, methods, features, and advantages be included within this description, be within the scope of the invention, and be protected by the following claims.
BRIEF DESCRIPTION OF THE DRAWING FIGURES
[0037] The invention can be better understood with reference to the following drawings and description. The components in the figures are not necessarily to scale, emphasis instead being placed upon illustrating the principles of the invention. Moreover, in the figures, like referenced numerals designate corresponding parts throughout the different views.
[0038] The full nature of this invention will be understood from the accompanying drawings and the following description and claims.
[0039] FIG. 1 is a block diagram of the system according to this invention and is a typical embodiment thereof.
[0040] FIG. 2 is a representation of a typical “Director's mix” of sound as presented to a theater, church, movie or similar venue house public address sound system as well as the venue's hearing assist system(s).
[0041] FIG. 3 is a representation of a typical mix of sound presented to the hearing assist systems after processing by this invention.
[0042] FIG. 4 is a typical hearing assist receiver with headphones as claimed in this invention.
[0043] FIG. 5 is a special hearing aid often used by students in specially equipped classrooms for severely hearing-impaired youth as well as other severely hearing impaired individuals.
[0044] FIG. 6 illustrates hearing aids and related devices, such as streamers which accept a direct electrical input from an external source.
[0045] FIG. 7 illustrates and adapter device to allow a T-Loop equipped hearing aid to receive a magnetic T-Loop signal from a standard hearing assist receiver having a headset output.
[0046] FIG. 8 shows an overview of the system embodying the teaching of the present invention.
[0047] FIG. 9 shows a BSS Processor display suitable for use with the system embodying the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0048] The present description is made with reference to the accompanying drawings, in which example embodiments are shown. However, many different embodiments may be used, and thus the description 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. Like numbers refer to like elements throughout.
[0049] As explained above, the sound heard by a hearing-impaired, hearing-assist user in a large venue may be muddled and garbled. This muddled, garbled sound heard by a hearing-impaired, hearing-assist user in a large venue is a result of several problems. There may be an ‘overdose’ of bass/mid-low frequencies that the hearing-impaired person receives whereby the bass/low frequency sounds mask the dialog sounds so the dialog is rendered inaudible to the hearing-assist user. The reasons for the overdose are (A) the hearing-assist headset is transmitting the bass and mids, (B) the house system is also transmitting the bass/mids and is heard by the hearing-impaired person through his ears and via body/bone conduction, (C) house reverberation tends to add to the bass energy and create a boom, and there is a timing difference between the headset sound and the ambient, further causing an overall smearing and further loss of intelligibility. Also, a hearing-impaired person may tend to have a hearing loss of mid-mid-high frequencies important for speech, putting the bass even more predominate. Masking of desired sounds by undesired sounds (maskers) can be a function of frequency, both absolute and relative, as well as the loudness level of both the masker and the masked signal and the bandwidth of the masking sound. The system of the present invention permits a venue to control parameters so such masking is minimized and the desired signals reach the listeners.
[0050] More specific examples will be presented herein below.
Home or Classroom Hearing-Assist Situation
[0051] In the typical home or classroom environment, the effect of the ambient room sound is not of concern because it is typically not excessively loud and may be considered in sync with the headset sound since the rooms are small enough that propagation delay of airborne sound from a TV or teacher's voice to the listener is of no concern.
[0052] For example, consider the electronic transmission of sound to a user's headset to be virtually instantaneous. Propagation delay for sound traveling through air is approximately (for ease in this discussion) 1 ms per foot. If a hearing-impaired student is sitting at the back of the classroom perhaps 20 feet from the teacher, the delay until the teacher's direct sound reaches the student as compared to an instant electronic sound is only 20 ms. Additionally, it is of lower volume. Under these conditions the ear and brain assumes the delayed sound is a typical echo and it correlates it with the main sound so no disturbing echo or loss of intelligibility occurs. (Psycho-acoustically, single low level echo delays of up to about 80 ms can be tolerated by most people, so 20 ms delay under these conditions is easily tolerable.) Further, the ambient environment is quiet and the headset audio is relatively undistorted because the only energy being amplified is the teacher's voice. Thus low-cost headsets that do not attenuate ambient sound or even a one-ear headset may be used. Further, in these situations, the dialog/speech energy prevails which is important for the hearing-impaired person to understand the essence of what is taking place.
[0053] In addition to the air-borne delay, most larger venues employ loud, sophisticated sound systems with digital processing and loud speakers, for example, located far above the stage. The added distance and processing may add another delay of perhaps 30-40 ms.
[0054] In summary, the ‘good environment’ of the classroom or similar environment for this illustration:
[0055] 1. Has no delay or timing conflicts between instantaneous electronically delivered sound and the later ambient sound.
[0056] 2. Does not have a loud amplified ambient venue sound (including delays and echoes) which may be even louder than the main headset sound—a situation that reduces the brain's ability to provide intelligibility.
[0057] 3. Does not have excessive music and heavy bass energy-either in the hearing-assist sound stream or the ambient room sound- which would further greatly interfere with intelligibility and may cause distortion to the hearing-assist system itself. (It is of interest to note that many performance directors of musical shows purposely make the music louder than the words of a song. That is so patrons go home humming the melodies which sells musical purchases. Reciting the words would not sell musical purchases as well.)
[0058] 4. Does not have excessive reverberation created by the larger size room of a venue and its hard surfaces. Reverberation may be thought of as a series of long decaying echoes or energy at particular frequencies caused by the sound bouncing off of hard surfaces such as walls, ceiling and flooring. Echo and reverberation of lower and mid frequencies is especially bothersome. This tends to appear to lengthen bass notes etc. so that the energy is available for a longer time to interfere with the desired voice energy. This further interferes with intelligibility and adds to the common complaint that ‘the music is too loud to understand the words’.
[0059] 5. Does not have an excessively wide dynamic range of music and sound effects which may further cause system distortion and be painful to the listener.
[0060] 6. Does not have the talker's or other microphone(s) further picking up the ambient disturbances as above and reentering them into the system as more extraneous energy.
[0061] A common misconception is that the hearing-impaired person does not hear any of the ambient venue sound. This is not true and is a major part of the problem that exists when a classical (i.e. classroom) hearing-assist system is installed in a theater, church or similar venue. There are many audio inputs that a hearing-impaired person may still receive directly which ultimately can interfere with the dialog intelligibility hopefully afforded by the hearing-assist system. These include:
[0062] A. Near normal hearing in one or both ears. (Many people with normal or near-normal hearing often request hearing-assist headsets just to better understand and enjoy a performance. This population too is well-served by this invention.)
[0063] B. Hi frequency loss only. This is a very common situation, especially with age or repeated exposure to high volume concerts. The continued low frequency response admits considerable disturbing energy which masks dialog and greatly interferes with intelligibility.
[0064] C. Body and bone conduction which directly admits disturbing low frequency energy to the inner ear.
[0065] D. Hearing aid amplification increasing the amplitude of ambient house sound at the same time hearing-assist sound is being received. This is because certain hearing aids have the dual or greater capacity to electronically receive the hearing-assist signal and at the same time their microphone may pick up the ambient house sound. Besides the general ‘loud ambient noise’, this may create an ambient sound and/or echoes plus reverberation actually louder than the main microphone signal. This is an unnatural situation to the brain. The result may be ‘gibberish’ or sound like two or more separate voices saying the same thing a fraction of a second apart. Intelligibility is virtually impossible. By experiment, under these conditions the inventor has found that only 10 ms −20 ms or less between the echo and main signal can be tolerated as compared to about 80 milliseconds for a conventional lower-level delayed echo.
Live Theater, Movie or Church and Similar Venues
[0066] There are many ways in which the hearing-impaired person can still hear all or portions of the ambient sound presented to the audience at large. For example, one might consider how very loud movie sound, live theater or concert sound may be as compared to the benign quiet ambient sound in a classroom or home. In addition, it should be remembered that the hearing-impaired person is also receiving sound at the same time electronically via the hearing-assist system. Most often the ambient and hearing-assist sounds are at conflict with each other, especially with regard to intelligibility which for the hearing-impaired person may be virtually impossible.
[0067] Using the same numbering as above for the classroom environment, the conflicts that exist in these environments as compared to the quiet classroom environment for the hearing-impaired person can be considered.
[0068] 1. The hearing-assist sound is electronically transmitted from the source and arrives virtually instantaneously at the user headsets. In the theater/church/movie/concert venues there is typically a powerful house sound amplification system. The system may contain various inherent delays due to digital signal processing and the loudspeakers are often elevated and away from even the first row of the audience, further creating propagation delay of the air-borne sound. Thus there may be a delay of perhaps 30 ms before the loud amplified ambient sound reaches even the first row of the audience. Although the ear and brain might typically deal with delays of this magnitude with regard to soft echoes, this ambient amplified sound may be so loud as compared to the headset sound that the brain is compromised in trying to correlate the signals and intelligibility suffers or the user must subconsciously strain to try to understand the dialog and hence the event. This strain becomes uncomfortable and enjoyment of the event suffers. The further back one sits from the front row additional propagation delay is added, making the problem even worse. Eventually a point is reached, perhaps 50 feet from the stage or podium, where the hearing-assist dialog intelligibility is virtually destroyed because of the long delay and high level of the ambient sound as compared to the instant sound in the headsets.
[0069] The solution to this problem is to introduce a time delay in the hearing-assist system. In this example assume a delay of 40 ms could be added to the hearing-assist sound. Now the time correlation between the ambient and headset sound is greatly improved, reducing or eliminating the intelligibility problem. Finally the point of loss of intelligibility which was at 50 feet before is now at approximately 90 feet which may include the entire theater as an acceptable intelligibility zone. For larger venues, additional hearing-assist transmitters and receivers on different frequencies with longer delays as necessary maybe added to accommodate the rear sections of the venue with regard to keeping the timing of the hearing-assist and ambient sounds close enough for good intelligibility
[0070] 2 , 3 , 4 . The mere presence of a high noise ambient house sound with added echoes and reverberation interferes with the clear hearing-assist signal. This is one reason some people who have been at a movie, concert or theater event and not been able to understand the dialog due to the loud music or sound effects—including such a high level of sound that an audience member's ears may actually distort from it. All this is worse for the hearing-impaired person in addition to the timing conflicts previously discussed. Especially if the hearing-assist signal is wide-range, a situation is created of excess bass, further interfering with intelligibility.
[0071] A properly designed hearing-assist headset can help mitigate these problems. The headset should provide sound to both ears and contain a degree of isolation to reduce the ambient noise level perceived by the hearing-impaired user. 3 , 5 , 6 . For the house sound, a show's director may specify a mix with very loud levels of music, bass and sound effects as compared to dialog. This alone may be troublesome to a person with normal hearing. This same mix is typically fed to the hearing-assist system, and it's effects are far worse for the hearing-impaired person if the response is ‘flat’ and includes bass frequencies at full amplitude. For example, if the hearing-impaired person's hearing loss is at high frequencies the excessive bass becomes even more disturbing in masking dialog than it would be for a person with normal hearing. The wide dynamic range of a typical mix may cause headphone and system distortion and even discomfort or pain to the user. Excessive bass energy and wide dynamic range may introduce yet another problem to the hearing-assist system-reduced signal to noise ratio. The maximum transmitter level must be set according to the maximum expected instantaneous signal. This may be much louder than the dialog energy. Thus the dialog energy may be transmitted at a relatively low level. This reduces the dialog signal to noise level ratio at the receiver and makes the system sound static prone or noisy and further inhibits ability to understand dialog.
[0072] Specific implementation details of the invention will now be given. Referring first to FIGS. 1 and 8 , the main processing unit, 11 , contains the processing used to modify the input sound, 21 , to a form more suitable for hearing assist applications, 22 . The various processing stages, 12 , 13 , 14 , 15 , 16 , 17 may be accomplished by discrete componentry or state-of-the-art digital sound processors such the such as those manufactured by BSS. One skilled in the art will find a large variety of options available and may modify this example as required for the particular installation at hand. A BSS processor display suitable for use in the system embodying the present invention is shown in FIG. 9 .
[0073] An example of a quick control screen can be found in BSS London Architect., (http://bssaudio.com/en-US/softwares/hiqnet-london-architect-v6-00-r4-windows), the disclosure of which is fully incorporated herein by reference. This unit has been modified for use in this system. The processing chain includes an input mixer/router which then passes through signal prefiltering. (Highpass and corrective EQ). The prefiltered signal then passes through a 4-way multiband compressor and a parallel compressor. The multiband compressor forces a general tonal shape and balance across the frequency spectrum and the parallel compressor decreases the dynamic range of the signal. Basically, the two compressors work to make the average signal louder by reducing the difference between peaks and nominal and also provides additional separation between foreground and background noises. The compressed and filtered signal passes to the output stage where gain, EQ, and delay can be applied to suit the venue dimensions and correct for differences in assistive listen transmitter/receiver combinations.
[0074] The input signal, 21 , is typically the same input signal as furnished to the house public address sound system. FIG. 2 describes the components of this input signal. It may contain music components, 23 , such as high-energy low bass notes which may be destructive both to ongoing signal processing and to intelligibility for the hearing impaired listener. This energy may often be much greater than the important dialogue/speech energy, 24 . Similarly, sound effect energy, 25 , may often be greater than dialogue energy. FIG. 3 illustrates the energy balance after processing. The music energy, 26 , and sound effect energy, 28 , are in better balance with the important dialogue energy, 27 . This balance creates a situation for the hearing impaired user such that comfort against loud noise peaks and intelligibility is dramatically improved.
[0075] In this example the function of the first processing stage, 12 , is to reduce high-energy components not required for intelligibility by the hearing impaired person. For example, this may be excessive musical bass notes which would cause an “overdose” of bass energy to the user since the bass notes are also received by bone conduction and leakage through headsets from the house sound system. This excessive bass energy, often made worse by reverberation spreading the energy in the time domain, can greatly reduce intelligibility and cause subsequent distortion both electronically and physically to the ear as well as a poorer signal/noise ratio to the user.
[0076] The second processing stage, 13 , further optimizes the desired speech components, such as applying filtering to accentuate significant speech frequencies or reduce frequencies outside the typical speech band, adding a moderate amount of high frequency energy to compensate for common high-frequency loss, especially in the speech band or employing speech enhancement techniques such as APHEX or other approaches often used in broadcast systems.
[0077] The final processing stage, 14 , applies a suitable reduction/attenuating technique, such as companding (compression of high amplitude signals, expansion of low amplitude signals) or similar processing to reduce the resultant dynamic range. This further improves overall performance by providing a better comfort level to the user, and an increased signal to noise ratio when transmitted over a typical hearing assist system and reduced distortion along with a louder signal of interest (such as dialog) within the hearing assist system including the headset.
[0078] Finally, various stages of delay are added, 15 , 16 , 17 as required for each section of the venue via its specifically related hearing assist transmitter/receiver system, 18 , 19 , 20 to improve the time correlation between the ambient house sound and the instantaneous electronic sound in the particular section of the venue served by the respective transmitter as required due to system and propagation delay. As discussed above, a user's brain can accommodate a delay of as much as 80 ms; therefore the system of the present invention can introduce delays in the signal so that the signal from the system reaches the user within a preselected time delay, with the just-mentioned 80 ms delay being an example of the preselected time delay.
[0079] As an example, hearing assist transmitter, 18 , may service patrons in the front of the venue and they will be furnished with a receiver tuned to the frequency of transmitter 18 . Transmitter 19 may service a “classroom compatible” section of the venue where elementary school youth use hearing aids equipped with FM receivers and activated microphones, with the respective transmitter tuned to the frequency of the students' FM hearing aids and the respective delay optimized for that precise area of the venue. (Severely hearing-impaired adults with similar hearing aids may be able to sit anywhere in the venue since they can turn off their microphone and not hear the venue's ambient sound.) Transmitter 20 may serve patrons in the rear of the venue with delay 17 set accordingly and frequency of the patron's receivers in that area set to the transmitter's, 20 , frequency.
[0080] Various delivery options complete the furnishing of the improved sound to the various hearing impaired users. In FIG. 4 receiver 21 provides an output signal to headset 22 which is equipped with foam isolation, 23 . The function of isolation 23 is to reduce the level of the ambience house sound. This further improves intelligibility and increases the user's margin to tolerate echoes by lowering their amplitude. It also helps mitigate against an overdose of low-frequency base energy interfering with intelligibility. In FIG. 5 the “class room compatible” FM signal is received directly by hearing aid 24 which may also include a microphone and output to a cochlear implant. In FIG. 6 the receiver, 25 , may be equipped with a patch cord output, 26 , which may interface directly into various modern hearing aid inputs such as line inputs or intermediate devices such as streamers, 27 , which mix various signals together such as cell phone, Bluetooth and microphones that, for example, a severely hearing impaired user may place directly in front of his table partners in a noisy restaurant. In FIG. 7 receiver 28 supplies a device, 29 , known as a T Loop adapter. This adapter contains a magnetic coil which delivers a magnetic field of the hearing assist audio to a corresponding coil in the hearing aid which is known as a T Loop receiver.
[0081] Suitable hearing assist transmitters and receivers are available from a variety of sources such as Listen Technologies.
[0082] Other variations similar to the above will be obvious to one schooled the art; including accommodating interfaces to new hearing devices they become available in the future.
[0083] As one such example consider the use of cell phones as hearing assist receivers. Hearing assist transmitters 18 , 19 , 20 could be replaced by telephones with line input capability to accept their respective input signals. The telephones could then be connected to existing conference services. Cell phone users in the venue audience could dial the respective conference number and hence be connected to the desired hearing assist signal. These might be standard cell phones or cell phones special-purposed for the hearing impaired. Another variation might use the Wi-Fi functionality of a cell phone within the venue transmitting a Wi-Fi hearing assist signals. Further, the hearing-assist headsets may be equipped with inductive coupling and the system embodying the present invention includes circuitry (TC in FIG. 1 ) for connecting a user's headset to the hearing assist system via the inductive coupling.
[0084] In summary, the system embodying the present invention completes the following steps to achieve its goals.
[0085] 1. Start with the house sound feed and remove or reduce unwanted energies. Three main reasons are:
a. To reduce sonic overload at the user with regard to sounds typically received through the hearing assist system and the house ambient sound. That creates a muddle heard by the hearing-assisted audience member in a large venue, such as a concert or symphony hall or large church. a. After this reduction, the remaining electrical signal is composed primarily of the dialogue or other desired frequencies. Thus, subsequent processing can concentrate on the desired dialogue without being distorted or confused by the unwanted energy. For, example an unremoved bass boom could fool a compressor circuit so that it would reduce the dialogue at the time of the boom, clearly the situation that would hurt or destroy intelligibility at that time. c. Permit the headset or other transducer device to achieve a louder volume of the desired frequencies without the distortion or dangerous loud levels that may be caused if excessive undesired energy were also present at the headset or trannsducer.
[0089] 2. Next, the system processes the audio un-encumbered by excess energy that is unwanted in with the processing optimized for the needs of the hearing impaired users.
[0090] 3. The system then takes the optimized electrical signal and provides a number of output channels as needed. Each channel can include appropriate delay circuitry as needed for a specific purpose. For example the delay can create better general time alignment between the house sound and hearing assist sound. This further gets rid of the muddle and enhances intelligibility.
[0091] 4. Next, the system includes various transmitting means based on how the sound is to be delivered. For example, the delivery system might include different FM transmitters, connection to a wide area network, etc.
[0092] 5. Finally the system can include various options at the user's end. For example headsets covering both ears, or headsets with the foam isolation to further reduce the ambient sound, or patch cables to interconnect the system hearing assist receiver to a user's personal hearing devices (for example, a ‘relay transmitter’ or magnetic adapter to couple the hearing assist sound directly into his/her hearing aid.
[0093] The system embodying the present invention can also be used for the following applications.
[0094] 1. Frequency optimization for music for the hearing impaired. What was described above with respect to dialog will work in a similar manner for music alone. There might be a slight change in frequencies, but the remaining music for a hearing-assist user will still be worthwhile.
[0095] 2. The system embodying the present invention can also be used with echo suppression and noise reduction on the input signal, especially for situations where is the key actors in the venue are not wearing wireless mics so their voices are picked up only a few inches from their mouth. Wireless mics do a lot to increase the signal to noise ratio for dialog. However, in many smaller or low cost venues there are only hanging or floor mics to pick up the actors. The voice sounds further away and the mic is also picking up room reverberation and echoes. These are damaging to everyone (even hearing able audience members often have trouble understanding dialog in these theaters); however, this is especially damaging to the hearing impaired person because the reverberation and echoes may be in the frequency range where their hearing is still most sensitive-further covering up their weaker high frequency dialog intelligibility reception. The above-described system may be modified by adding additional processing steps for these cases when the actors do not use wireless mics. Examples may be (1) echo suppression (borrowed from the telephony world where echo suppressors are used to stop echo from the distant phone), (2) additional filtering of frequencies responding to that venue's reverberation frequencies, (3) volume compression of frequencies related to room reverberation or other lower energy random noise, (4) other intelligibility enhancements.
[0096] The system embodying the present invention can also be adapted for binaural hearing for the hearing-assisted audience members. That is, binaural hearing occurs when a listener receives different inputs from each ear. The listener's brain will fuse the two inputs to form a simple, coherent auditory image which is a function of the difference in the two signals. One difference is, as has been discussed above, the time delay between signals. The time delay for signals received from each side of a venue can be controlled. If properly controlled, a hearing-assisted audience member can receive auditory signals in each ear that will exactly simulate the signals a hearing audience member receives. The stereophonic effect will be similar for both the hearing-assisted audience member and the hearing audience member thereby enhancing the experience for the hearing-assisted audience member. The noise, or masking signal, can also be controlled from each side of the venue so that such unwanted signals arrive at the user in a timed sequence so that the listener's brain compensates and the unwanted signal is ignored by the listener in a phenomena known as masking level differences (MLDs) and can be used to squelch noise and reverberation by binaural hearing.
[0097] In some cases, certain users may have headsets which can be directly attached to the system of the present invention by means of an input plug (IP in FIG. 8 ). In such cases, the system can further include hearing-assist receiver output circuitry (OC in FIG. 8 ), and the headset will include an input plug (IP in FIG. 8 ) to which the cable is attached to connect the headset to the hearing-assist receiver output circuity.
[0098] The system may be used in environments where ‘local ambient echoes’ because of strength or excessive time delay such that the brain does not integrate them out (approximately 80 ms or longer) to delay the original signal transmitted by the hearing assist system until it is essentially coherent with the local echoes and can therefore be integrated by the brain and the speech or other audio signal understood.
[0099] While various embodiments of the invention have been described, it will be apparent to those of ordinary skill in the art that many more embodiments and implementations are possible within the scope of this invention. Accordingly, the invention is not to be restricted except in light of the attached claims and their equivalents. | A hearing-assist system for use in a venue in which ambient sounds contain dialogue as well as other components which comprises circuitry inserted in a signal path between a program source feed in a program occurring in the venue and a hearing-assist unit worn by a user in that venue which reduces psychoacoustic conflict and interference between sound which is ambient in the venue and sound heard by the user via the hearing-assist unit. | 6 |
This is a divisional of copending application Ser. No. 07/806,478 filed on Dec. 13, 1991, now U.S. Pat. No. 5,225,282.
BACKGROUND OF THE INVENTION
NMR has found increasing use since the early 1970's as a medical diagnostic tool, in particular as an imaging technique. The technique provides high resolution and differentiation of soft tissue without the use of potentially harmful radiation. For several years, radiologists believed that with the high contrast achieved in NMR imaging in soft tissues without the use of contrast agents, the use of contrast agents would not be necessary. However, it has recently been found that paramagnetic complexes can be used with advantage to achieve enhanced contrast in NMR imaging thereby extending the diagnostic utility of the technique.
The nuclei of many atoms have a property called spin which is associated with a small magnetic moment. In the absence of an external magnetic field, the distribution of the orientations of the magnetic moments is random. In the presence of a static magnetic filed the nuclear magnetic moments process about the field direction and there will be a net alignment in the field.
In NMR imaging, a patient is placed in a static field and a short radio frequency pulse is applied via a coil surrounding the patient. The radio frequency or RF signal is selected for the specific nuclei which are to be resonated. The RF pulse causes the magnetic moments of the nuclei to align with the new field and to process in phase, and on termination of the pulse moments return to the original distribution of alignments with respect to the static field and to a random distribution of procession phases giving off a nuclear magnetic resonance signal which can be picked up by a receiving coil. The NMR signal is generally from 1 H nuclei and represents a proton density of the tissue being studied. R. S. First, NMR In Medicine In The 1980's (1983).
Two additional values can be determined when the RF pulse is turned off and the nuclear magnetic moments are relaxing or returning to equilibrium orientations and phases. These are T1 and T2, the spin-lattice and spin-spin relaxation times. T1 represents a time characteristic of the return to equilibrium spin distribution, i.e. equilibrium alignment of the nuclear magnetic moments in the static field. T2 on the other hand represents a time characteristic of the return to random precession phase distribution of the nuclear magnetic moments.
The NMR signal that is generated thus contains information on proton density, T1 and T2 and the images that are generated are generally the result of complex computer data reconstruction on the basis of that information.
The potential application of contrast agents in extending the diagnostic utility of NMR imaging is discussed, for example, by R. C. Brasch in Radiology 147:781 (1983). Although numerous methods of contrast are available, many, such as manipulation of tissue temperature, viscosity or hydration, are clearly not clinically feasible and the most advantageous prior art technique appears to be the use of paramagnetic contrast agents to reduce the spin-lattice relaxation of time T1.
A paramagnetic substance is one which contains one or more fundamental particles (electrons, protons or neutrons) with a spin whose effect is not cancelled out by another particle with like spin. These particles create a small magnetic field which can interact with neighboring nuclear magnetic dipoles to cause a reorientation of the dipole, i.e. a change in nuclear spin and precession phase.
Since the magnetic field created by an electron is much greater than that created by a proton or a neutron, in practice only ions, molecules, radicals or complexes, which are paramagnetic due to the presence of one or more unpaired electrons, are used as paramagnetic NMR contrast agents.
The contrast effect of paramagnetic ions and complexes is predominantly the result of reduction in T1. However, paramagnetic stable free radicals will also cause some reduction in T2. R. C. Brasch, Radiology, 147:781 (1983). Nevertheless the relative reduction of T1 is greater than that of T2.
The use of paramagnetic contrast agents in NMR imaging has been extensively investigated and solutions and colloidal dispersions of such agents have been proposed for oral and paraenteral administration in conjunction with diagnostic imaging.
Ferromagnetic materials have also been used as contrast agents because of their ability to decrease T2. Medonca-Dias and Lauterbur, Magn. Res. Med., 3:328 (1986); Olsson et al, Mag. Res. Imaging, 4:437 (1986). Ferromagnetic materials have high, positive magnetic susceptibilities and maintain their magnetism in the absence of an applied field. The use of ferromagnetic materials as MRI contrast agents are described, for example, in PCT Application No. WO86/01112 and PCT Application No. WO85/043301.
A third class of magnetic materials, termed superparamagnetic materials, have been used as contrast agents. Saini et al., Radiology, 167:211 (1987); Hahn et al., Soc. Mag Res. Med. 4(22):1537 (1986). Like paramagnetic materials, superparamagnetic materials are characterized by an inability to remain magnetic in the absence of an applied magnetic field. Superparamagnetic materials can have magnetic susceptibilities nearly as high as ferromagnetic materials and far higher than paramagnetic materials. Bean and Livingston, J. Appl. Phys., Supp. 1 to Vol. 30, 1205, (1959).
Ferromagnetism and superparamagnetism are properties of lattices rather than ions or gases. Iron oxides such as magnetite and gamma ferric oxide exhibit ferromagnetism or superparamagnetism depending on the size of the crystals comprising the material, with larger crystals being ferromagnetic. G. Bate In: Ferromagnetic Materials, Vol. 2, Wohlfarth (ed.) p. 439.
As generally used, superparamagnetic and ferromagnetic materials alter the MR image by decreasing T2 resulting in image darkening. When injected, crystals of these magnetic materials accumulate in the targeted organs or tissues and darken the organs or tissues where they have accumulated.
Superparamagnetic particles have also been shown to be effective for the delivery and targeting of drugs directly to an infected organ, tissue or joint. Delivery systems, for example, using magnetic particles 100 Angstroms (A) in diameter encapsulated in albumin microspheres have been demonstrated for delivery of chemotherapeutic agents into Yoshida rat sarcoma. Widder, U.S. Pat. No. 4,345,588 (1982); Senyei et al., U.S. Pat. No. 4,357,259 (1982).
All of the aforementioned in vivo applications have the marked disadvantage of the lack of particle or cluster biodegradability. Half lives of Fe 3 O 4 100 A particles, for example, are in excess of 8 months when injected into a patient's body.
Particles of less than 50 A in diameter will generally clear from a patient after in vivo application very quickly; however, below 50 A in diameter there is no evidence of domain wall support and particles of this size are non-magnetic.
SUMMARY OF THE INVENTION
The present invention relates to biodegradable superparamagnetic microclusters and methods of their preparation. The present microclusters comprise clusters of metal or metal oxide particles that are about 70 A or less in crystallite size and which are non-magnetic in the unclustered state. The non-magnetic unit crystals ("crystallites") are encapsulated or bonded together to form a superparamagnetic cluster of crystallites having a cluster size of from about 100 A to 2 microns in diameter.
In one embodiment of the present invention, the individual non-magnetic crystallites are coated with monomers functionalized to participate in subsequent crosslinking reactions. Accordingly, the monomers are adsorbed or covalently bound to the crystallites, and the crystallites are covalently linked by crosslinking between the coated crystallites, thereby forming magnetic microclusters. For physiological applications, the crosslinks are hydrolyzable bonds which hydrolyze in the physiological environment. In another embodiment, the crystallites can be coated directly with polymer coatings, which encapsulate the crystallites into magnetic microclusters, wherein the microcluster is conveniently degraded by simply dissolving it in a solvent suitable for the given polymer.
The magnetic clusters are biodegradable to the unit crystallites and become non-magnetic upon biodegradation. The magnetically responsive microclusters of this invention overcome problems associated with size, surface area, biodegradation,and magnetic character of previously developed magnetic particles. The present microclusters are useful in clinical applications, such as contrast agents for nuclear magnetic resonance imaging.
DETAILED DESCRIPTION OF THE INVENTION
The present invention is based on the discovery that, remarkably, when a population of non-magnetic particles of iron metal, magnetic iron oxide or magnetic metal alloy having a diameter of about 70 A or less are linked or encapsulated into a bead structure of about 100 A or greater in diameter, the bead will behave as a superparamagnetic species. If the bead is designed with appropriate chemistry rendering the bead biodegradable, the magnetizable particle will, upon degradation to the unit crystal size, become non-magnetic.
The present magnetic microclusters are clusters of particles comprising a core of metal, metal alloy or metal oxide. These 70 A or less particles are referred to herein as "crystallites". The individual crystallites can be coated with a functionalized organo-metallic monomer which is adsorbed onto or covalently bound to the crystallites thereby forming an organometallic polymer coating. The functional or reactive terminal groups on the organometallic polymer coating are then reacted together via chemical reactions, e.g. covalent crosslinking, formation of coordination complexes or bioaffinity coupling to form magnetizable microclusters. These magnetizable clusters have a mean cluster size of about 100 A to about 2 microns in diameter and are referred to hereinafter as "microclusters".
Each crystallite is a subdomain (less than 70 A) crystal, or group of crystals, of a transition metal, alloy or metal oxides comprised of trivalent and divalent cations of the same or different transition metals or magnetic metal crystal group. Metals, alloys and oxides which are useful as magnetic core material in the present invention include the metals, alloys, and oxides based on metals which appear in the Periodic Table in Groups 4a and b, 5a and b, 6a and 7a. These include, for example, divalent transition metals, such as iron, magnesium, manganese, cobalt, nickel, zinc and copper, alloys of these metals such as iron alloys or oxides (e.g., iron magnesium oxide, iron manganese oxide, iron cobalt oxide, iron nickel oxide, iron zinc oxide and iron copper oxide), cobalt ferrite, samarium cobalt, barium ferrite, and aluminum-nickel-cobalt and metal oxides including magnetite (Fe 3 O 4 ), hematite (Fe 2 O 3 ) and chromium dioxide (CrO 2 ). By way of illustration, the crystallite may be comprised of crystals of iron or iron oxide, or may consist of a single crystal of an iron oxide or metal alloy.
The present crystallites are preferably between about 0.001 and about 0.007 microns (10 A to 70 A) in diameter and have a surface area of about 25 to 1000 square meters per gram.
The crystallite particles can be prepared according to the following general procedure: metal salts, or organometallocenes, are precipitated in a base at high temperature and pressure to form fine magnetic metal oxide crystals. The crystals are redispersed, then washed in water and in an electrolyte. Magnetic separation can be used to collect the crystals between washes, as the crystals are generally superparamagnetic at this stage. The crystals are then milled, for example, in a ball mill, under conditions sufficient to form subdomain (less than 50 A) crystallites, which are non-magnetic.
In one embodiment of the present invention, superparamagnetic iron oxide particles are made by precipitation of divalent (Fe 2+ ) and trivalent (Fe 3+ ) iron salts, for example, FeCl 2 and FeCl 3 , in base and then milled to produce the sub 50 A particles. The ratio of Fe 2+ and Fe 3+ can be varied without substantial changes in the final product by increasing the amount of Fe 2+ while maintaining a constant molar amount of iron. A Fe 2+ /Fe 3+ ratio of about 2:1 to about 4:1 is useful in the present invention; a ratio of about 2:1 Fe 2+ :Fe 3+ is particularly useful. An Fe 2+ :Fe 3+ ratio of 1:1 produces magnetic particles of slightly inferior quality to those resulting from the higher Fe 2+ /Fe 3+ ratios, the particle size is more heterogeneous than that resulting from Fe 3+ Fe 2+ of 2:1 or 4:1.
In this embodiment, aqueous solutions of the iron salts are mixed in a base, such as ammonium hydroxide, which results in the formation of a crystalline precipitate of superparamagnetic iron oxide. The precipitate is washed repeatedly with water by magnetically separating and redispersing it until a neutral pH is reached. The precipitate is then washed once in an electrolytic solution, e.g. a sodium chloride solution. The electrolyte step is important to insure fineness of the iron oxide crystals. The precipitate is then washed with a solvent (e.g. acetone) to remove all of the water.
The metal powder is then collected, e.g. by magnetic separation or by filtration, and added to a commercial ball mill as an acetone slurry in a concentration of about 1-25%. The mill is filled about halfway with 1/4" stainless steel balls and the slurry is milled for a period of time necessary to form the subdomain crystallites, generally about 3-60 days. At the completion of the milling period, the subdomain particle slurry formed is treated as the magnetite described in the previous section.
In another embodiment of the present invention, the crystallites can be made by precipitating metal powders using borohydrides and reducing the particle size by milling the resulting precipitate, for example, in a ball mill. In this process, the metal powder is precipitated from an aqueous solution of, for example, Fe +2 or Fe +3 salt, with sodium borohydride. The resulting properties of the metal powder are unaffected by the balance of the counter ion or by the iron metal salt selected. Complete precipitation occurs spontaneously upon addition of the borohydride. The magnetic metal powder is then collected by magnetic separation or filtration, washed with water to remove all soluble salts, and then washed in acetone to remove all residual water. The particle is added as an aqueous slurry in a concentration of about 1-25% by weight to a commercial ball mill filled half way with 1/4" stainless steel balls and milled for about 10-60 days. At the completion of the milling period, a subdomain metal slurry is formed.
In yet another embodiment of this invention, subdomain crystallites are grown directly from solution at high temperature and pressure. For example, an aqueous solution of 2:1 Fe +2 /Fe +3 is added to an aqueous solution of ammonium hydroxide at >60° C. and >1 atmosphere of pressure. The pressure and temperature are slowly reduced to begin formation of a crystal seed bead. The reactants are incubated at the lower temperature and pressure until the precipitation is complete and the reagents are completely used. The pressure and temperature of the reaction vessel are then reduced to ambient conditions and the particles are collected by filtration, washed 3 times, e.g., with deionized water, to remove excess reactants and 3 times with a solvent, such as acetone, to remove excess water. The subdomain particles thus prepared are non-magnetic.
In another embodiment of this invention, the subdomain crystals are grown by the reaction of a metallocene with a base. In one embodiment of this method, ferrocene is combined with iron II hydroxide. Iron II hydroxide is prepared by reacting an aqueous solution on iron II (ferrous) chloride, for example, with ammonium hydroxide to form a gelatinous precipitate of iron II hydroxide ((FeO(OH)). The iron hydroxide is collected by filtration, transferred into a commercial ball mill filed halfway with 1/4" stainless balls and one-quarter way with water, and the resulting iron hydroxide slurry is milled for a period of 1-30 days.
A second ball mill is one-quarter filled with an aqueous slurry of ferrocene (1-25%) and half filled with 1/4" stainless balls. The ferrocene slurry is milled for a period of 1-90 days to produce ferrocene crystals in the size range desired for the finished iron oxide crystallites.
The contents of the two ball mills are then mixed together and milling is continued for about 1 hour to about 10 days to produce the subdomain crystallites. This method is described in detail in co-pending U.S. application Ser. No. 07/565,801 filed Aug. 10, 1990, by M. S. Chagnon et al, the teachings of which are hereby incorporated herein by reference.
Other divalent transition metal salts such as magnesium, manganese, cobalt, nickel, zinc and copper salts may be substituted for iron salts in the precipitation and milling procedure to yield magnetic metal oxides. For example, the substitution of divalent cobalt chloride (CoCl 2 ) for FeCl 2 in the above procedure produced ferromagnetic metal oxide particles. Ferromagnetic metal oxide particles such as those produced with CoCl 2 can be washed in the absence of magnetic fields by employing conventional techniques of centrifugation or filtration between washings to avoid magnetizing the particles.
The crystallites can be coated with an organo-metallic monomer material capable of adsorptive or covalently bonding to the magnetic core particles. The organo-metallic monomers also contain an aliphatic moiety and organic functionality to which a wide variety of organic and/or biological molecules can be coupled. Organo-metallic monomers useful for the present coated particles are organic coordinate complexes of selected transition and/or post transition metals which are capable of forming a stable coordination compound which can be adsorbed onto or covalently bound to the magnetic particle. The organometallic monomers must be capable of crosslinking in situ on the particle surface, thereby forming the organo-metallic polymer coating.
Particularly useful organo-metallic compounds are coordinate complexes formed from selected transition metals (e.g., Fe, Ni, Co, Cr, Ti, Zr, Hf, V, Ta, Nb) and/or post-transition metals (e.g. Sn, Sb). Organo-titanium compounds which are useful include, for example, titanium-tetra-isopropoxide, amino-hexyl-titanium-tri-isopropoxide, amino-propyl-titanium-tri-isopropoxide and carboxyl-hexyl-titanium-tri-isopropoxide. Other compounds which are useful include silicon-tetra-isopropoxide and carbon-tetra-isopropoxide. The monomers must be able to be functionalized in a manner that allows the polymer coating formed therefrom to form covalent bonds with bioaffinity or chemical reactants. For this purpose, the monomers can be post-functionalized or derivatized, if necessary, with an aliphatic "spacer arm" which is terminated with an organic functional group capable of coupling with bioaffinity adsorbents or chemically reacting to form covalent cross linkages or forming coordinate complexes. The "spacer arm" is an aliphatic hydrocarbon having from about 3 to about 30 atoms, e.g. carbon, nitrogen and/or oxygen atoms. The purpose of the spacer arm is to provide a non-reactive linker (or spacer) between the organic functional group and the polymer coating. The organic functional group is generally a reactive group such as an amine (NH 2 ), carboxy group (COOH), cyanate (CN), phosphate (PO 3 H), sulfate (SO 3 H), thiol (SH), or hydroxyl (OH) group, or a functional ligand such as a catechin.
In one embodiment of the present invention, amino-hexyl-titanium-tri-isoproxide is coated onto the magnetic particle of choice, and thermally crosslinked to form an organo-titanium polymer coating having an aliphatic spacer arm (the hexyl moiety) and organic functional group.
In one embodiment of the present method, an organo-titanium compound, such as titanium-tetra-isopropoxide which lacks the spacer arm and organic functional group, is functionalized by reaction with an agent such as 1-hydroxy-6-amino hexane, to form the amino-hexyl-titanium-tri-isopropoxide. A method of coating metal or metal oxide particles with an organometallic coating is described in detail in co-pending U.S. application Ser. No. 07/566,169, filed Aug. 10, 1990, by M.S. Chagnon, the teachings of which are hereby incorporated herein by reference. The functionalized particle can then be reacted, coupled, or crosslinked via the reaction method of choice.
In a further embodiment of the present invention, the biodegradable magnetic microclusters can be formed by macromolecular encapsulation of the non-magnetic metal or metal oxide particles. More particularly, the particle crystallites are prepared as a particle slurry and are mixed with a solution of polymer for a time sufficient to substantially disperse the polymer within the slurry. The crystallites are then encapsulated by the addition of a solvent which causes the polymer to flocculate and collapse onto their surface. The encapsulated crystallites thereby form a superparamagnetic cluster having a cluster size of from about 100 A to 2 microns in diameter, with a saturation magnetization of about 2,000 gauss, with no remnant magnetization. Particularly useful polymers include poly(vinyl alcohol), hydroxypropyl cellulose, carboxymethylcellulose, poly(vinyl pyrrolidone), polyurethanepolyester block copolymers, polystyrene and poly(vinyl acetate)-poly(vinyl chloride) copolymers. These clusters can then be conveniently degraded, for example, by dissolving in a solvent suitable for a given polymer. At that point, the particles no longer remain encapsulated and the resulting unit crystals have no magnetization.
The microclusters formed by crosslinking or bonding between the non-magnetic crystallites, or by encapsulation of said crystallites, are superparamagnetic in character. These superparamagnetic microclusters can be used in a number of in vitro and/or in vivo applications where magnetic particles are used. For example, a bioaffinity adsorbent can be covalently linked to the organometallic coating, on the microcluster, and the microcluster can then be used in in vitro separations. Methods of covalently linking a bioaffinity adsorbent to an organometallic-coated particle are described in detail, for example, in co-pending U.S. application Ser. No. 07/566,169, filed Aug. 10, 1990 by M. S. Chagnon, the teachings of which are incorporated herein by reference.
The present microclusters because of their unique characteristics are particularly useful for in vivo and in vitro applications, specifically magnetic tracers for homogeneous immunoassays. The microclusters are superparamagnetic, that is, they are responsive to an applied magnetic field, but do not exhibit remnant magnetization once the magnetic field has been removed. The microclusters are biodegradable, and once the cluster has degraded into its component crystallites, the crystallites are non-magnetic. The microclusters are therefore well suited for use in in vivo diagnostic localization of cells or tissues recognized by the particular bioaffinity adsorbent coupled to the particle, and also for magnetically directed delivery of therapeutic agents coupled to the particles to pathological sites. The microclusters are particularly useful for use in magnetic resonance imaging.
The invention will now be further illustrated by the following examples.
EXAMPLES
Example 1: Preparation of Subdomain Magnetite Particles by Precipitation and Subsequent Size Reduction by Milling
200 grams (1.58 moles) of ferrous chloride (VWR Scientific) and 325 grams (2.0 moles) of ferric chloride were dissolved in 3 liters of water. 2000 grams of ammonium hydroxide (VWR Scientific) concentrate were added at a rate of 50 ml/minute under constant agitation, during which time the temperature of the solution was kept between 25 and 40 degrees C. After the addition of the ammonium hydroxide was complete, the magnetic particle (Fe 3 O 4 ) aqueous slurry was allowed to cool to room temperature.
The particles were then washed with 5 volumes of water, and collected between each wash. On the final wash step the particles were adjusted to an aqueous slurry volume of 25% and added to a commercial ball mill. The mill was filled 1/2 way with 1/4" stainless steel balls and the slurry was milled for a period of 60 days to reduce the particles to 30 A diameter.
Example 2: Preparation of Subdomain Metal Particles by Sodium Borohydride Reduction and Size Reduction by Milling
200 gm (1.58 moles) of ferrous chloride was dissolved in 1 liter of water. 500 gm of dry sodium borohydride were added to the solution to form a fine iron powder precipitate. The precipitate was washed with water and collected by filtration. The filtered powder was resuspended in water and re-filtered. The washing procedure was done 4 additional times. On the final suspension, the slurry was adjusted to a concentrate of 20% and milled as described in Example 1 for a period of 75 days to produce particles with a mean diameter of less than 50 A. The resulting particles had no magnetic field response.
Example 3: Preparation of Subdomain Magnetite Particles by Reaction of Particulate Ferrocene and Iron (II) Hydroxide
A 100 gm slurry containing 20% by weight ferrocene in water was milled in a commercial ball mill as described in Examples 1 and 2 for 60 days.
A second slurry was prepared by the following procedure: An aqueous solution containing 20 gm of ferrous sulfate was precipitated using 50 gm of ammonium hydroxide concentrate to form the gelatinous ferrous hydroxide. The gel was filtered and the filtrate washed with 5-100 gm volumes of water. The washed gel was then made into a 20% aqueous slurry and milled as previously described for 30 days.
The ferrocene and hydroxide slurries were mixed and milled together for 3 days to form fine Fe 3 O 4 crystallites. The crystallites had a mean diameter of 30 A and were non-responsive to a magnetic field.
Example 4: Preparation of Amino-Hexyl-Titanium-Tri-Isopropoxide
0.1 moles of titanium-tri-isopropoxide (Tyzor TPT Dupont, Wilmington, Del.) and 0.1 moles of 6-amino-1-hexanol were added to a 50 ml beaker and stirred at room temperature for 1 minute to form 0.1 mole of amino-hexyl-titanium-tri-isopropoxide. The reaction mixture was heated to 70° C. for 10 minutes to evaporate the isopropyl alcohol formed during the reaction.
The material was cooled to room temperature and used as a monomer in making the tetravalent titanium organometallic coating in Example 5.
Example 5: Preparation of Amine Functional Organo-titanate Coated Particle
Particles were prepared according to the procedures set out in Examples 1, 2 and 3. The particles were washed 5 times with water and 3 times with acetone to remove the water. N,N-dimethyl formamide (DMF) was added to the precipitate in the following ratio:10 ml of DMF per gram of particle. The mixture was loaded into an Eiger Mill and milled continuously for 10 minutes. The mixture was then transferred to a beaker and heated with stirring for 30 minutes at 100° C. The amine functional organo-titanate prepared in Example 4 was immediately added after preparation with constant stirring to the mixture in a ratio of 1 g dry Fe 3 O 4 per 3 g of amine functional organo-titanate.
This mixture was then heated with stirring for 20 minutes at 65 degrees C. and then passed through the Eiger Mill for two passes. The resulting material was washed five times with water, the coated particles were collected by filtration and the aqueous waste was decanted.
Example 6: Preparation of Hydroxy-Hexyl-Titanium-Tri-Isopropoxide
0.1 moles of titanium-tri-isopropoxide (Tyzor TPT DuPont, Wilmington, Del.) and 0.1 moles of 6-hydroxy-1-hexanol were added to a 50 ml beaker and stirred at room temperature for 1 minute to form 0.1 mole of hydroxy-hexyl-titanium-tri-isopropoxide. The reaction mixture was heated to 70 degrees C. for 10 minutes to evaporate the isopropyl alcohol formed during the reaction.
The material was cooled to room temperature and used as a monomer in making the tetravalent titanium organometallic coating in Example 7.
Example 7: Preparation of Alcohol-Functional Organo-titanate Coated Particle
Particles were prepared according to the procedures set out in Examples 1, 2 and 3. The particles were washed 5 times with water and 3 times with acetone. N, N-dimethyl formamide (DMF) was added to precipitate in the following ratio:10 ml of DMF per gram of particle. The mixture was loaded into an Eiger Mill and milled continuously for 10 minutes. The mixture was then transferred to a beaker and heated with stirring for 30 minutes at 100 degrees C. The alcohol functional organo-titanate prepared in Example 6 was immediately added after preparation with constant stirring to the mixture in a ratio of 1 g dry Fe 3 O 4 per 3 g of amine functional organo-titanate.
This mixture was then heated with stirring for 20 minutes at 65 degrees C. and then passed through the Eiger Mill for two passes. The resulting material was washed five times with water, the coated particles were collected by filtration and the aqueous waste was decanted.
Example 8: Coated Particles of Dihydroxy-Benzene-Hexyl-Titanium-Tri-Isopropoxide
10 grams of amino functional particles prepared in Example 5 were prepared in an aqueous slurry containing 10% by weight particle. 10 grams of 2,3-dihydroxy-5-benzoic acid were added to the slurry and dissolved. 5 grams of cyclohexyl carbodiiomide were added to form a C6 amide coupled product with a 2,3 dihydroxy-benzene termination.
Example 9
An organo-titanium coated particle was prepared exactly as in Example 4 and 5 except that 6-carboxy-1-hexanol was used in place of 6-amino-1-hexanol to form a carboxy terminated organo-titanium coated particle.
Example 10: Formation of a Magnetic Cluster
10 grams of 2,3 dihydroxy-benzene terminated particles as prepared in Example 8, and 10 grams of carboxy terminated magnetic particles as prepared in Example 9 were mixed with 5 grams of sodium molybdate. The reaction mixture was stirred for a period of 24 hours. The resulting materials were molybdenum coordinate particle clusters about 1 micron in diameter that had a saturation magnetization of about 2000 gauss and no remnant magnetization. The particles could then be degraded back to the original 30 Angstrom magnetic particle by exposure to pH 6 acid for 24 hours.
Example 11: Formation of a Magnetic Cluster
10 grams of hydroxyl terminated particles as prepared in Example 7 and 10 grams of carboxy terminated magnetic particles as prepared in Example 9 were mixed. To the mixture was added 10 grams of 1 Normal HCl. The reaction mixture was heated to 60 degrees C. and stirred for a period of 24 hours. The resulting materials were ester linked magnetic particle clusters about 1 micron in diameter that had a saturation magnetization of about 2000 gauss and no remnant magnetization. The particles could then be degraded back to the original 20 Angstrom magnetic particle by exposure to pH 6 acid for 24 hours.
Example 12: Formation of a Magnetic Cluster-Polymer Bead
10 gm of 30 A particles were prepared as in Example 3. The particle slurry was mixed into an aqueous 25% 100 cc solution of polyvinyl alcohol (mw 50,000 daltons) and transferred into a 16 oz glass jar filled 25% with 1/4" ss balls. The suspension was mixed on a ball mill for a period of 2 hours. When the mixing was completed, the slurry was removed from the jar mill and added to a blender filled with 500 cc of acetone. The mixture was agitated in the blender at the highest speed for 10 minutes causing the polymer to flocculate onto the magnetic particle's surface. The magnetic beads were collected. The resulting polymer encapsulated magnetic particle clusters were about 100 Angstroms to 2 microns in diameter and had a saturation magnetization of about 2,000 gauss and had no remnant magnetization. The bead could easily be degraded by dissolving it in hot water and the resulting unit crystals had no magnetization.
Example 13: Formation of a Magnetic Cluster-Polymer Bead
10 gm of 30 A particles were prepared as in Example 3. The particle slurry was mixed into a glass, 25% 100 cc solution of hydroxy propyl cellulose (mw 50,000 daltons) and transferred into a 16 oz glass jar filled 25% with 1/4" ss balls. The suspension was mixed on a ball mill for a period of 2 hours. When the mixing was completed, the slurry was removed from the jar mill and added to a blender filled with 500 cc of acetone. The mixture was agitated in the blender at the highest speed for 10 minutes causing the polymer to flocculate onto the magnetic particle's surface. The magnetic beads were collected. The resulting polymer encapsulated magnetic particle clusters were about 100 Angstroms to 2 microns in diameter and had a saturation magnetization of about 2,000 gauss and had no remnant magnetization. The bead could easily be degraded by dissolving it in hot water and the resulting unit crystals had no magnetization.
Example 14: Formation of a Magnetic Cluster-Polymer Bead
10 gm of 30 A particles were prepared as in Example 3. The particle slurry was mixed into a glass, 25% 100 cc solution of carboxymethy cellulose (mw 50,000 daltons) and transferred into a 16 oz glass jar filled 25% with 1/4" ss balls. The suspension was mixed on a ball mill for a period of 2 hours. When the mixing was completed, the slurry was removed from the jar mill and added to a blender filled with 500 cc of acetone. The mixture was agitated in the blender at the highest speed for 10 minutes causing the polymer to flocculate onto the magnetic particle's surface. The magnetic beads were collected. The resulting polymer encapsulated magnetic particle clusters were about 100 Angstroms to 2 microns in diameter and had a saturation magnetization of about 2,000 gauss and had no remnant magnetization. The bead could easily be degraded by dissolving it in hot water and the resulting unit crystals had no magnetization.
Example 15: Formation of a Magnetic Cluster-Polymer Bead
10 gm of 30 A particles were prepared as in Example 3. The particle slurry was mixed into a glass, 25% 100 cc solution of poly(vinyl pyrrolidone) (mw 50,000 daltons) and transferred into a 16 oz glass jar filled 25% with 1/4" ss balls. The suspension was mixed on a ball mill for a period of 2 hours. When the mixing was completed, the slurry was removed from the jar mill and added to a blender filled with 500 cc of acetone. The mixture was agitated in the blender at the highest speed for 10 minutes causing the polymer to flocculate onto the magnetic particle's surface. The magnetic beads were collected. The resulting polymer encapsulated magnetic particle clusters were about 100 Angstroms to 2 microns in diameter and had a saturation magnetization of about 2,000 gauss and had no remnant magnetization. The bead could easily be degraded by dissolving it in hot water and the resulting unit crystals had no magnetization.
Example 16: Formation of a Magnetic Cluster-Polymer Bead
10 gms of 30 A particles were prepared as in Example 3. The particle slurry was washed 5× with acetone by magnetic filtration of the suspended particles after each successive wash and decanting the supermagnetic liquid. The particle slurry was then washed 3× in cyclohexanone using the same technique as the acetone washing procedure, and diluted to 50 cc with cyclohexanone after the final wash.
The suspension was added to 100 cc of a 20% solution of polyester polyurethane block co-polymer (BF Goodrich Estane 5719) dissolved in cyclohexanone and mixed in a blender.
The slurry was then added to 200 cc of acetone in a blender as described in Example 12 and mixed at high speed for 5 minutes causing the urethane to flocculate and collapse onto the particle's surface forming beads about 0.5-1 micron in diameter.
The resulting beads had a magnetization of about 2,000 gauss and no remnant magnetization.
The beads could easily be degraded to unit crystals by contact in organic solvent or by hydrolytic decomposition of the ester bonds in the back bone of the polymer by boiling the beads in water for 24 hours or by autoclaving an aqueous suspension of the beads for 90 minutes.
Example 17: Formation of a Magnetic Cluster-Polymer Bead
10 gms of 30 A particles were prepared as in Example 3. The particle slurry was washed 5× with acetone by magnetic filtration of the suspended particles after each successive wash and decanting the supermagnetic liquid. The particle slurry was then washed 3× in cyclohexonone using the same technique as the acetone washing procedure, and diluted to 50 cc with cyclohexonone after the final wash.
The suspension was added to 100 cc of a 20% solution of polystyrene dissolved in toluene and mixed in a blender using a laboratory paddle stirrer for this.
The slurry was then added to 200 cc of acetone in a blender as described in Example 12 and mixed at high speed for 5 minutes causing the polystyrene to flocculate and collapse onto the particle's surface forming beads about 0.5-1 micron in diameter.
The resulting beads had a magnetization of about 2,000 gauss and no remnant magnetization. The beads could easily be degraded to unit crystals by contact in organic solvent.
Example 18 Formation of a Magnetic Cluster-Polymer Bead
10 gms of 30 A particles were prepared as in Example 3. The particle slurry was washed 5× with acetone by magnetic filtration of the suspended particles after each successive wash and decanting the supermagnetic liquid. The particle slurry was then washed 3× in cyclohexanone using the same technique as the acetone washing procedure, and diluted to 50 cc with cyclohexaone after the final wash.
The suspension was added to 100 cc of a 20% solution of polyvinyl acetate) polyvinyl chloride (Union Carbide VAGH) dissolved in cyclohexanone and mixed in a blender using a laboratory paddle stirrer for this.
The slurry was then added to 200 cc of acetone in a blender as described in Example 12 and mixed at high speed for 5 minutes causing the urethane to flocculate and collapse onto the particle's surface forming beads about 0.5-1 micron in diameter.
The resulting beads had a magnetization of about 2,000 gauss and no remnant magnetization. The beads could easily be degraded to unit crystals by contact in organic solvent or by decomposition of the backbone of the polymer by boiling the beads in CMF for 24 hours.
EQUIVALENTS
Those skilled in the art will recognize, or be able to ascertain using no more than routine experimentation, many equivalents to the specific embodiments of the invention described herein. Such equivalents are intended to be encompassed by the following claims. | Subdomain metal or metal oxide particles covalently coupled to chemically reactive organic moieties and subsequently reacted together to form biodegradable magnetic microclusters are disclosed. The magnetic microcluster can be used as contrast agents in NMR imaging for the production of images suitable for use in diagnosis, for in vivo delivery and targeting of drugs, as in vivo, biodegradable agents for the sequestering of free metal ions in the treatment of metal driven disease. | 0 |
FIELD OF THE INVENTION
This invention relates to data processing systems and, in particular, to data processing systems involving the transfer, manipulation, storage and retrieval of large amounts of data.
BACKGROUND OF THE INVENTION
In data processing applications involving the transfer, manipulation, storage and retrieval of large amounts of data, the most serious performance limitations include (1) difficulties in moving data between users who need access to the data and resources used to store or process the data and (2) difficulties in efficiently distributing the workload across the available resources. These difficulties are particularly apparent, for example, in disk-based storage systems in which the greatest performance limitation is the amount of time needed to access information stored on the disks. As databases increase in size, requiring more and more disks to store that data, this problem grows correspondingly worse and, as the number of users desiring access to that data increase, the problem is compounded even further. Yet the trends toward both larger databases and an increased user population are overwhelmingly apparent, typified by the rapid expansion of the Internet.
Current techniques used to overcome these difficulties include reducing access time by connecting users to multiple resources over various types of high-speed communication channels (e.g., SCSI buses, fiber channels and Infiniband busses) and using caching techniques in an attempt to reduce the necessity of accessing the resources. For example, in the case of storage systems, large random-access memories are often positioned locally to the users and are used as temporary, or cache, memories that store the most recently accessed data. These cache memories can be used to eliminate the need to access the storage resource itself when the cached data is subsequently requested and they thereby reduce the communication congestion.
Various distribution algorithms are also used to allocate tasks among those resources in attempts to overcome the workload distribution problem. In all cases, however, data is statically assigned to specific subsets of the available resources. Thus, when a resource subset temporarily becomes overloaded by multiple clients simultaneously attempting to access a relatively small portion of the entire system, performance is substantially reduced. Moreover, as the number of clients and the workload increases, the performance rapidly degrades even further since such systems have limited scalability.
SUMMARY OF THE INVENTION
In accordance with one illustrative embodiment of the invention, users are connected to access interfaces. In turn, the access interfaces are connected to a pool of resources by a switch fabric. The access interfaces communicate with each client with the client protocol and then interfaces with the resources in the resource pool to select the subset of the resource pool to use for any given transaction and distribute the workload. The access interfaces make it appear to each client that the entire set of resources is available to it without requiring the client to be aware that that the pool consists of multiple resources.
In accordance with one embodiment, a disk-based storage system is implemented by client interfaces referred to as host modules and processing and storage resources referred to as metadata and disk interface modules, respectively.
The invention eliminates the prior art problems by enabling both client interfaces and processing and storage resources to be added independently as needed, by providing much more versatile communication paths between clients and resources and by allowing the workload to be allocated dynamically, with data constantly being directed to those resources that are currently least active.
BRIEF DESCRIPTION OF THE DRAWINGS
The above and further advantages of the invention may be better understood by referring to the following description in conjunction with the accompanying drawings in which:
FIG. 1 is a block schematic diagram of a resource access system constructed in accordance with the principles of the present invention.
FIG. 2 is a block schematic diagram of an illustrative storage system embodiment implemented with the architecture of FIG. 1 .
FIG. 3 is a detailed block schematic diagram of a host interface module.
FIGS. 4A-4C , when placed together, form a flowchart illustrating the steps in a process carried out by the host interface module in response to a request from a client.
FIG. 5 is a detailed block diagram of a disk interface module.
FIG. 6 is a flowchart illustrating the processing steps performed by software running in the disk interface module.
FIG. 7 is a detailed block schematic diagram of a metadata module.
FIGS. 8A and 8B , when placed together, form a flowchart illustrating processing steps performed by software running in the metadata module.
FIG. 9 is a detailed block schematic diagram of a switch module.
DETAILED DESCRIPTION
A block schematic diagram of a resource access system 100 in accordance with an embodiment of the invention is shown in FIG. 1 . The system consists of three components. Access interfaces 106 - 112 provide clients, such as client 102 and 104 , with access to the system 100 and provide other access-related resources. A pool of resources 118 - 124 may comprise, for example, data processing or storage devices. A switch fabric 114 and 116 interconnects the access interfaces 106 - 112 and the resources 118 - 124 . Since the requirements for communicating control information differ significantly from those for data communication, the switch fabric consists of a control switch fabric 114 and a data switch fabric 116 in order to provide different paths and protocols for control and data. For example, control transfer protocols generally divide the control information into relatively small packets that are transferred using packet-switching technology. In contrast, data transfer protocols generally consist of larger packets conveyed over a circuit-switched fabric. The separation of the switch fabric into two sections 114 and 116 allows each type of communication path to be optimized for its specific function and enables service requests to be transferred to a resource, via the control switch fabric 114 without interfering with the data transferring capacity of the data switch fabric 116 .
In accordance with the principles of the invention, the access interfaces 106 - 112 operate to virtualize the pool of resources 118 - 124 , thereby making it appear to each client, such as clients 102 and 104 , that the entire set of resources 118 - 124 is available to it without requiring the client to be aware of the fact that that the pool is in fact partitioned into multiple resources 118 - 124 .
This virtualization is accomplished by enabling the access interfaces 106 - 112 to serve as communication protocol terminators and giving them the ability to select the subset of the resource pool 118 - 124 to use for any given transaction. An access interface, such as interface 106 , is thus able to communicate with a client, such as client 102 , using the client's protocol for messages. The interface 106 parses a message received from the client into a portion representing data and a portion consisting of commands or requests for service. The interface 106 then interprets those requests and distributes the workload and the associated data across the pool of resources 118 - 124 .
The distribution of the workload may entail accessing a number of resources by the access interface and brings with it several major advantages. For example, it allows the workload to be distributed across the available resources, preventing the “hotspots” typically encountered when multiple clients independently attempt to access multiple resources. Since clients generally do not have knowledge about other clients' activities, it is very difficult, if not impossible, for the clients themselves to achieve any such level of load balancing on their own. In addition, it enables resources to be added non-disruptively to the resource pool. Clients need not be aware that additional resources have been made available since the access interfaces themselves are responsible for allocating resources to requests for service. This, in turn, allows the system capacity to be scaled to meet demand as that demand increases over time. Similarly, the ability of the access interfaces to distribute workloads allows the external connectivity to be increased to accommodate additional clients, again without disrupting on-going activities with existing clients.
The inventive system can be used to construct resource allocation systems for any type of resources. The remainder of this disclosure describes an embodiment which implements a disk-based storage system, but this embodiment should not be considered as limiting. In this embodiment, the access interfaces 106 - 112 are referred to as “host interface modules” and the resources are disk storage devices. The disk storage devices are connected to the switch fabric by “disk interface modules” and separate processing modules called “metadata” modules are also provided.
The storage system embodiment is shown in FIG. 2 . The storage system 200 consists of a set of access modules 206 - 210 called host interface modules, and two types of resource modules: disk interface modules 218 - 222 and metadata modules 212 - 214 . The host interface modules 206 - 210 provide one or more clients, of which clients 202 and 204 are shown, access to the system 200 and communicate with each client 202 , 204 using the client's message passing protocol. The host interface modules 206 - 210 parse requests from the clients 202 , 204 for disk and file system accesses and distribute the storage load across the entire set of disks connected to the system 200 , of which disks 226 - 230 are shown. The host interface modules are responsible for the logical allocation of the storage resources.
The disk interface modules 218 - 222 each support up to 450 disks and are responsible for the physical allocation of their disk resources. The disk interface modules provide data buffering, parity generation and checking and respond to requests from the host interface modules for access to their associated disks.
The metadata modules 212 - 214 provide a processing resource that maintains the structure and consistency of file systems used in the system. They are used when the storage system serves as a standalone file system, for example, in a networked environment, and hence assumes the responsibility for maintaining the file systems. The data used to describe the objects in the file system, their logical locations, relationships, properties and structures, is called “metadata.” In applications in which the storage system is directly attached to a host that implements this function itself, metadata modules are not needed and are accordingly not included in configurations intended for such applications. Since these applications and other storage system applications (e.g., HTTP server, web cache protocol server, and FTP server applications) require a subset of the functionality needed for standalone file systems, the illustrated embodiment is configured as a standalone file system, but the invention is equally effective in direct-attach applications. The following description applies equally to systems configured for direct attachment.
The switch module 216 provides the command and data paths used to interconnect the other three module types and contains both the control and data switches. In this embodiment of the invention, module 216 is capable of passing a block of data, for example, two kilobytes, between arbitrary pairs of modules at approximate fixed time increments, for example, approximately every four microseconds. Each host interface, disk interface and metadata module operates in full duplex mode, thereby enabling it to transmit and receive simultaneously at the aforementioned rate thereby supporting a system-level data bandwidth of up to N gigabytes/second, with N the total number of host interface, disk interface and metadata modules in the system.
The previously listed advantages of this architecture take the following more concrete forms when applied to the storage system. First, host interface modules are allowed to send incoming data to any available disk interface module for storage regardless of where that data might have been previously stored. This ability, in turn, distributes read accesses across the full complement of disks avoiding the inevitable hotspots encountered in conventional storage systems in which disks are partitioned into physical volumes and data must be directed to a specified volume.
Second, additional metadata modules, disk interface modules and physical disks can be added at any time. Clients need not be aware that additional resources have been made available since knowledge of where data is physically stored is not visible to them. This allows the logical space allocated to clients to far exceed the physical space that is currently available. Physical disk space does not need to be added until clients begin to use up a significant portion of the available physical space, which is typically much less than the allocated logical space.
Third, additional host interface modules can be added at any time to increase the connectivity available to the current clients or to add new clients. Since all host interface modules have equal access to all resources, traditional data segmentation and replication is not needed to provide access to an expanded set of clients. For the same reason, clients can transfer data to multiple disks in a single transfer; clients are, in fact, unconcerned about where that data is physically stored.
A more detailed diagram of a host interface module is shown in FIG. 3 . Each host interface module 300 is composed of four major components: a central processing unit (CPU) complex 324 , a data complex 318 , an input/output (I/O) complex 302 for communicating with the host and a switch interface 352 . The CPU complex 324 , in turn, consists of a microprocessor CPU 332 with its associated level-one (internal) and level-two (external) caches 330 , memory and I/O bus control logic 334 , local random-access memory (RAM) 326 , content-addressable memory (CAM) 338 . A peripheral bus 336 provides access to the CAM 338 , the data complex 318 , the switch interface 352 , and, through an I/O buffer 328 , to the I/O complex 302 . A PCI bus 339 provides access over the data transfer bus 350 to the data complex 318 and to two full-duplex channel adapters 340 , 342 which connect to two full-duplex 10/100 megabit Ethernet channels called the Interprocessor Communication channels (IPCs) 346 , 348 used to communicate with other modules in the system.
The data complex 318 comprises a large (typically two-gigabyte), parity-protected data memory 322 supported with a memory controller 320 that generates the control signals needed to access the memory 322 over a 128-bit data bus 323 and interface logic and buffers providing links to the I/O complex 302 , the switch interface 352 and, over the data transfer bus 350 , to the CPU complex 324 . The memory controller 320 responds to read requests from the other sections of the host interface module and forwards the requested information to them. Similarly, it accepts write requests from them and stores the associated data in the specified locations in memory 322 .
The I/O complex 302 is used to communicate with the clients via ports 307 - 313 . There are two versions of the I/O complex 302 , one version supports four one-gigabit, full-duplex Ethernet ports and the second version supports four one-gigabit, full duplex Fibre Channel ports. The second of these versions is typically used for systems directly attached to hosts; the first version is used for network-attached storage systems and is a preferred embodiment. Multiple protocols, including SCSI, TCP/IP, UDP/IP, Fibre Channel, FTP, HTTP, bootp, etc., are supported for communicating over these ports between clients and the host interface modules. These protocols are interpreted at the host interfaces 306 - 312 . Commands (e.g., read or write a file, lookup a file or directory, etc.) are buffered in the local I/O memory 304 for access by the CPU software via bus 314 . Data received from the clients, via ports 307 - 313 , is sent to the data memory 322 where it is buffered pending further action. Similarly, data passed from the storage system 300 to clients is buffered in the data memory 322 while the I/O complex 302 generates the appropriate protocol signals needed to transfer that data to the client that requested it.
The switch interface 352 contains a buffer memory 354 and associated logic to accept, upon command from the CPU software over the peripheral bus 336 , commands to transfer data, via bus 357 , from the data complex 318 to external modules. It buffers those commands and submits requests to the switch ( 216 , FIG. 2 ) for access to the destinations specified in those commands. When a request is granted, the switch output logic 356 commands the memory controller 322 to read the specified locations in memory 322 and transfer the data to it to be forwarded to the intended destination. Similarly, the switch input logic 358 accepts data from the switch at the full switch bandwidth and forwards it, along with the accompanying address, to the data complex 318 via bus 364 . Data is transferred from the output logic 356 to the switch and from the switch to the input logic 358 using, in each case, four serial, one-gigabit/second connections 360 , 362 giving the host interface module the ability to transmit, and simultaneously to accept, data at a rate of 500 megabytes/second. Similarly, the request and grant paths to the switch are also both implemented with serial one-gigabit/second links.
When a request is received from a client over one of the Ethernet or Fibre Channels 307 - 313 , the I/O complex 302 generates the appropriate communication protocol responses and parses the received packet of information, directing the request to buffer 304 to await processing by the CPU software and any associated data to buffer 304 for subsequent transfer to the data memory 322 . The processing steps taken by the software running on the host interface module CPU 332 are illustrated in the flowchart shown in FIGS. 4A-4C .
In FIG. 4A , the process starts in step 400 and proceeds to step 402 , where, the host interface receives a request from the client. The request always contains a file or directory “handle” that has been assigned by internal file system processing to each data object. This file system processing is typically done in the metadata module. The handle identifies that object and is sent to the client to be used when the client is making future references to the object. Associated with each such handle is an “inode” which is a conventional data structure that contains the object “attributes” (i.e., the object size and type, an identification of the users entitled to access it, the time of its most recent modification, etc.) of the file or directory. Each inode also contains either a conventional map, called the “fmap”, or a handle, called the “fmap handle”, that can be used to locate the fmap. The fmap identifies the physical locations, called the global physical disk addresses (GPDAs), of the component parts of the object indexed by their offsets from the starting address of that object. In step 404 , upon reading the request from the request buffer 304 , the CPU software extracts the object handle from the request.
Next, in step 406 , the CPU software queries the local CAM memory 338 , using the extracted object handle as a key, to determine if the desired inode information is already stored in host interface local memory 326 . If the inode information is present in the memory 326 , the CAM memory access results in a “hit” and the CAM memory 338 returns the address in local memory 326 where the inode information can be found. In step 408 , this address is then used to fetch the inode information from the local memory 326 .
If the inode information is not present in the local memory as indicated by a CAM memory “miss”, then, in step 410 , the software uses the IPC links 346 and 348 to contact the appropriate metadata module (which is identified by the object handle) for the needed information which is returned to it also over the IPC links. Once the software has located the inode (or a critical subset of the contents of the inode), it verifies that requested action is permitted (step 412 ). If the action is not permitted, an error is returned in step 414 and the process ends in step 415 .
Alternatively, if the requested action is permitted, then, in step 416 , the CPU software determines which response is required. If stored data is to be read, the process proceeds, via off-page connectors 419 and 421 to step 418 shown in FIG. 4C where the CPU software determines whether the fmap or the fmap handle required to honor that request is in the inode. If the fmap itself is too large to be contained in the inode, the process proceeds to step 420 where the software again consults its CAM 338 , this time using the fmap handle as the key, to determine if the fmap pointed to by that handle is stored locally. If it is not, the process proceeds to step 422 , where the software extracts the GPDA for the fmap from the fmap handle and sends a request for the fmap, or for the next level of fmap pointers, over the IPC links 346 , 348 to the disk interface module identified by the GPDA, which returns the fmap, or the page containing the next level of fmap pointers, through the switch module and switch interface 352 to the host interface module data memory 322 . The software can then access this information over the data transfer bus 350 . In step 424 , the software checks the information in the local data memory 322 to determine whether it has obtained the fmap. If not the process returns to step 420 and continues this process until it finds the fmap and the GPDA of the data itself, during each iteration of the process checking its CAM 338 at step 422 to determine if the desired information is cached in the data memory 322 .
When the software locates the GPDA of the desired data either through the process set forth in steps 420 - 424 or if it was determined that the fmap was in the inode in step 418 , in step 426 , the software again checks the CAM 338 to determine if the data resides in the host interface data memory 322 . If the data is not in the data memory 322 , in step 428 , the software sends a read request for the data to the disk interface module to retrieve that data identified by the GPDA. Once the data is in the host interface data memory 322 , in step 430 the software sends a response over the peripheral bus 336 via the I/O buffer 328 to the I/O complex 302 indicating the location in the data memory 322 where the desired information resides, thereby enabling the I/O complex 302 to complete the transaction by returning the requested information to the client. The least-recently-used (LRU) replacement algorithm is used to manage the local memory 322 and data memory caches. The process then ends in step 432 .
If in step 416 , a write operation is requested, the process proceeds, via off-page connectors 417 and 433 , to steps 434 - 440 in FIG. 4B . Prior to any writes to disk, the disk interface module preallocates or assigns “allocation units” (AUs) of physical disk space to each host interface module. Each allocation unit consists of a 512-kilobyte segment spread evenly across a plurality of (for example, four) disks. The disk interface module sends to each host interface module over an IPC channel 346 , 348 , the logical addresses of the allocation units that have been set aside for it. The host interface module then uses these logical addresses to specify the location of an object. Accordingly, the GPDA assigned by a host interface module to identify the location of a particular object specifies the “system parity group number” (SPGN), “zone” and offset within the zone where that object can be found. During initialization, the system determines the storage topology and defines a mapping associating SPGNs and specific disk interface modules. This level of mapping provides additional virtualization of the storage space, enabling greater flexibility and independence from the specific characteristics of the physical disks. The zone defines a particular region within a given SPGN. The disk module reserves certain zones for data represented by that allocation unit. The disk interface module also reserves certain zones for data that is known to be frequently accessed, for example, metadata. It then allocates these zones near the center of the disk and begins allocating the rest of the space on the disk from the center outward towards the edges of the disk. Consequently, most of the disk activity is concentrated near the center, resulting in less head movement and faster disk access.
If, in step 416 , it is determined that the host interface module received a write request from the client, the process proceeds, via off-page connectors 417 and 433 , to step 434 where the host interface module forwards the request to the metadata module or other file system. In parallel, the software assigns the associated data, which is buffered by the I/O complex 302 , to the appropriate preallocated allocation unit in the data memory 322 and sends a request to the switch through the switch interface 352 to enqueue the data for transmission, in, typically, two-kilobyte packets, to the corresponding disk interface module.
Next, in step 436 , the software then sends the GPDA(s) of the new location for that data over an IPC channel 346 , 348 to the appropriate metadata module and broadcasts that same information over IPC channels 346 , 348 to all other host interface modules in the system so that they can update their copies of the fmap in question. Alternatively, the software can broadcast invalidate messages to the other host interface modules causing them to invalidate, rather than update, the associated fmap. Then in step 438 , the host interface module waits for acknowledgements from the disk interface module and metadata module. Acknowledgements are sent to the host interface module over the IPC channels 346 , 348 from the disk interface module when the data has been received and from the metadata module when it has updated its copy of the fmap. When both acknowledgements have been received, in step 440 , the CPU software signals the I/O interface 302 to send an acknowledgement to the client indicating that the data has been accepted and is secure. By “secure” it is meant that the data has been stored in two independent modules (the host interface module and a disk interface module) and the associated metadata updates either have also been stored in two modules (the host interface module and a metadata module) or a log of those updates has been stored on a second module. The process then ends in step 442
The preallocation of allocation units has several significant advantages over the current state of the art in disk storage. In particular, the host interface module is able to respond to write requests without having to wait for disk space to be allocated for it, allowing it to implement the request immediately and to acknowledge the write much more rapidly. In effect, the preallocation gives the host interface module direct memory access to the disk. This ability to respond quickly is also enhanced by the fact that the data write does not need to wait for the metadata update to be completed.
As discussed below each disk interface module also maintains cached copies of allocation units. When a cached copy of an allocation unit in a disk interface module has been filled and written to disk, the disk interface module releases the cached copy, preallocating a new allocation unit, both on disk and in its cache, and sending the host interface module a message to that effect over the IPC 346 , 348 . The disk interface module can then reuse the cache memory locations previously occupied by the released allocation unit. At any given time, each host interface module has several allocation units preallocated for it by each disk interface module. Host interface modules select which allocation unit to use for a given write based solely on the recent activity of the associated disk interface module. This enables the workload to be distributed evenly across all disks, providing the system with the full disk bandwidth and avoiding the serious performance limitations that are frequently encountered in standard storage systems when multiple hosts attempt to access the same disk at the same time.
In accordance with one aspect of the invention, the data assigned to a given allocation unit may come from multiple hosts and multiple files or even file systems. The only relationship among the various data items comprising an allocation unit is temporal; they all happened to be written in the same time interval. In many cases, this can offer a significant performance advantage since files, or portions of files, that are accessed in close time proximity tend to be re-accessed also in close time proximity. Thus, when one such file is accessed, the others will tend to be fetched from disk at the same time obviating the need for subsequent disk accesses. On the other hand, this same process obviously gives rise to potential fragmentation, with the data associated with a given file ending up stored in multiple locations on multiple disks. Procedures to mitigate the possible deleterious effect of fragmentation when those files are read are discussed below. This technique for allowing data to be stored anywhere, without regard to its content or to the location of its prior incarnation, allows for superior, scalable performance.
As in any storage system, it is necessary to identify disk sectors that contain data that is no longer of interest, either because the file in question has been deleted or because it has been written to another location. This is accomplished in the current invention by maintaining a reference count for each page stored on disk. When a page is written to a new location, new fmap entries must be created to point to the data as described in the preceding paragraphs. Until the pages containing the old fmap entries have been deleted, other pages pointed to by other entries on those same pages will now have an additional entry pointing to them. Accordingly, their reference counts must be incremented. When an fmap page is no longer needed (i.e., when no higher-level fmap points to it) it can be deleted and the reference counts of the pages pointed to by entries in the deleted fmap page must be decremented. Any page having a reference count of zero then becomes a “free” page and the corresponding disk locations can be reused.
This procedure allows volumes to be copied virtually instantaneously. Volume copies are commonly used to capture the state of a file system at a given instant. To effect a volume copy, it is only necessary to define a new volume with pointers to the fmaps of the files that are being copied. When a page in a copied file is to be modified, the new fmap entries point to the new location while the old fmap entries point to the original, static, version of the file. As a result, unmodified pages are now pointed to by more than one fmap entry and their reference counts are incremented accordingly to prevent their being deleted as long as any copy of the volume is still of interest.
FIG. 5 illustrates in more detail the construction of a disk interface module 500 . All disk interface modules contain the same construction and are interchangeable. The construction of each disk interface module is similar to the construction of a host interface module shown in FIG. 3 and similar parts have been given corresponding numeral designations. These parts operate in a fashion identical with their corresponding counterparts in FIG. 3 . For example, data memory 322 corresponds to data memory 522 . The major differences between the two modules lie in the I/O complex 502 and in the data complex 518 . The I/O complex 302 in each host interface module is replaced in each disk interface module with a complex 502 consisting of five one-gigabit, full-duplex Fibre Channel interfaces ( 504 - 515 ), each containing the logic needed to send data to and to retrieve data from disk drives from various manufactures over five Fibre channels 507 - 517 . These Fibre Channel interfaces 504 - 515 are used to communicate with sets of five disks, each channel supporting up to 90 disks, enabling each disk interface module 500 to control up to 450 disks. Parity information is stored along with the data, so twenty percent of the disk space is used for that purpose. However, each disk interface module can still manage nearly 33 terabytes of data using 73-gigabyte disks.
All disks connected to a disk interface module are dual-ported with the second port connected to a second disk interface module. In normal operation, half the disks connected to any given disk interface module are controlled solely by it. The disk interface module assumes control over the remaining disks only in case of a fault in the other disk interface module that has access to the disks. This prevents the loss of any data due to the failure of a single disk interface module.
The data complex 518 in each disk interface module is identical to the data complex 318 in a host interface module 300 except for the addition of a special hardware unit 521 that is dedicated to calculating the parity needed for protection of the integrity of data stored on disk. During a disk write operation, the memory controller 520 successively transfers each of a set of four blocks of data that is to be written to disk to the parity generator 521 which generates the exclusive-or of each bit in the first of these blocks with the corresponding bit in the second block, the exclusive-or of these bits with the corresponding bits in the third block and the exclusive-or of these bits with their counterparts in the fourth block. This resulting exclusive-or block is then stored in memory 522 to be transferred, along with the data, to the five disks over five independent channels 507 - 515 . The size of the blocks is referred to as the “stripe factor” and can be set according to the application. The specific disk used to store the parity block is a function of the allocation unit being stored. This allows the parity blocks to be spread evenly across the five disk channels 507 - 515 .
The steps taken by the disk interface module CPU 532 in response to read and write requests are illustrated in the flowchart in FIG. 6 . The process begins in step 600 and proceeds to step 602 in which a new event is received by the disk interface module. On detecting that a new event has occurred, i.e., that either data has been received over the switch or a request has been received over the IPC, the CPU software in the target disk interface module determines the appropriate action in step 604 . If the event is a read request, the process proceeds to step 610 in which the CPU software checks the disk interface module CAM 538 , using the GPDA provided in the request as a key, to determine if the desired object is cached in its local data memory 522 . If the data is cached, the process proceeds to step 616 , described below.
Alternatively, if in step 610 , it is determined that the data is not cached, the process proceeds to step 612 in which software sends a request to the I/O complex 502 directing that the requested data be read, along with, typically, several adjacent disk sectors in anticipation of subsequent reads, and stored in an assigned location in the data memory 522 . The number of additional pages to be read is specified in the read request generated in the requesting host interface module, this number is determined from an examination of the type of file being read and other information gleaned by the host interface module from the attributes associated with the file. The additional pages are cached in case they are subsequently needed and overwritten if they are not.
The CPU software then polls the I/O complex 502 to determine when the read is complete as illustrated in step 614 . When the data is located in the data memory 522 , either through a cache hit or by being transferred in from disk, in step 616 , the software sends a message to the switch interface 552 thereby enqueuing the data for transmission to the requesting host interface module. While any data item cached in the disk interface module data memory 522 as the result of a write must also be cached in some host interface module data memory, the data item is not necessarily cached in the memory of the host interface module making the read request. Similarly, data may be cached in a disk interface module due to a prior read from some host interface module other than the one making the current request.
If, in step 604 , it is determined that a write request has been received, the process proceeds to step 606 . Allocation units that have been preallocated to host interface modules are represented by reserved cache locations in the disk interface module local memory 522 and by “free space” on disk, that is, by sectors that no longer store any data of interest. When the switch interface 552 receives write data from a host interface module, it stores the data directly in the preassigned allocation unit space in its data memory 522 and enqueues a message for the CPU software that the data has been received. Upon receiving the message, the software sends an acknowledgement over the IPC links 546 , 548 to the appropriate host interface module as shown in step 606 and enqueues the data for transfer to disk storage, via the I/O complex 502 , as shown in step 608 . The process then terminates in step 618 .
When disk bandwidth is available, or when space is needed to accommodate new data, the CPU software instructs the I/O complex 502 to transfer to disk storage the contents of one allocation unit cached in the data memory 522 . If possible, the CPU software selects an allocation unit that is already full to store to disk and, of full allocation units, it selects an allocation unit that is “relatively inactive.” One typical method for performing this selection is to select the allocation unit that has been least recently accessed (according to one of several well-known least-recently-used algorithms) but other criteria could also be used. For example, one of the pre-allocated 2% allocation units may be selected at random. Alternatively, the switch unit could keep track of the length of queues of transactions awaiting access to the various disk modules. This information could then be communicated back the host interface module and used to make a decision as to which allocation unit to select based on actual disk activity.
As previously noted, the parity-generation hardware 521 is used to form the parity blocks that are stored along with the data, therefore, in order to store one allocation unit, 128 kilobytes of data and parity information are sent over each of the five channels 507 - 515 to five different disks. Once the data has been stored on disk, the software sends a message to the relevant host interface module over the IPC links 546 , 548 informing the host interface module that the contents of the allocation unit can now be released. However, those contents are not overwritten in either the host interface module or the disk interface module until the space is actually needed, thereby allowing for the possibility that the information might be requested again before it is expunged and hence can be retrieved without having to access physical disk storage.
Note that since an allocation unit is written as a unit, the parity information stored along with each disk stripe never has to be read and updated, reducing by ¾ths the number of disk accesses that would otherwise be needed to store a single page. For example, in prior art systems, the prior contents of the page to be stored has to be read, the parity page has to be read and modified based on the change between the new and old contents of the page in question, and the new page and the parity page both have to be stored. In the inventive system, the only time a parity page normally has to be read is when the data on some sector fails the standard cyclic residue code (CRC) check always used to protect data stored on disk. In this event, the parity sector is read and, in combination with the three error-free sectors, is used to reconstruct the contents of the defective sector.
As previously noted, the policy of writing data to arbitrary locations, while offering major performance advantages, can result in fragmentation of files that are only partially updated. Since each host interface module can use any allocation unit at its disposal, and, in fact, selects allocation units solely on the basis of the recent activity of the associated disks, files may well be split up among multiple disk interface modules. This tendency toward fragmentation is mitigated by a write-back policy. That is, when a host interface module reads a file that has been fragmented, it follows that read with a write, placing all the file fragments, or all that will fit, in the same allocation unit. The previously described technique for ensuring that newly written data and metadata are consistent is, of course, used with write-back operations as well.
Another potential inefficiency resulting from the “write anywhere” policy is that sections of allocation units are gradually replaced by more up-to-date versions written elsewhere, leaving holes in those allocation units that represent wasted disk space unless they are identified and reused. Since the reference count technique described earlier allows those sections to be identified, they can, in fact, be reused. To make their reuse more efficient, the software running on the disk interface modules CPU 532 , as a background task, identifies those allocation units having more than a predetermined percentage of unused space and sends the GPDAs of the still-valid sectors to a host interface module so that the vectors can be read and rewritten more compactly.
The detailed construction of a metadata module 700 is shown in FIG. 7 . The metadata module 700 differs from the host interface module 300 and disk interface module 500 in two basic ways: The metadata module 700 has no I/O complex since it does not communicate with either clients or disks; and the data complexes present in the host interface modules and disk interface modules are eliminated and their large data memories replaced by relatively a small memory 754 that serves as store-and-forward buffer. Data destined to be stored through the switch output 756 and connections 760 is first transferred, using a DMA engine 753 , from the CPU's local memory 726 into the buffer memory 754 before being enqueued for transfer. Similarly, data received over the switch via connections 762 and switch input 758 is transferred from the input buffer 754 directly into preassigned locations in local memory 726 .
Since the local memory 726 in the metadata module 700 stores all data received over the switch, it is considerably larger than its counterpart in the host interface 300 and disk interface modules 500 , normally comparable in size to the latter modules' data memories, 322 and 522 , respectively. The local memory 726 is used primarily for caching inodes and fmaps. The other elements shown in FIG. 7 are similar in function and implementation to the corresponding elements shown in FIGS. 3 and 5 .
The purpose of the metadata module 700 is to maintain the file system structure, to keep all inodes consistent and to forward current inodes to host interface modules that request them. When a new file or directory is created, it is the responsibility of the metadata module to generate the associated inode and to insert a pointer to it into a B-tree data structure used to map between inodes and GPDAs. Similarly, when a file or directory is deleted, the metadata module must delete its associated inode, as well as those of all its descendents, and modify the B-tree data structure accordingly.
When a host interface module receives a request from a client that requires inode information that the host interface module cannot find in its own local memory, it uses the IPC links to query the metadata module associated with the file system in question. The steps taken by the software running on a metadata module CPU 732 to service a typical request are depicted in FIGS. 8A and 8B .
In FIG. 8A , the process begins in step 800 and proceeds to step 802 where a request is received by the metadata module. All requests to a metadata module for an object are accompanied by a handle that includes an “inode number” uniquely identifying the object, or the parent of the object, being requested. These unique inode numbers are assigned by the file system to each of its files and directories. The handle used by a client to access a given file or directory includes the inode number, which is needed to locate the object's associated inode. In step 804 , the metadata module checks its CAM 738 using that inode number as a key. If the inode information is in the CAM 738 , the process proceeds, via off-page connectors 815 and 819 , to step 816 , discussed below.
If the inode information is not in the local memory 726 , as indicated by a cache “miss,” the CPU software then searches through an inode B-tree data structure in memory 726 to find the GPDA of the inode data as indicated in step 806 . If the necessary B-tree pages are not present in local memory, the process proceeds to step 808 where the software sends a message over IPC links 746 , 748 to the appropriate disk interface module requesting that a missing page be returned to it over the switch. The metadata module 700 then waits for a response from the disk interface module (step 810 .)
In step 812 , the CPU software examines either the cached data from step 806 or the data returned from the request to the disk interface module in step 810 to determine if the data represents a leaf page. If not, the process returns to step 808 to retrieve additional inode information. If the data does represent a leaf node, then the process proceeds, via off-page connectors 813 and 817 , to step 814 . Once the metadata module 700 has located the GPDA of the inode itself (the desired leaf node), in step 814 , the metadata module 700 sends a request over the IPC links 746 , 748 for the page containing that inode. At this point, the inode information has been obtained from the CAM 738 in step 804 or by retrieving the information in step 814 .
The process then proceeds to step 816 where a determination is made concerning the request. If the request received from the host interface module was to return the handle associated with a named object in a directory having a given inode number, the retrieved inode is that of the directory and the process proceeds to step 820 .
To fulfill the request, the metadata module 700 must read the directory itself as shown in step 820 . The CPU software first queries its CAM 738 , using the directory's GPDA as a key, to determine if the directory information is cached in its local memory 726 . If the desired information is present, then the process proceeds to step 818 . If the directory, or the relevant portion of the directory is not cached, the software must again send a message over the IPC to the disk interface module storing the directory requesting that the directory information be returned to it through the switch as indicated in step 822 . Once it has access to a directory page, it searches the page to find the desired object. If the object is not found in step 824 , the process returns to step 820 to obtain a new page. Eventually it locates the named object and its associated inode number.
Finally, once the metadata module has located either the inode of the object specified by the handle or the inode of the named object, depending on the specific request, it forwards the requested information on to the requesting host interface module as set forth in step 818 . The process then ends in step 826 .
A detailed diagram of the switch module is shown in FIG. 9 . The switch module 900 is composed of three major components: a crossbar switch complex 906 providing non-blocking, full-duplex data paths between arbitrary pairs of host interface modules, disk interface modules and metadata modules; an IPC complex 904 composed of switches 942 for two sets of full-duplex, serial, 10/100 Ethernet channels 938 and 940 that provide messaging paths between arbitrary pairs of modules; and a configuration management complex 902 including system reset logic 924 and the system clock 908 . The switch module is implemented as a redundant pair for reliability and availability purposes, however, only one of the pair is shown in FIG. 9 for clarity.
The I/O processor 954 in the crossbar switch complex 906 accepts requests from the switch interfaces 356 , 556 and 756 on the host interface modules, disk interface modules and metadata modules, respectively over the request links and grants access over the grant links. Each module can have one request outstanding for every other module in the system or for any subset of those modules. During each switch cycle, the arbiter 950 pairs requesting modules with destination modules. The arbiter assigns weights to each requester and to each destination. These weights can be based on any of several criteria, e.g., the number of requests a requester or destination has in its queue, the priority associated with a submitted request, etc. The arbiter then sequentially assigns the highest weight unpaired destination to the unpaired requester having the highest weight among those requesting it. It continues this operation as long as any unpaired requester is requesting any, as yet, unpaired destination.
The I/O processor 954 then sends each requesting module, over the appropriate grant link, the identity of the module with which it has been paired and to which it can send a data packet during the next switch cycle. The arbiter 950 sets the crossbar switch 952 to the appropriate state to effect those connections.
The switch 952 itself consists of four sets of multiplexers, one multiplexer from each set for each destination, with each multiplexer having one input from each source. Switch cycles are roughly four microseconds in duration, during which time two kilobytes of data are sent between each connected pair with a resulting net transfer rate of approximately 500 megabytes/second per connected pair.
The function of the IPC switches 942 is to connect source and destination IPC ports 944 long enough to complete a given transfer. The standard IEEE 802.3 SNAP (sub-network access protocol) communication protocol is used consisting of a 22-byte SNAP header followed by a 21-byte message header, a data packet of up to 512 bytes and a 32-bit cyclic residue code (CRC) to protect against transmission errors.
The configuration management complex 902 coordinates system boot and system reconfiguration following faults. To support the first of these activities, it implements two external communications links: one 936 giving access through the PCI bus 928 via full-duplex, serial, 10/100 Ethernet channel 932 ; and the other 912 giving RS-232 access 914 through the peripheral bus 922 . To support the second activity, it implements the reset logic 924 for the entire system. It also implements and distributes the system clock 908 .
The disclosed invention has several significant fault-tolerant features. By virtue of the fact that it is implemented with multiple copies of identical module types and that all of these modules have equal connectivity to all other modules, it can survive the failure of one or more of these modules by transferring the workload previously handled by any failed module to other modules of the same type. The switch fabric itself, of course, is a potential single point of failure since all inter-module communication must pass through it. However, as mentioned in the previous section, the switch in the preferred implementation is implemented with two identical halves. During the initialization process, the two configuration management complexes 902 communicate with each other, via the IPC channels, to determine if both are functioning properly and to establish which will assume the active role and with the standby role. If both switch halves pass their self-diagnostic tests, both sets of IPC channels are used and the configuration management complexes 902 cooperate in controlling the system configuration and monitoring its health. Each switch half, however, supports the full data bandwidth between all pairs of modules, therefore only the active half of the switch is used for this purpose. If one switch half becomes inoperative due to a subsequent failure, the configuration management complexes cooperate to identify the faulty half and, if it is the half on which the active configuration manager resides, transfer that role to the former standby half. The surviving configuration manager communicates the conclusion to the other system modules. These modules then use only the functioning half of the switch for all further communication until notified by the configuration manager that both halves are again functional. Although the IPC bandwidth is halved when only one switch half is operational, the full data bandwidth and all other capabilities are retained even under these circumstances.
Several complementary methods are used to identify faulty modules, including (1) watchdog timers to monitor the elapsed time between the transfer of data to a module and the acknowledgement of that transfer and (2) parity bits used to protect data while it is being stored in memory or transferred from one point to another. Any timeout or parity violation triggers a diagnostic program in the affected module or modules. If the violation occurred in the transfer of data between modules, the fault could be in the transmitting module, the receiving module or in the switch module connecting the two so the diagnostic routine involves all three modules checking both themselves and their ability to communicate with each other. Even if the diagnostic program does not detect a permanent fault, the event is logged as a transient. If transient event recurs with a frequency exceeding a settable parameter, the module involved in the greatest number of such events is taken off line and the failure treated as permanent, thereby triggering manual intervention and repair. If transients continue, other modules will also be taken off line as a consequence until the fault is isolated.
Byte parity is typically used on data stored in memory and various well-known forms of vertical parity checks and cyclic-residue codes are used to protect data during transfer. In addition, in the storage system embodiment described here, data tags consisting of 32-bit vertical parity check information on each data page are stored on disk separately from the data being protected. When data is retrieved from disk, the tag is also retrieved and appended to the data. The tag is then checked at the destination and any discrepancy flagged. This provides protection not only from transmission errors but also from disk errors that result in reading the wrong data (or the wrong tag). This latter class of errors can result, for example, from an addressing error in which the wrong sector is read from disk or from a write current failure in which old data is not overwritten.
Another important fault-tolerant feature of the storage system embodiment of the invention is the requirement that all data and metadata be stored on at least two different modules or on parity-protected disk before the receipt of any data is acknowledged. This guarantees that the acknowledged data will still be available following the failure of any single module. Similarly, data stored on disk is protected against any single disk failure, and against any single disk channel failure, by guaranteeing that each data block protected by a parity block is stored on a different physical disk, and over a different disk channel, from all other blocks protected by the same parity block and from the disk storing the parity block itself.
Finally, the fact that all disks are dual-ported to two different disk interface modules guarantees that data can still be retrieved should any one of those disk interface modules fail. Following such an event and the resulting reconfiguration, all subsequent accesses to data stored on the affected disks are routed through the surviving disk interface module. While this may result in congestion because the surviving disk interface module is now servicing twice as many disks, it retains full accessibility. In addition, the previously described load-balancing capability of the system will immediately begin redistributing the workload to alleviate that congestion.
Similar protection against host interface module failures can be achieved by connecting clients to more than one host interface module. Since all host interface modules have full access to all system resources, any client can access any resource through any host interface module. Full connectivity is retained as long as a client is connected to at least one functioning host interface module and, connection to more than one host interface module provides not only protection against faults, but also increased bandwidth into the system.
The architecture described in the previous paragraphs exhibits several significant advantages over current state-of-the-art storage system architectures:
1) It is highly scaleable. Host interface modules, disk interface modules and metadata modules can all be added independently as needed and their numbers can be independently increased as storage throughput or capacity demands increase. A system using a 16-port crossbar switch, for instance, can support any combination of host interface modules, disk interface modules and metadata modules up to a total of 16. This would allow a system to be configured, for example, to give 32 directly connected clients access to over 40 terabytes of data (using 36-gigabyte disks) supported by two metadata modules. Obviously, even larger configurations can be realized with larger IPC and wider crossbar switches. 2) Since writes can be directed to arbitrary disk interface modules, demand can be equalized across all disk resources, ensuring that throughput will increase nearly linearly with the number of disk interface modules in the system. Further, writes can take place in parallel with fmap updates thereby decreasing the latency between the initiation of a data write and the acknowledgement that it has been accepted. Since both the data and the metadata associated with a new write are always stored in two independent places before that write is acknowledged, write acknowledgements can be issued before data is actually stored on disk while still guaranteeing that the data is secure. 3) Relegating metadata operations to modules designed for that purpose not only enables faster metadata processing but, in addition, allows the host interface and disk interface modules to be structured as efficient data pipes, with the bulk of local memory partitioned as a bi-directional buffer. Since the client's communication protocol is terminated in the host interface module I/O complex, the bulk of data passing through this data memory does not need to be examined by the host interface module CPU software.
Although an exemplary embodiment of the invention has been disclosed, it will be apparent to those skilled in the art that various changes and modifications can be made which will achieve some of the advantages of the invention without departing from the spirit and scope of the invention. For example, it will be obvious to those reasonably skilled in the art that, although the description was directed to particular embodiments of host interface modules, disk interface modules, metadata modules and switch modules, that other designs could be used in the same manner as that described. Other aspects, such as the specific circuitry utilized to achieve a particular function, as well as other modifications to the inventive concept are intended to be covered by the appended claims | A data system architecture is described that allows multiple processing and storage resources to be connected to multiple clients so as 1) to distribute the clients' workload efficiently across the available resources; and 2) to enable scaleable expansion, both in terms of the number of clients and in the number of resources. The major features of the architecture are separate, modular, client and resource elements that can be added independently, a high-performance cross-bar data switch interconnecting these various elements, separate serial communication paths for controlling the cross-bar switch settings, separate communication paths for passing control information among the various elements and a resource utilization methodology that enables clients to distribute processing or storage tasks across all available resources, thereby eliminating “hot spots” resulting from uneven utilization of those resources. | 6 |
BACKGROUND OF THE INVENTION
The present invention relates to an induced current-proof detonating system and method and more particularly to a detonating system and method in which the possibility of a premature explosion from current induced in the conductor connecting the control site to the remote explosive by natural or man-made electromagnetic fields is significantly reduced.
Conventionally, explosive devices such as dynamite are generally detonated at a remote location by the manual operation of a switch at a control site. By the operation of the switch, power is supplied by an electrical conductor to the detonating device. This electrical conductor is, for safety reasons, often of considerable length and the individual connecting the conductor to the detonator is in danger of premature detonation until he can clear the area. This danger exists even when the conductor is not connected to the switch, because the conductor may act as an antenna and have current induced therein as a result of either natural (e.g., lightning) or man-made (e.g., radio telephone signals, power line coupling) electromagnetic fields or electrical fields (e.g., downed power lines). In addition to the injuries at blasting sites, the danger of premature detonation results in the loss of a significant number of man hours where safety requires that blasting operations be suspended because of sporadic local thunderstorm activity, the presence of citizen band radio transmissions, etc.
It is accordingly an object of the present invention to provide a novel detonator system and method in which the risk of premature detonation is materially reduced.
It is another object of the present invention to provide a novel and inexpensive piston-type arming device for use in detonation systems.
It is a further object of the present invention to provide a novel and inexpensive diaphragm-type arming device for use in detonation systems.
These and many other objects and advantages of the present invention will be readily apparent from the claims and from the following detailed description when read in conjunction with the appended drawings.
THE DRAWINGS
FIG. 1 is a pictorial representation of the system of the present invention;
FIG. 2 is a schematic diagram of one embodiment of the present invention;
FIG. 3 is a pictorial representation of one embodiment of the arming device of the present invention;
FIG. 4 is a section taken through lines 4--4 of FIG. 3;
FIG. 5 is an elevation in cross-section illustrating one embodiment of the piston-type arming device of the present invention;
FIG. 6 is an elevation in cross-section illustrating one embodiment of the diaphragm-type arming device of the present invention; and
FIG. 7 is a top plan view of one embodiment of a connector lug utilized in the embodiments of FIGS. 5 and 6.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
With reference to FIG. 1, the system of the present invention is pictorially illustrated as including a plunger-type switch 10 electrically connected by way of a conductor 12 through the arming device 14 to the contact 16 of a detonator 18 pictorially illustrated as a cap to a dynamite charge 20.
With continued reference to FIG. 1, the pump 22 at the control site may be connected by a tube 24 to the arming device 14 at the remote location. The arming device 14 includes the reservoir for an electrically conductive fluid which, under the influence of pressure from the pump 22 via tubing 24, effects the filling of a tube 26 with the electrically conductive fluid to thereby connect the conductor 12 to the contact 16. Without this fluid pressure responsive connection, the explosive 20 is electrically connected only to a short length of wire 28 associated with the detonator 18. Thus any current induced in the conductor 12 by the presence of an electromagnetic field cannot be passed to the detonator 18.
In operation, the explosive 20 may be placed in the desired position with the arming device 14, the tube 26, and the detonator 18 contact 16 in close proximity thereto. The conductor 12 and tube 24 may then be connected to the arming device and run over a safe distance to the location from which the operation is to be controlled. Activation of the pump 22 from the control site only after all personnel have safely cleared the blasting area to apply pressure to the arming device 14 will effectively establish the electrical connection between the conductor 12 and the detonator 18, thus arming the detonator 18 for activation in response to the manual operation of the switch 10.
The system of FIG. 1 incorporates a suitable conventional electrical switch and pressure source 22, as well as a conventional detonator 18.
The system of FIG. 1 may be adapted for two-wire use as shown in FIG. 2 by utilization of two arming devices 14, tubes 26, and contacts 16. In such a two-wire embodiment, it may be desirable to utilize dual tubes from the pump 22, one each to the arming devices 14. Alternatively, a single tube may be used to simultaneously apply pressure to both of the arming devices 14.
A better understanding of the operation of the arming device 14 of FIGS. 1 and 2 may be gained with reference to FIGS. 3 and 4 where an exemplary structure is illustrated. As shown in FIGS. 3 and 4, the illustrated arming device 14 includes two reservoirs 30 and 32, both containing a suitable conventional electrically conductive solution 34. The electrical conductor 12 from the power source and switch (not shown) may be connected to a pair of electrodes 36 projecting respectively in a suitable conventional manner into the interior of the reservoirs 30 and 32.
Also as shown in FIG. 3, two tubes 24 may be connected respectively from the pump 22 (not shown) at the site of the electrical switch 10 of FIG. 1 to communicate with the upper portions respectively of the chambers 30 and 32.
With continued reference to FIGS. 3 and 4, a pair of generally upright tubes 26 are illustrated as projecting into the top of the reservoirs 30 and 32 to a point spaced from but adjacent to the bottom of the reservoirs. The tubes 26 are desirably of short length, e.g., approximately one foot, and are of a insulative or electrically non-conductive substance such as a thermoplastic. The contacts 16 are illustrated as projecting into the top of the tubes 26 and are in electrical contact with the detonator 18.
In operation, the application of a positive pressure to the upper portion of one of the reservoirs will effect a displacement of the electrically conductive fluid therefrom, forcing the conductive fluid 34 to rise within the tube 26 into contact with the contact 16 associated with the detonator 18. This completes the electrical circuit between the conductor 24 and the detonator 18 as shown in the right hand position of FIG. 4.
Clearly, the device illustrated in FIGS. 3 and 4 could easily be adpated for single reservoir operation, for one rather than two arming tubes, for a single rather than two wires to the detonator so long as the other wire is appropriately grounded, or for use with either or both positive and negative pressures to control the level of the electrically conductive fluid which arms the circuit. Such modifications are easily within the level of skill of one skilled in this art.
A preferred embodiment of the arming device of the present invention is illustrated in FIG. 5 as including a cylinder 40 opened at one end and having an axial aperture on the upper end through which a fitting 42 may be inserted by insertion into the open end of the housing 40. As illustrated in FIG. 5, the fitting 42 is desirably provided with a flange 44 and effects a fluid-tight seal under the pressure of a nut 46 threaded onto the portion of the fitting 42 external of the housing. In addition to the seal, the flange 44 increases the surface area for contact by the electrolyte 48 within the chamber 50 formed at the upper end of the housing 40 by a piston 52.
The lower end of the housing 40 is desirably externally threaded to receive a screw-on end cap 54 and gasket 56. The end cap 54 is desirably provided with a fitting to which the fluid pressure control line may be attached.
The housing 40 and the end cap 54 are desirably made of an electrically non-conductive material such as a conventional thermoplastic material, as is the piston 52. The fitting 42 is desirably constructed of a non-corrosive material such as stainless steel and serves as the contact for the electrical conductor 12 attached by way of a suitable conventional fitting such as the contact lug 58 illustrated in FIG. 7. The electrical contact may be made from the conductor 12 in any suitable conventional manner to the contact lug 58 and from there either directly to the fitting 42 or through the lug 46 to the fitting 42.
While not shown in FIG. 5, the tube 26 of FIGS. 1-4 may be secured to the fitting 42 and may contain at the upper end thereof any suitable conventional electrical contact 16 adapted to be connected to the detonator 18.
In operation, the application of a positive pressure to the fitting 60 formed on the end cap 54 will increase the pressure within the chamber 62 formed by the end cap 54, housing 40, and piston 52, and thus effect movement of the piston 52 upwardly to force the conductive fluid into the fitting 42 and up the tube 26 (not shown). The application of a negative pressure to the chamber 62 will effect the reverse movement of the piston 52 to clear the electrical contact with the detonator as may be appropriate.
A second embodiment of the arming device 14 of FIGS. 1 and 2 is illustrated in FIG. 6. With reference to FIG. 6, a shallow cylindrical housing 70 may be internally threaded at the open end thereof and be provided with an aperture at the upper end. A fitting 72 may thus be inserted through the open end of the housing 70 and protrude through an axial aperture in the upper end thereof. The fitting 72, like the fitting 42 of the device of FIG. 5, may be provided with a flange 74 to effect the liquid-tight seal under the application of pressure from the nut 76. As in the embodiment of FIG. 5, a lug 58 such as illustrated in FIG. 7 may be provided for electrical contact with the conductor 12.
With continued reference to FIG. 6, an end cap 78 with a molded fitting 80 may be threadably secured to the housing 70 to define an internal chamber. A diaphragm 82 may be secured between the housing 70 and the end cap 78 to separate the electrically conductive solution 84 from the pressure chamber 86.
In operation, the application of a positive pressure through the fitting 80 will pressurize the chamber 86, displace the diaphragm 82 upwardly and thereby force the electrically conductive solution 84 through the fitting 72 into the tube 26 (not shown) to thereby complete the circuit from the lug 58 to the contact 16 of the detonator. The application of a negative pressure to the fitting 80 will, of course, reverse the movement of the diaphragm 82 and cause the electrolyte 84 to flow downwardly under the pressure of gravity into the chamber.
The arming devices 14 illustrated in FIGS. 5 and 6 may be carried to the blasting site filled with the conducting fluid. Suitable conventional plugs (not shown) may be removed from the fittings at the time that the device is mechanically connected to the tube 26 and its contact 16. By using the arming device to delay the electrical connection of the detonator to the conductor 12, the possibility of the conductor 12 serving as an antenna responsive to either natural or man-made electromagnetic fields can be eliminated. Work at the blasting site may thus continue even in presence of intermittent thunderstorm activity or citizens band radio transmissions.
Although previously described in association with FIGS. 3 and 4 as operating in response to fluid pressure, the embodiments described above can also function in response to a vacuum or negative pressure by changing the position of the tubing 24 from communicating with the chambers 30 and 32 to communicating with the upper portion of the upright tubes 26. If a partial vacuum is then applied to the tubing 24, the electrically conductive solution 34 will rise within the tube 26 into contact with the contact 16, completing the electrical circuit between the conductor 12 and the detonator 18.
Many other modifications of the present invention will be readily apparent to one skilled in the art, being understood that the scope of the invention is defined by the appended claims when accorded a full range of equivalents, rather than by the illustrative embodiments disclosed. | An arming device is interposed in the electrical circuit between the electrical switch at a control site and a remote explosive. The arming device is physically located near the explosive and is connected by a fluid pressure line to a pressure source at the control site. Until such time as the arming device is activated, the danger of premature detonation of the explosive from current induced in the conductor between the explosive and the switch is eliminated, and the fluid-pressure controlled arming device is not susceptible to such induced current. Both piston and diaphragm-type arming devices are disclosed. | 5 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to an automatic washing machine agitator construction and more specifically to an agitator construction wherein the agitator is comprised of an oscillatory rotating portion and a vertically reciprocating portion.
2. Description of the Prior Art
A number of different types of agitating structures are disclosed in the prior art for automatic washing machines which provide both reciprocatory and rotary movement of an agitator. For example, U.S. Pat. Nos. 3,678,714 and 4,193,275 both disclose thrusters that are driven in reciprocating motion by the oscillatory motion of the agitator shaft. In the '714 patent, the thruster is driven by driving lugs riding on a cam member. In the '275 patent the thruster is driven by a screw thread on the agitator shaft when the force of the clothes in the basket prevent rotational movement of the thruster. Both thrusters disclosed have a reciprocation period equal to or greater than the oscillation period of the agitator.
SUMMARY OF THE INVENTION
The purpose of the present invention is to provide an improved washing action by increasing the rollover of the articles to be washed. This improved washing action is accomplished by means for securing both oscillation and vertical reciprocation in an agitator element. The agitator is particularly designed for those types of washing machines which include perforate basket assembly connected to a vertically disposed shaft, with an oscillating agitator being disposed in the perforate basket and having a shaft which is concentric with the shaft which rotates the perforate basket. Drive means are provided to selectively drive the perforate basket continuously in a wash liquid extraction stage, and to oscillate the agitator vanes during the washing cycle.
In accordance with the present invention, a secondary agitator provides vertical movement in the wash liquid during agitation. The preferred form of the invention involves the use of a one-way clutch mechanism to provide intermittent rotary motion to unidirectionally drive a drive barrel in the agitator. The drive barrel contains driving lugs which engage inner and outer cam surfaces in the barrel of the agitator thruster. When the thruster barrel is restrained against movement by a clothes load adjacent the barrel, the lugs engage the cam as the barrel rotates. The resultant force raises and lowers the thruster barrel. At the ends of each cam stroke the lugs transfer back and forth between the inner cam barrel and the outer cam barrel.
Through the use of the combined reciprocation and oscillation, an improved washing action is obtained through the increase rollover of the articles being washed. Because of this improved washing action, a larger capacity load can be washed than would be possible with a conventional agitator which provides only rotary oscillation. The present invention produces the required rollover of a heavy clothes load within acceptable power usage requirements.
The inner and outer cam barrels are indexed to each other and secured coaxially whereby the driver barrel which houses the drive lugs will rotate between the inner and outer cam barrels. The reciprocating action is positive and smooth and provdes great cam variation configuration and stroke length to satisfy any possible washer configuration and requirement. Also, the period of reciprocation can be changed throughout a wide range.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a washing machine embodying the present invention, partially cut-away to show the interior mechanism thereof.
FIG. 2 is a side sectional view of the agitator assembly within the tub and basket of the washing machine.
FIG. 3 is a top elevational view of the agitator shown in FIG. 2.
FIG. 4 is a sectional view of the one-way clutch mechanism taken generally along the lines IV--IV of FIG. 2.
FIG. 5 is a partial side sectional view of the agitator thruster shown in FIG. 2.
FIG. 6 is a partial sectional view of the cam driving arrangement taken generally along the lines VI--VI of FIG. 2.
FIG. 7 is a partial sectional view of the cam driving arrangement with the thruster in the upper most position as distinguished from the view shown in FIG. 6.
FIG. 8 is an exploded side view of the inner cam barrel, the driving barrel and the outer cam barrel.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
A laundry appliance 10 comprising an automatic clothes washer embodying the principles of the present invention is depicted in FIG. 1. The washer is comprised of a cabinet 12 having a top 14 with a lid 16 and a console 18 having presettable controls 20 thereon of the type wherein an operator may preselect a program of automatic washing, rinsing and drying steps in a laundering process. The lid 16 in the top 14 of the cabinet 12 permits access into the top of a tub 22 housed within the cabinet 12. Enclosed and supported within the tub 22 is a clothes container or spin basket 24 within which is oscillatably mounted an agitator 26.
Below the tub 22 but within the cabinet 12 there is provided an electric motor 28 which oscillatably drives the agitator 26 through a transmission 30. The agitator 26 is shown in greater detail in FIGS. 2 and 3 where it is seen that the agitator 26 is comprised of a skirt portion 32 near the bottom of the agitator and a substantially vertical barrel portion 34 integrally connected with the skirt and projecting upwardly therefrom. A plurality of pumping vanes 36 are provided around the periphery of the barrel 34 and extend downwardly and outwardly along the skirt portion 32 of the agitator 26.
A thruster portion 38 of the agitator is mounted concentrically about the barrel portion 34 and above the pumping vanes 36. The thruster portion 38 has a plurality of thrusting vanes 40 provided around the periphery of the thruster 38 which extend downwardly and outwardly along the entire length of the thruster portion 38.
A drive shaft 42 for the agitator extends upwardly through the barrel portion 34 of the agitator and is drivingly connected to the barrel portion by means of a splined end 44 matingly engaging a coversely shaped opening 46 in the barrel 34. Fastening means 48 such as a screw retains the splined connecting portions in a fixed axial relationship. The fastening member 48 also retains a splined cap 50 driven by splines 35 on barrel 34 mating with splines 51 on cap 50 for oscillatory movement with barrel 34. Thus, oscillation of the drive shaft 42 oscillates the barrel 34 via the splined conections 44, 46 on the drive shaft 42 and the barrel 34 which also drives cap 50 in oscillation.
Carried within the top portion of the thruster 38 is an outer cam barrel 52, an inner cam barrel 54 and a driving barrel 56 positioned concentrically between the inner and outer cam barrels 52, 54. Two driving lugs 58 are carried in the drive barrel 56 and alternately engage cam surfaces 90 and 92 in the cam barrels 52, 54.
As shown in FIG. 4, the drive barrel 56 is driven by means of the drive shaft 42 in accordance with the principles of the invention disclosed in U.S. Pat. No. 4,164,130. In particular, the drive shaft 42 is drivingly connected through barrel 34 to drive cap 50 as previously explained. The cap 50 is formed with a radially extending flange 60 and, below the flange 60, a pair of cam lobes 62. The cap 50, the flange 60, and the cam lobes 62 together form an oscillating member which rotates with the drive shaft 42, the upstanding barrel 34, the skirt 32 and the vanes 36.
Each of the cam lobes 62 is formed with a first, driving surface 64 extending generally in a circumferential direction, and a second, capture surface 66 extending generally in a radial direction. The driving surface 64 comprises a spiral which proceeds radially inwardly in the direction of the driving rotation shown by arrow 67. The capture surface 66 is tilted forwardly in the direction of the non-driving rotation from a line radial to the axis of the assembly.
Carried outwardly of the cam lobes 62 are a pair of clutch shoes or members 68. Each clutch shoe 68 is retained axially about the cam lobe 62 between the flange 60 and an upper side of a support rim 70 of the driving barrel 56. The clutch shoes 68 are restrained from radially outward movement by surrounding cylindrical engagement surface 72 formed on an inner surface of the driving barrel 56. The engagement surface 72 of the driving barrel 56 is preferably toothed as at 74, and each clutch shoe 68 carries on a radially outer surface thereof at least one corresponding tooth 76 engageable therewith for a positive driving connection. More than tooth 76 may be provided on each shoe 55 if desired, although one is sufficient.
A radially inward part of each clutch shoe 68 is formed with a first, curved surface 78 extending radially inwardly in the direction of driving oscillations, the surface 78 corresponding to the driving surface 64 of each cam lobe 62. It is preferred that the surfaces 64 and 78 have cooperating spacers 80 extending radially of the surfaces to reduce surface contact area between them to avoid sticking of the parts should they become wet in the washing machine environment.
Each clutch shoe 68 has a further, capture surface 82 formed on a shoulder 84 at a circumferentially forward end thereof in the direction of non-driving rotation. The surface 82 is aligned with the capture surface 66 of the cam lobe 62. The forward tilting of the surfaces 66, 82 in the non-driving direction assures that the clutch shoes 68 are cammed radially inwardly when the drive shaft 42 and connected parts rotate in such non-driving direction. Such capture and camming action removes the teeth 76 from engagement with the teeth 74 of the drive barrel 56. Since the shoes 68 are withdrawn radially inwardly from the teeth 74 of the inner surface 72 of the drive barrel 56, no ratcheting occurs, providing a substantially noiseless clutch action. In this manner, the drive barrel 56 is unidirectionally rotated by means of the one-way clutching arrangement.
The drive barrel 56 acts through the drive lugs 58 and the inner and outer cam barrels 52 and 54 to drive the thruster 38 in an axially reciprocating motion. The clothes and water within the basket 24 provide the restraining force required on the thruster 38 to prevent its rotational movement, thus forcing the rotational movement of the drive barrel to be changed into vertical motion of the thruster. To provide additional friction to overcome any reverse rotational forces and to reduce the amount of friction required of the clothes load in the basket, a plurality of resilient fingers 86 are provided around the periphery of the driving barrel 56 which engage with an inner surface 88 of the thruster 38.
As seen in FIGS. 6, 7 and 8, the driving barrel 56 is nested between the outer cam barrel 52 and the inner cam barrel 54. The outer cam barrel 52 has a cam surface 90 which is arranged in a spiral manner through the cylindrical wall 52a of the outer cam barrel 52. The cam surface 90 may be arranged about the inner surface of the outer cam barrel 52 if desired. The inner cam barrel 54 has a cam surface 92 arranged in a spiral manner about the exterior surface of the inner cam barrel 54 and in a reverse spiral direction from the cam surface 90 of the outer cam barrel 52. The cam surfaces 90, 92 alternately receive the drive lugs 58 as the agitator rotates. The drive lugs are transferred from engagement with the cam surface 90 of the outer cam barrel 52 to the cam surface 92 of the inner cam barrel 54 and back again by means of ramps 94 and 104 located at transfer areas over the inner and outer cam barrels. The cam surfaces 90, 92 can be of various configurations to provide a selected period of reciprocation within a wide range of periods.
As shown in FIG. 6, when the thruster is in its lowermost position (FIG. 2) the drive lugs 58 are positioned in engagement with the cam surfaces 92 of the inner cam barrel 54. Ramp surface 96 of the outer cam barrel 52 transfers the drive lug 58 from engagement with cam surface 90 into engagement with the cam surface 92 of the inner cam barrel 54 as the driving barrel 56 rotates relative to the inner and outer cam barrels. A radially outer end 94 of the driving lug 58 engages ramp surface 96 and forces lug 58 inwardly to the position shown. An interfacing ramp surface 98 in the inner cam barrel 54 allows for receipt of the driving lug 58.
As the driving barrel 56 continues to rotate in the clockwise direction indicated by arrow 99, the drive lugs are caused to move along the cam surface 92 of the inner cam barrel 54 thereby urging the inner cam barrel 54 in an upward direction carrying the entire thruster 38 upwardly. As the thruster approaches its uppermost position, the drive lugs 58 are transferred into the position shown in FIG. 7 by a ramp surface 100 in the inner cam barrel 54 by means of the radial engagement between the ramp surface 100 and a radially inward end 102 of the cam lug 58. An interfacing ramp surface 104 in the outer cam barrel 52 allows for receipt of the drive lug 58 into engagement with the cam surface 90 of the outer cam barrel 52. At this point the thruster 38 would be in its highest position as shown in FIG. 5.
As the agitator continues to oscillate and the drive barrel 56 continues to rotate in a clockwise direction, the drive lugs 58 in engagement with the cam surface 90 of the outer cam barrel 52 will cause the outer cam barrel 52 and thus the entire thruster assembly 38 to move downwardly until the thruster assembly has reached its lowest position as shown in FIGS. 2 and 6. This up and down movement will be continuously repeated.
As seen in FIG. 5, the thruster assembly 38 is comprised of the driving barrel 56 captured between the inner cam barrel 54 and outer cam barrel 52. An outer thruster shell 106 encompasses the entire assembly and a removable cap 108 provides a cover. The outer cam barrel 52 is permanently secured to the outer shell 106 to comprise essentially a single unit. The inner cam barrel 54 is indexed by a plurality of pins 109 (one being shown) and secured coaxially with the outer cam barrel 52 by means of a retaining means or snap ring 110 such that the transfer areas consisting of the interfacing ramps are aligned. The thruster vanes 40 are comprised of a main vane 112 which extends generally vertically downwardly and then curves as at 114 to a downwardly sloped region which curves again at 116 into a more vertically downwardly disposed section. A plurality of vertically downwardly disposed fingers 118 are provided beneath the sloped portion of the main vane 112.
As the thruster reciprocates up and down, the thruster vanes drive the clothes downward along the agitator barrel to the pumping vanes 36 at the lower portion of the agitator 26. The sloped portion of the thruster vane allows the thruster to move upwardly without pulling clothes with it and the downward dependent finger portions 118 assist the vanes in driving the clothes downwardly while the thruster is moving in a downward direction.
Thus, an agitator thruster for an automatic washer agitator is provided wherein the reciprocating motion in the thruster is obtained by inner and outer cam surfaces wherein a driving barrel has lugs which alternately transfer to the inner and outer cam surfaces.
As is apparent from the foregoing specification, the invention is susceptible of being embodied with various alterations and modifications which may differ particularly from those that have been described in the preceding specification and description. It should be understood that I wish to embody within the scope of the patent warranted hereon all such modifications as reasonably and properly come within the scope of my contribution to the art. | An agitator thruster is provided for an automatic washer for increasing the rollover of clothes during the agitation portion of a washing cycle wherein the thruster moves in a vertical reciprocating motion by using inner and outer reversely spiraled cam surfaces and a driving barrel having a driving pin which alternately transfers to the inner and outer cam surfaces. | 3 |
FIELD OF THE INVENTION
This invention relates to improvements in toilets and more particularly to a self ventilating toilet adapted to remove the fumes and odors from the bowl and discharge the same into the waste pipe.
BACKGROUND OF THE INVENTION:
Various forms of structures have been heretofore provided for venting objectionable odors from within toilet bowls.
However, some of these structures cannot meet the minimal safety electrical standards required in bathrooms for certain regions.
Canadian Patent 3,120,006 and U.S. Pat. No. 1,972,774 are patents disclosing toilet bowl ventilating systems which could prove to be potentially dangerous because an electrical wire is exposed and connected by a wall plug.
Indeed, since the extension chord supplying power to the ventilation units is not fully enclosed and is therefore exposed to the humid environment of the bathrooms, previously cited structures cannot be considered safe for people using them.
Furthermore, some of the above-mentioned patents disclose structures which require costly installation procedures.
Canadian Patent 1,012,304 in an example of a patent disclosing a structure which would require setting up of a duct system in the wall of the bathroom.
SUMMARY OF THE INVENTION
The invention relates to a self ventilated toilet which is adapted to be mounted on the floor of a bathroom. The floor must be provided with a first perforation connected to a sewage connecting line and a second perforation allowing an electrically conducting wire to extend through the floor.
The ventilated toilet features a bowl chamber adapted to contain water which will be flushed through a flushing aperture which is provided at the bottom of the bowl. A discharge passage is connected to the flushing aperture.
The discharged passage is disposed adjacent the bowl chamber and extends to a first outlet situated below the bowl for eliminating the flushed water through the first perforation.
A ventilating chamber is mounted adjacent the discharge passage and leads through the first outlet. A least one ventilating inlet aperture is provided in the bowl and located above the water in the bowl.
The ventilating inlet apertures pneumatically link the bowl with the ventilating chamber. An electrical air suction device isdisposed across the ventilating chamber between the ventilating aperture and the first outlet for circulating the air from the ventilating aperture through the first outlet.
A conduit adapted to receive the electrical wire is also provided. The electrical wire is adapted to electrically actuate the suction device. The conduit is located adjacent the ventilating chamber and extends upwardly between the suction device and a second outlet which is positioned below the bowl.
The second outlet is adapted to face the second perforation provided in the floor. The electrical wire is therefore adapted to extend through the floor below the bowl and the suction device is adapted to expel the air through the sewage connecting line.
In one embodiment of the invention, the electrical suction device comprises an electrical fan and a set of guiding fins which extend from the fan in the direction of the first aperture whereby the guiding fins limit the air turbulence inside the ventilating chamber and promote air circulation toward the first aperture.
In another embodiment of the invention, the suction device comprises a hinged flap which prevents the air from circulating from the first outlet to the ventilating aperture thus backing up into the bowl chamber. In an alternative embodiment of the invention the suction device comprises an electro-magnetic valve for operating the flap. The hinged flap can be kept in a normally closed position by a counterweight and is opened by the flow of air emanating from the fan. The fan can be either of an axial or a centrifugial type.
The ventilating chamber has a generally upstanding peripheral wall. The conduit for receiving the electrical wire is characterized by a channel extending substantially vertically in the body of the peripheral wall.
The ventilating chamber is preferably provided with a removable cover allowing access to the suction device.
Accordingly, the present invention relates to an improved self ventilating toilet which will draw the fumes and odors from within the bowl and discharge the same through the drain pipe.
Another object of this invention is to provide a self ventilating toilet whereby, the electrical chord supplying power to the ventilation unit is fully enclosed and therefore protected against the humid environment often present in bathrooms, thus making the self ventilating toilet safe against electrical shocks.
A still further object of this invention is to provide a self ventilating toilet which can be readily and easily installed at low cost and which uses the same drain pipe arrangement as a conventional toilet, thus allowing for easy replacement of a conventional toilet by the present self ventilating toilet.
Another object of this invention is to provide a ventilating system for toilet bowls which is so arranged and incorporated in the toilet bowl structure as to be fully enclosed therein without unduly altering the symetrical and more or less conventional exterior appearance of the toilet bowl structure so that a neat and compact appearance is maintained.
A still further object of this invention is to provide a self ventilating toilet which will conform to conventional manufacturing methods, be of simple construction and easy to use, economical, long lasting and relatively trouble free in operation.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of the ventilated toilet bowl;
FIG. 2 is a side view of the bowl shown in FIG. 1;
FIG. 3 is a horizontal cross-sectional view taken along line 3--3 of FIG. 2;
FIG. 4 is a vertical cross-sectional view taken along line 4--4 of FIG. 2;
FIG. 5 is a cross-sectional view taken along line 5--5 of FIG. 3;
FIG. 6 is a horizontal cross-sectional view taken along line 6--6 of FIG. 5;
FIG. 7 is a horizontal cross-sectional view taken along line 7--7 of FIG. 4;
FIG. 8 is a perspective view of a cover located at the upper rear end of the bowl;
FIG. 9 is a cross-sectional view taken along line 9--9 of FIG. 2; and,
FIG. 10 is an enlarged view of the installation of the fan shown in FIG. 5.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The ventilated toilet 10 has a body 12 which is cast as an integral structure, and is shaped interiorly to provide an upwardly open bowl chamber 14 having a flushing aperture 13 leading to a siphonic discharge passage 16. The body 12 is adapted to rest on the floor 18 of a bathroom. The discharge passage 16 is hydraulically connected to a sewage collecting line 20 through an outlet 17 provided in the bottom of the body 12. The collecting line 20 opens upwardly through the floor 18. A pivoted seat 22 and a pivoted seat lid 24 are both hinged to the body 12.
In addition, a conventional water tank 26 is operatively associated with the bowl chamber 14 in a conventional manner for discharging flushing water into the bowl chamber 14.
The flushing water leaves the tank 26 through an opening 28 and enters a water intake chamber 30. The chamber 30 communicates hydraulically with an annular water passage 32 extending around the upper marginal portion of the bowl chamber 14. The annular water passage 32 leads to a flushing conduit 34 which delivers flushing water to the bowl 14 through an opening 36 provided at its base. A set of discharge opening 35 provided inside the annular passage 32 serves to discharge cleansing water over an interior surface 33 of the bowl chamber 14.
The bowl tapers down at the back to form a housing 38 enclosing the discharge passage 16 and a ventilating system 40. The ventilating system 40 includes an air chamber 42, a blower assembly 44, an air duct 46 and an electrical extension cord conduit 48.
The housing 38 is provided with a removable cover 39 allowing access to the blower assembly 44 for installation and repairs. The cover 39 is safely held in place by the tank 26 which partially rests on it and which must be removed prior to the removal of the cover 39.
The cover per se 39 is illustrated in FIG. 8 and is shown in its installed position in FIGS. 2, 3 and 4. It is retained to the bowl by a pair of tongues 37 located at the lower end of the cover and by its horizontal portion which hooks onto the bowl.
The fumes emanating from the bowl chamber 14 are drawn into the air chamber 42 by the blower assembly 44 along the arrows A through an air inlet aperture 50 provided through the back of the interior wall 33 above the discharge passage 16.
The fumes move rearwardly from the aperture 50 in the direction of arrow A (in FIG. 5), towards each side of the water intake chamber 30 and progresses upwardly in the channel 53 defined by walls 55 and 57. The path followed by the water comes out of the water intake chamber at a level lower than horizontal part of the inlet aperture 50. It is split by the partition wall 51 and progresses toward the lateral passages 32. The entrance of the inlet aperture 50 is substantially vertical to prevent solid matters to enter the aperture 50. The air inlet is superposed over the opening 28 of the outer chamber 30 (see FIG. 9).
This particular arrangement of the air passage from the bowl 14 to the air chamber 42 prevents an overflow of water in the bowl from reaching the air chamber. The channel 53 opens up at a level higher than the maximum level of the water in the bowl 14. This is particularly due to the upper leading edge 59 of the wall 57 which can be set at a higher level than the upper edge of the bowl.
The blower assembly 44 subsequently forces the fumes through the air duct 46 towards an air outlet 52 which discharges into the sewage collecting line 20. The air duct 46 is defined by a back wall 54 a front wall 57 corresponding to a wall of the discharge passage 16 and a pair of side walls (not shown).
The blower assembly 44, as particularly shown in FIG. 10 includes an electrical rotary motor 58 coupled to a centrifugal fan 60 linked to an air guiding case 61. An electro-magnetic valve 41 is mounted at the exit of the case 61. The electro-magnetic valve is provided to prevent the fumes from backing up into the bowl 14 when the blower assembly 44 is not in use.
The fan 60 is provided with a lateral rim 66 allowing it to rest on an edge 68 defined in the back wall 54 and the discharge passage wall 57. Sealing material such as silicone is positioned between the rim 66 and the edge 68 in order to provide a sealing action between the case 66 and the edge 68.
The air guiding case 61 extends from the fan 60 into the air duct 46. The guiding fins 62 direct the flow of air, therefore, limiting air turbulence and increasing the efficiency of the blower assembly 44.
Power to the electric motor 58 is provided through an extension cord 74. The extension cord 74 originating from a power supply, not shown, extends through a first aperture 76 in the floor 18 into an outlet 78 in the bottom of the body 12 leading to the extesion cord conduit 48 from which it exits through a sealing ring 80. The sealing ring 80 closes the passage 48 adjacent the air chamber 42.
One of the main features of the present invention is the extension cord conduit 48 which consists of a substantially upstanding passage which is self-contained, distinct from the substantially upstanding air duct 46 but longitudinally adjacent the latter. The conduit or channel 48 preferably extends upwardly inside the back wall 54 and fittingly surrounds the extension cord 74.
Since the extension cord 74 is not exposed to the air in the air duct 46 nor to water, the ventilating system meets safety standards which require that electrical systems be fully enclosed when operated inside a bathroom.
Another feature of the present invention is its ability to use a conventional drain pipe 20.
The installation therefore only necessitates the drilling of the aperture 76 in the floor 18 allowing passage of the extension cord 74.
The manner in which the present ventilated bowl is installed only requires that a predetermined length of extension cord 74 be pulled up through the aperture 76. Such predetermined length is introduced through the outlet 78 and slidden in the passage 48 while the body 12 is vertically lowered in the collecting line 20 in the usual manner. | A ventilated toilet having a water discharge passage is mounted over a sewage connecting line. The latter line is also connected to a ventilating chamber for receiving air from the bowl chamber through an electrical suction device. The electrical cord supplying the suction device extends through a self-contained passage adjacent the ventilating chamber for isolating the cord from the ventilating chamber. | 4 |
FIELD OF THE INVENTION
The present invention relates to a flexible forming device for forming three-dimensional shaped workpieces, which belongs to the field of plastic forming.
BACKGROUND OF THE INVENTION
At present, the forming of three-dimensional shaped workpieces, such as plate-shaped, tube-shaped and bar-shaped workpieces, is realized by various press machines or specialized machine tools with the assistance of specialized dies. The completion of each type of shaped workpieces requires a set or sets of dies. The designing, manufacturing and adjusting of these dies consumes a great amount of manpower, material resource as well as time. Moreover, the traditional forming device for forming three-dimensional shaped workpieces is automated to a low degree, thus its efficiency cannot meet the need of modernized industrial production. In addition, manual forming, which is unsatisfactory with its poor forming quality, low manufacturing efficiency and requirement of intensive labor, is mainly used for forming workpieces which are large in size and small in quantity.
In addition, without specialized dies, the continuous forming devices adopting current technologies can only form workpieces with straight generatrixes, such as various sheets, strips and profiles, while the forming of three-dimensional shaped workpieces is achieved mainly through die forming or manual production. When it is required to form tube-shaped or bar-shaped workpieces, especially those with varying diameters, special techniques such as spinning, roll forging as well as cross-wedge rolling, are usually applied, which have a much high cost and require a long processing period. Moreover, workpieces with different shapes require different dies when using various forming devices, thus urging a long preparation cycle with a lot of manpower, material resource consumed and a low degree of automation, which could not meet the need of modernized production of small quantity.
SUMMARY OF THE INVENTION
In view of the above facts, an object of the present invention is to change the traditional forming process using special dies to form three-dimensional workpieces, and provide a flexible forming device for forming three-dimensional shaped workpieces based on a technology of bendable flexible roll forming, which can fulfill the forming of many types of three-dimensional shaped workpieces, such as plate-shaped, tube-shaped and bar-shaped workpieces, etc. Compared with the traditional die forming technology, the flexible forming device can greatly reduce the production cost, increase the production efficiency, and thus achieve automatic control in a more convenient way.
To achieve the above object, the present invention provides a flexible forming device for forming three-dimensional shaped workpieces, comprising a frame, at least two working rollers, one or more working roller driving mechanisms and one or more adjusting mechanisms. The at least two working rollers, the one or more working roller driving mechanisms and the one or more adjusting mechanisms are installed on the frame, respectively, so that a blank to be formed can be clamped between the working rollers. The blank can be formed into a three-dimensional shaped workpiece under the rolling action of the working rollers, wherein at least one of the working rollers is a flexible working roller, which is bendable and adjustable.
The flexible forming device in the present invention adopts at least two working rollers, which can be arranged according to certain rules, to perform a forming process of three-dimensional shaped workpieces, such as plate-shaped, tube-shaped and bar-shaped workpieces, etc. In the present invention, the relative position between the working rollers as well as the bendable axis of the flexible working roller can be adjusted by the adjusting mechanism, and can be located at any selected position. Therefore, it can form any type of three-dimensional workpieces in accordance with the shape of workpieces required. Elastic materials such as steel wire flexible axle, spring, steel wire flexible axle-polyurethane, spring-polyurethane and polyurethane, etc. can all be applied to the flexible working roller. The working rollers can be divided into active rollers, passive rollers and brake rollers. The active rollers drive the workpiece to be formed to pass through between the working rollers by the driven rotation of the active rollers. The passive rollers are brought into rotation by the formed workpiece. The brake rollers are not able to rotate in a braked state but can be brought into rotation by the formed workpiece in the same way as the passive rollers in a non-braked state.
The working roller driving mechanism can be a regular transmission mechanism such as a gear mechanism, a hydraulic mechanism, etc. In addition, an anti-distortion device and an anti-loose device can be installed on the non-forming area of the flexible working roller.
The position change of the working rollers and the curvature change of workpiece forming can be achieved through mechanical or Numerical Control (NC) means, which can also be applied to the rotation of the working rollers and one or more workpiece clamping and spinning mechanisms.
Advantageously, the flexible working roller is made of one or more materials selected from steel wire flexible axle, helical spring, steel wire, polyurethane rubber, etc.
Advantageously, the flexible working roller is an integral working roller or a segmented working roller. The segments in the segmented working roller rotate synchronously or asynchronously, in the same or opposite direction.
Advantageously, one or more workpiece clamping and spinning mechanisms whose rotatable parts can rotate actively or passively are arranged at an end of the integral working roller or between the segments of the segmented working roller.
Advantageously, the flexible forming device is used for forming a tube-shaped workpiece, and comprises two flexible working rollers, one of which is located outside the tube-shaped workpiece, and the other one of which is located inside the tube-shaped workpiece.
Advantageously, the flexible working roller located inside the tube-shaped workpiece is configured to be a passive bendable roller or a simple elastic roller, so as to simplify the structure of the inside working roller and eliminate the need for adjustment.
Advantageously, the flexible forming device is used for forming a tube-shaped or bar-shaped workpiece, and comprises at least two flexible working rollers, all of which are located outside the workpiece in the circumferential direction, and the workpiece undergoes a diameter shrinking deformation along with the self-rotation and centripetal movement of the flexible working rollers.
Advantageously, the flexible forming device is used for forming a tube-shaped workpiece, and comprises at least two flexible working rollers, all of which are located inside the tube-shaped workpiece in the circumferential direction, and the workpiece undergoes a diameter expanding deformation along with the self-rotation and centrifugal movement of the flexible working rollers.
Advantageously, a plurality of adjusting mechanisms with adjustable height for supporting and adjusting the axis position and bendable degree of the flexible working roller are arranged on the bendable and adjustable flexible working roller, and the adjustment of the adjusting mechanism is achieved through pre-adjustment before the forming is started or consecutive adjustment whenever necessary during the forming process.
Advantageously, an open bearing is installed on an end of an adjusting rod of the adjusting mechanism, so as to adjust and support the flexible working roller, and the open bearing can swing its head in accordance with the change of the bending contour tangent of the flexible working roller.
Advantageously, the working roller driving mechanism is arranged on one or both ends of the working roller.
Advantageously, the flexible working roller consists of a plurality of sub-rollers with mutual independence, adjustable axis position, swayable axis angle (for example, the axis angle of the sub-roller can be swayed freely in accordance with the change of the transverse curvature of the workpiece), and the sub-rollers can be constructed as, according to the requirement, active sub-rollers, passive sub-rollers or brake sub-rollers. The sub-rollers can be displaced so that their positions are adjusted under the action of the adjusting mechanism, and can rotate through a certain angle and be located at any position, thus different curvatures in the longitudinal and transverse directions of the workpiece can be obtained through the change of relative position between the working rollers, the displacement or rotation of the sub-rollers of the working rollers. The change of the relative position between the working rollers and the displacement of the sub-rollers can be achieved through mechanical or hydraulic driving devices. In addition, the surface of the sub-roller can be made of steel or other metal materials, and polyurethane rubber sleeves can be attached to the surface of the sub-roller.
The flexible forming device in the present invention can be used to replace the traditional dies to realize the flexible forming task of various workpieces such as plate-shaped, tube-shaped and bar-shaped workpieces, etc. With reference to the flexible and changeable characteristics of the multi-point forming technology, the traditional two-dimensional forming technology and multi-roller forming technology, the flexible forming device in the present invention makes the straight rollers in the traditional forming device or the multi-roller forming device flexible. Thereby, the working rollers can be deformed flexibly in the longitudinal and transverse directions (with their axes bendable and adjustable). The bending of the working rollers can be achieved manually (adjusted before the forming process and remain unchanged throughout the process) or by an automatic adjustment under the control of a computer (adjusted before or during the forming process automatically). The degree of deformation or bending can be determined by the shape of the three-dimensional workpieces. This kind of forming can achieve consecutive forming of three-dimensional shaped workpieces, and yet compared with the traditional forming device using dies, the flexible forming device in the present invention has the following advantages: no requirement for special design, manufacture and adjustment of dies; a low manufacturing cost; a shortened preparation period for production; savings in manpower, material resource and time; and increased production efficiency.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will be better appreciated from the following description in more details made with reference to the illustrative embodiments shown in the drawings, in which:
FIG. 1 a is a schematic view of a three-roller flexible forming device according to a first embodiment of the present invention;
FIG. 1 b is a P-P direction view of FIG. 1 a;
FIG. 2 a is a schematic view of a two-roller flexible forming device according to the first embodiment of the present invention;
FIG. 2 b is a P-P direction view of FIG. 2 a;
FIG. 3 a is a schematic view of another type of two-roller flexible forming device according to the first embodiment of the present invention;
FIG. 3 b is a P-P direction view of FIG. 3 a;
FIG. 4 is a schematic view of a flexible working roller composed of a helical spring;
FIG. 5 is a schematic view of a flexible working roller composed of a helical spring and a polyurethane rubber sleeve;
FIG. 6 is a schematic view of a working roller with a steel wire flexible axle;
FIG. 7 is a schematic view of a flexible working roller composed of a steel wire flexible axle and a polyurethane rubber sleeve;
FIG. 8 is a schematic view of a flexible working roller composed of polyurethane rubber;
FIG. 9 is a schematic view of a flexible forming device composed of three bendable working rollers according to a second embodiment of the present invention, wherein each of the bendable working rollers is segmented into two segments;
FIG. 10 is a schematic view of a flexible forming device composed of three bendable working rollers according to the second embodiment of the present invention, wherein each of the bendable working rollers is segmented into two segments, and there is a workpiece clamping and spinning mechanism between the two segments;
FIG. 11 is a schematic view of a portion of the flexible forming device composed of three bendable working rollers according to the second embodiment of the present invention, wherein each of the bendable working rollers is segmented into two segments, and there is a workpiece clamping and spinning mechanism between the two segments;
FIG. 12 is an A-A section view of FIG. 9 , FIG. 10 and FIG. 11 ;
FIG. 13 is a B-B section view of FIG. 10 and FIG. 11 ;
FIG. 14 is a three-dimensional diagram of an adjusting mechanism;
FIG. 15 is a section view of a workpiece clamping and spinning mechanism;
FIG. 16 is a schematic view of a flexible forming device used to process three-dimensional shaped workpieces through two bendable working rollers according to a third embodiment of the present invention;
FIG. 17 is an A-A section view of FIG. 16 ;
FIG. 18 and FIG. 19 are schematic views of flexible forming devices used to process three-dimensional workpieces to shrink or expand a diameter of the workpieces through two bendable working rollers according to the third embodiment of the present invention;
FIG. 20 is a schematic view of a flexible forming device used to process tube-shaped three-dimensional workpieces through a bendable working roller and a simple elastic roller according to the third embodiment of the present invention;
FIG. 21 is a B-B section view of FIG. 20 ;
FIG. 22 and FIG. 23 are schematic views of flexible forming devices used to process three-dimensional shaped workpieces to shrink or expand a diameter of the workpieces through three bendable working rollers according to the third embodiment of the present invention;
FIG. 24 is a C-C section view of FIG. 18 and FIG. 22 ;
FIG. 25 is a D-D section view of FIG. 19 and FIG. 23 ;
FIG. 26 a is a schematic view of a flexible forming device having three sets of flexible working roller according to a fourth embodiment of the present invention;
FIG. 26 b is a P-P direction view of FIG. 26 a;
FIG. 27 a is a schematic view of a flexible forming device having two sets of flexible working roller according to the fourth embodiment of the present invention;
FIG. 27 b is a P-P direction view of FIG. 27 a;
FIG. 28 a is a schematic view of a sub-roller in FIG. 26 a and FIG. 27 a , wherein the surface of the sub-roller is made of steel or other metal materials;
FIG. 28 b is a side view of FIG. 28 a;
FIG. 28 c is a P-P direction view of FIG. 28 b;
FIG. 29 a is a schematic view of a sub-roller with a polyurethane rubber sleeve;
FIG. 29 b is a side view of FIG. 29 a ; and
FIG. 29 c is a P-P direction view of FIG. 29 b .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
First of all, referring to FIGS. 1 a - 8 , a flexible forming device according to the first embodiment of the present invention, which is mainly used for forming plate-shaped three-dimensional workpieces, will be described.
As shown in these figures, the flexible forming device adopts at least two working rollers arranged according to certain rules, so as to achieve a different curvature shape in the longitudinal direction of a plate-shaped workpiece (referred to “sheet” hereinafter) through the change of the relative position between the working rollers, and achieve different curvature forming in the transverse direction of the sheet through the deformation of the axis of the bendable working roller(s). In in the case where the relative position between the working rollers can be changed, and the shape of the axes of the working rollers can be adjusted, the consecutive forming condition for plate-shaped three-dimensional workpieces can be fulfilled. Thereby, if a sheet is led through between the working rollers under the rotation of the active roller, the object of sheet forming can be achieved. The change of relative position between the working rollers and the bending of the axis of the working roller can both be achieved through mechanical or hydraulic driving devices, etc. Workpieces with different curvatures can be formed as a result of the change of the relative position between the working rollers and different degrees of shape adjustment of the axes of the working rollers. Depending on different types of three-dimensional plate-shaped workpieces, the change of the relative position between the working rollers and the bending state of the axes of the working rollers can both be adjusted by mechanical means and by a computer, so as to fulfill the flexible forming of plate-shaped workpieces.
As shown in FIGS. 1 a - 3 b , according to a first embodiment, the flexible forming device of the present invention comprises a frame (not shown), at least two working rollers, one or more working roller driving mechanisms (not shown), and one or more adjusting mechanisms 3 , wherein the working rollers, the working roller driving mechanism(s) and the adjusting mechanism(s) are all installed on the frame. A blank to be formed (a plate-shaped workpiece or sheet 2 here) can be clamped between the working rollers, so as to undergo a plastic forming process under the rolling action of the working rollers, wherein at least one of the working rollers is a flexible working rollers, which is bendable and adjustable. The frame can be set up in various forms as well-known in the art in accordance with an actual requirement, so the detailed description on the frame is omitted here. The working roller driving mechanism can be a normal transmission mechanism, such as a gear mechanism, a hydraulic mechanism, etc. The flexible working roller can be made of one or more materials selected from steel wire flexible axle, helical spring, steel wire and polyurethane rubber. One or a plurality of adjusting mechanisms 3 used to support the flexible working roller and to adjust the position of the axis and bending degree are provided on the flexible working roller, wherein the adjusting mechanism 3 of the flexible working roller can be adjusted through pre-adjustment or consecutive adjustment during the forming process whenever necessary.
The flexible forming device as shown in FIG. 1 a and FIG. 1 b comprises three flexible working rollers 1 , which are arranged as shown in FIG. 1 b . The axis of the flexible working roller 1 can be adjusted through the adjusting mechanism 3 before or during the forming process. The axis of the flexible working roller 1 is presented in a bending state during the forming process, and when passing through between the flexible working rollers, the plate-shaped workpiece is deformed in the transverse direction under the shape-adjusting function of the axes of the working rollers (see FIG. 1 a ). In the meantime, it is deformed in the longitudinal direction under the pressures provided by the three flexible working rollers (by means of the change of the relative position) (see FIG. 1 b ). All the three flexible working rollers 1 can be active rollers; or any one or two of them can be active rollers, and the other(s) can be passive roller(s); or at least one of the passive rollers serves the function of a brake roller.
The flexible forming device as shown in FIG. 2 a and FIG. 2 b comprises two flexible working rollers 1 and 4 , i.e., an upper roller (the smaller working roller) and a lower roller (the larger working roller), which are arranged as shown in FIG. 2 b . The axes of the flexible working rollers can be adjusted under the action of the adjusting mechanisms 3 during or before the forming process. During the forming process, the axis of the flexible working roller 1 is presented in a bending state. When the plate-shaped workpiece passes through between the flexible working rollers, it is deformed in the transverse direction under the action of the adjusting function of the axis of the flexible working roller (see FIG. 2 a ). In the meantime, the lower roller is locally deformed under the action of the upper roller, thus causing a deformation of a part of the workpiece which sticks to the surface of the lower roller (see FIG. 2 b ).
Advantageously, a polyurethane rubber sleeve is attached to the lower roller or the lower roller is composed of polyurethane rubber and the diameter of the lower roller is larger than that of the upper roller. Both the upper roller and the lower roller can be made to be active, or one of them can be made to be active and the other one can be made to be passive.
The flexible forming device as shown in FIG. 3 a and FIG. 3 b comprises two working rollers 1 and 5 , i.e., a smaller working roller and a larger working roller, which are arranged as shown in FIG. 3 b . The smaller working roller is a flexible working roller which is bendable, and the larger working roller is a cylindrical elastic roller whose diameter is larger than that of the smaller working roller. Both the smaller and the larger working rollers can be made to be active rollers, or one of them can be made to be active and the other one can be made to be passive. The axis of the smaller working roller can be adjusted under the action of the adjusting mechanism during or before the forming process, and remain in a bending state during the forming process. Under the action of the smaller working roller, the shape of the larger working roller can be deformed but its axis can remain straight. When passing through between the smaller and larger working rollers, the plate-shaped workpiece is deformed in the transverse direction under the shape-adjustment action of the axis of the smaller working roller and the axially shape-adjustment action of the larger working roller (see FIG. 3 a ). In the meantime, under the action of the smaller working roller, the larger working roller undergoes a radial deformation. Thus, the workpiece is deformed in the longitudinal direction, and a deformation is caused of a part of the workpiece which sticks to the surface of the larger roller (see FIG. 3 b ).
Through the flexible forming devices as mentioned above, a plate-shaped workpiece 2 can be rolled into various shapes as required by the working rollers. This type of forming device needs no die, however, controlling of the working rollers is required during the forming process. The working rollers 1 and 4 can be constricted in the manners as shown in FIGS. 4 , 5 , 6 , 7 or 8 ; the working roller 5 can be constructed in the manner as shown in FIG. 8 .
In the present invention, the more working rollers there are, the better the effect of the forming will be, and there can be a variety of other rules for the arrangement of the working rollers other than those shown in FIGS. 1 , 2 and 3 , and the working rollers can also be arranged in accordance with the actual requirement.
Moreover, the more the adjusting mechanisms for the working rollers are involved, the better the effect of the forming will be.
The flexible forming device according to the second embodiment of the present invention, which is also used for forming three-dimensional plate-shaped workpieces, will be described below with reference to FIGS. 9-15 . This flexible forming device is basically similar in structure to that of the first embodiment, except that the flexible working rollers can be classified into two types: integral and segmented ones, while the latter can rotate synchronously or asynchronously, in the same or opposite direction. In addition, a variety of assistant mechanisms providing reliable control and adjustment for this flexible forming device are also set up respectively.
In the embodiment of FIG. 9 , an adjusting rod 14 (see FIG. 14 ) of the adjusting mechanism 3 can be regulated by manual control or a numerical control system according to the three-dimensional shape required by the plate-shaped workpieces, so that the open bearing 13 (see FIG. 14 ) pulls or presses the flexible working roller 1 and causes it to bend. An expansion unit can be set on one or both ends of the flexible working roller, to ensure its free expansion and contraction during the adjusting process. The working roller can be fixed after being adjusted to prevent further relative displacement in the axial direction and circumferential direction. In the meantime, to facilitate the deformation of the flexible working rollers, the flexible forming device may be provided with an upper frame and a lower frame. The lower frame is capable of moving all the working rollers as a whole, thus bringing the height positions of the working rollers to optimization. To reduce the distortion and anti-loose deformation of the flexible working rollers under the action of high torque, an anti-distortion and anti-loose device 11 can be installed in the non-forming area. After the adjusting process, a workpiece 2 can be placed in the flexible forming device and the flexible working roller 1 on the upper side can be pressed against the workpiece through the manipulation of the upper frame. When the working rollers rotate synchronously in the same direction and the workpiece is caused to move in the longitudinal direction, then the workpiece will be deformed in the longitudinal and transverse directions by increasing the press-down amount, so as to fulfill the three-dimensional surface forming. When the two segments of the working roller rotate synchronously in different directions, the workpiece will be caused to rotate and undergo a deformation process. When the two segments of the working roller rotate asynchronously, the workpiece will be moved in the longitudinal direction and will be rotated at the same time, and thus a complex deformation will be achieved.
Referring to the embodiment in FIG. 10 , the flexible working roller 1 on the upper side is pressed against the workpiece through manipulation of the upper frame. When the workpiece clamping and spinning mechanism 12 is not functioning, the forming process is shown in FIG. 9 . The workpiece 2 will be rotated with the workpiece clamping and spinning mechanism 12 as its axis and undergo a deformation process when the workpiece is clamped by the workpiece clamping and spinning mechanism 12 and the two segments of the working rollers rotate synchronously in different directions under the action of the driving mechanism.
In the embodiment with reference to FIG. 11 , the workpiece clamping and spinning mechanism 12 is pressed against the workpiece 2 , and then the workpiece 2 can be caused to rotate with the workpiece clamping and spinning mechanism 12 as its axis and can be deformed. The A-A section view of FIGS. 9-11 is shown in FIG. 12 , and the B-B section view of FIG. 10 and FIG. 11 are shown in FIG. 13 .
Deformation and even successive forming of a workpiece 2 can be made through the pressing and spinning of the working rollers. The adjustment of the shape and amount of the deformation can be fulfilled by adjusting the bent degree and press-down amount of the working rollers.
As mentioned above, there should be at least two working rollers in the present invention, while the involvement of three working rollers can result in excellent forming effects. Of course, the more the number of working rollers are involved, the better the forming effects will be, and the arrangement of these working rollers can be set as required.
The flexible forming device according to the third embodiment of the present invention will be described below with reference to FIGS. 16-25 , which distinguishes itself from those devices in the first and second embodiments in its exclusive application to tube-shaped and bar-shaped workpieces with variable diameters.
The flexible forming device as shown in FIG. 16 comprises two bendable working rollers, which are arranged as shown in FIG. 17 . The shape of the bendable working roller 1 can be adjusted through manipulation of an adjusting mechanism 3 . Driving of the bendable working roller 1 can cause a synchronous rotation as well as a three-dimensional deformation of a tube-shaped or bar-shaped workpiece 15 .
In the embodiment with reference to FIGS. 18 and 19 , two bendable working rollers 1 can be arranged as required by different workpieces to be formed. According to the shape of the workpieces required, an adjusting mechanism 3 can be employed to regulate the shape of the bendable working roller 1 , and the two working rollers undergo a centripetal or centrifugal movement and approach the outer surface of the tube-shaped or bar-shaped workpiece or the inner surface of the tube-shaped workpiece. In the meantime, driving the bendable working roller 1 can rotate a tube-shaped or bar-shaped workpiece 15 synchronously, thus causing a diameter expanding or shrinking deformation of the tube-shaped or bar-shaped workpiece 15 .
In the embodiment shown in FIG. 20 , a flexible forming device comprises a rigid working roller 5 with an elastic sleeve and a bendable working roller 1 , which are arranged as shown in FIG. 21 and exercise pressure on the workpiece from both the internal and external sides. The shape of the bendable working roller 1 can be regulated through manipulation of an adjusting mechanism 3 according to the shape of the workpiece required. Driving of the bendable working roller can rotate a tube-shaped workpiece 15 synchronously, thus causing a three-dimensional deformation of the tube-shaped workpiece 15 .
In the embodiment shown with reference to FIGS. 22-25 , a flexible forming device comprises three bendable working rollers 1 , which are arranged as shown in FIG. 22 or 23 depending on different workpieces required to be formed. According to the shape of the workpiece required, the shape of the working rollers 1 can be regulated through an adjusting mechanism 3 . The three working rollers undergo a centripetal or centrifugal movement and approach the outer surface of the tube-shaped or bar-shaped workpiece. In the meantime, driving of the bendable working rollers 1 can rotate the tube-shaped or bar-shaped workpiece 15 synchronously and gradually press the tube-shaped or bar-shaped workpiece 15 to cause a diameter expanding or shrinking deformation of the workpiece 15 .
Similarly, the forming effect will be better if there are more working rollers, and in addition to the arrangement rules shown above, any other arrangements known to those skilled in the art or arrangements according to the actual requirement can be adopted. At least one of the working rollers shall be active, leaving the others to be passive or brake rollers. A flexible forming device with independently driven sub-rollers as shown FIGS. 26 a and 26 b comprises three flexible working rollers 1 , which are arranged as shown in FIG. 26 b . Each working roller comprises a plurality of sub-rollers, each of which can be regulated through an adjusting mechanism 16 . Each sub-roller can cause a deformation of the workpiece in the longitudinal and transverse directions correspondingly. The arrangements of the sub-rollers can adopt any one of the various manners as shown in FIGS. 28 a - 29 c , wherein the reference sign 17 refers to a sub-roller of metal material, the reference sign 18 refers to a hinged shaft, the reference sign 19 refers to a working roller driving means comprising a motor and a reducer, and the reference sign 20 refers to a sub-roller with a polyurethane rubber sleeve.
The flexible forming device with independently driven sub-rollers as shown FIGS. 26 a and 26 b comprises three flexible working rollers 1 , which are arranged according to the rule shown in FIG. 26 b . Each working roller consists of a plurality of sub-rollers, each of which can be regulated through a adjusting mechanism 16 , each sub-roller can cause a deformation of the workpiece in the longitudinal and transverse directions correspondingly; the arrangements of the sub-rollers can adopt any one of the various manners as shown in FIGS. 28 a - 29 c , wherein the reference sign 17 refers to a sub-roller of metal material, the reference sign 18 refers to a hinged shaft, the reference sign 19 refers to a working roller driving means comprising a motor and a reducer, and the reference sign 20 refers to a sub-roller with a polyurethane rubber sleeve. A flexible forming device with independently driven sub-rollers shown in FIGS. 27 a and 27 b comprises a working roller 1 and a highly elastic working roller 4 . The working roller 1 is composed of a plurality of sub-rollers, each of which can be regulated through an adjusting mechanism 16 . The highly elastic working roller 4 can undergo a radial deformation under the action of the working roller 1 , thus causing a deformation in the longitudinal and transverse directions of the workpiece.
The invention has been described in detail in combination with some embodiments as mentioned above. Obviously, the contents described above and shown in the drawings should be understood to be only illustrative, and not intended to limit the scope of the present invention. Various modifications or changes can be made on the basis of the concept of the present invention for one skilled in this field. For example, although some examples for forming plate-shaped, tube-shaped or bar-shaped workpieces using the flexible forming device have been shown, other three-dimensional shaped workpieces with complex shapes can also be processed by the flexible forming device of the invention. For example, although some illustrative embodiments with two or three working rollers are shown in the description, one skilled in this field can freely choose any other number numbers of working rollers as well as the arrangements thereof according to actual requirement. Obviously, all these changes or modifications will not depart from the scope of the present invention. | A flexible forming device for forming three-dimensional shaped workpieces, comprising a frame, at least two working rollers, one or more working roller driving mechanisms and one or more adjusting mechanisms, wherein the working rollers, the one or more working roller driving mechanisms and the one or more adjusting mechanisms are installed on the frame respectively. At least one of the working rollers is a flexible working roller, which is bendable and adjustable. The forming device need not use mold and can realize the continuous formation of a three-dimensional curved surface of a plate-shaped workpiece, and the gradual formation of a tube-shaped or bar-shaped three-dimensional shaped workpiece. The forming device can save manpower, material and time. | 1 |
BACKGROUND OF THE INVENTION AND PRIOR ART STATEMENT
This invention relates to a process for the manufacture of knotlessly braided nets according to the quadruple flyer wheel principle, in which the net mesh forming the net shanks comprises three, four, six or eight threads. The knotlessly braided net is used especially in the manufacture of fishing devices.
The so-called quadruple flyer wheel principle for the manufacture of four-threaded, knotlessly braided nets is known from DD-PS Nos. 30922, 43176 and 86061. It is characterized by the fact that a multiplicity of braiding heads are provided next to each other for the manufacture of four-threaded net shanks, which in each case comprises four squarely arranged flyer wheels. Manufacture of the net shanks on each braiding head is carried out by rotation of four bobbins diagonally arranged towards each other in figure 8-shaped paths. The flyer wheels are provided with four rectangularly arranged recesses for receiving and transporting the bobbins.
Shunts are provided between the flyer wheels of adjoining braiding heads to produce the connection point between adjoining, four-threaded net shanks, over which passage of the bobbins from one braiding head to the adjoining one is accomplished.
In view of the arrangement and the number of flyer wheels in the quadruple flyer wheel principle, as well as the formation of the flyer wheels with four recesses, eight steps or 90° revolutions of the flyer wheels are recessary to manufacture one braid in the shank. The same number of steps is necessary to manufacture the connection point.
An arrangement for the manufacture of four-threaded, knotlessly braided nets (DD-PS No. 103 282) has been known, in which the individual braiding heads for the manufacture of the net shanks comprise three flyer wheels (triple flyer wheel principle). Manufacture of the net shank on a braiding head is accomplished by rotating four bobbins, arranged in pairs vis-a-vis each other, according to a predetermined plan. Each flyer wheel has four 90°-spaced recesses for the bobbins.
In view of the arrangement and the number of flyer wheels under the triple flyer wheel principle, the manufacture of one braid in a squarely cord-shaped net shank requires twelve steps or 90° turns of the flyer wheels. The connection point between two net shanks can be manufactured in three steps.
An arrangement and a method for the manufacture of three-threaded knotlessly braided nets has been further known (DD-PS No. 49967). Each of the flyer wheels has three recesses arranged at angles of 120° for receiving the bobbins (120° separation of the flyer wheels).
The disadvantages of this braiding arrangement are that three 120° revolutions of the flyer wheels are necessary to manufacture the connection point, such connection point considered far from ideal in the physical-textile sense.
Finally, DD-PS No. 137 606 discloses an arrangement, including a method for the manufacture of a six-threaded, knotlessly braided net. The net is characterized by the fact that each net shank comprises two adjoining, triple-threaded, plaited nettings, in which at each connection point each triple-threaded netting of one net shank crosses each triple-threaded netting of the other net shank. Manufacture of the net is carried out on a braiding maching wherein each braiding head comprises four flyer wheels and each flyer wheel has three recesses arranged at angles of 120°.
The disadvantage of this net is that braiding of all the six threads does not occur in the net shank.
The object of this invention is to simplify the technical method for the manufacture of three, four, six and eigth-threaded, knotlessly braided nets according to the quadruple flyer wheel principle and to eliminate the physical-textile shortcomings of known knotlessly braided nets.
SUMMARY OF THE INVENTION
The invention has the object of creating a method for the manufacture of knotlessly braided nets based on the quadruple flyer wheel principle, that is less costly and less technically complicated for the manufacture of net shanks and connection points, provided that the square cord form of the net shanks, as well as the path of the bobbins which has been predetermined through the braiding of the net shanks, is maintained on manufacture of the connection point.
The method of this invention for manufacture of knotlessly braided nets according to the quadruple flyer wheel principle, in which the net shanks forming the net mesh comprise three, four, six or eight threads, is characterized by the fact that manufacture of the net shanks is carried out by paths formed by the flyer wheels of the individual braiding heads that diagonally cross each other and that the connection point of the net shanks is produced at the passage of the bobbins over shunts provided between the flyer wheels of adjoining braiding heads.
Manufacture of the three-threaded net shanks occurs in the figure 8-shaped paths formed by two flyer wheels per braiding head, in which the flyer wheels are provided with four recesses at 90° angles for the bobbins, and that to produce the connection point, one begins with bobbin positions concentrated in the recesses between flyer wheels of adjoining braiding heads, in which creation of the connection point is accomplished after two 90° turns of the flyer wheels.
Manufacture of the four-threaded net shanks occurs in the figure 8-shaped paths formed by four squarely arranged flyer wheels per braiding head, in which the flyer wheels are provided with recesses arranged at 120° angles for the bobbin pairs, the figure 8-shaped paths of each braiding head that diagonally cross each other are formed by the flyer wheels that are diagonally opposite and a pair of bobbins revolves in each figure 8-shaped path.
Manufacture of the six-threaded net shank occurs in figure 8-shaped paths formed by four squarely arranged flyer wheels per braiding head, in which the flyer wheels are either provided with four recesses at angles of 90° or with three recesses at angles of 120° for the bobbin pairs, and in which one pair of bobbins revolves in a path formed by the flyer wheels and the two remaining bobbin pairs revolve in a path that diagonally crosses the first path.
A final feature of the invention is that creation of the connection point is accomplished by shifting the bobbin pairs to the flyer wheel of the adjoining braiding head corresponding to the respective individual bobbin pairs, after manufacture of the eight-threaded net shank in the figure 8-shaped paths formed by the four squarely arranged flyer wheels per braiding head, in which the flyer wheels are provided with four recesses at angles of 90° for the bobbin pairs.
This invention makes it possible to simplify the technical process for the manufacture of the connection point of three-threaded, knotlessly braided nets, in which the physical-textile qualities of the connection point are improved at the same time.
Concerning the four-threaded net, utilization of the quadruple flyer wheel principle as opposed to the triple flyer wheel principle is an advantage because less steps are required for the manufacture of the braid in the net shank, in combination with a reduction of steps in the production of the connection point from eight to five steps.
Another advantage of the proposed method for the manufacture of four-threaded nets is that only three recesses are necessary for receiving and transporting the bobbins. (Previously four recesses per flyer wheel in the quadruple flyer wheel principle were all that were known.) Due to the smaller technical requirements per flyer wheel, the possibility arises of utilizing larger spools with a higher capacity.
In view of the production of six-threaded, knotlessly braided nets, the invention makes it possible to manufacture a compact, cord-formed netting mesh.
By utilizing the proposed method for the manufacture of eight-threaded, knotlessly braided nets, it is possible to make the connection point compact, symmetrical and with advantageous physical-textile properties, whereby the sturdiness of the net, for instance as cod end material of dragnets, is substantially improved.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention is described in more detail in the next paragraphs with reference to the drawings.
FIGS. 1(A)-(I) illustrate a braiding head and step by-step manufacture of a three-threaded net shank;
FIGS. 2(A)-(I) illustrate two adjoining braiding heads and step-by-step manufacture of the adjoining net shank;
FIGS. 3(A)-(B) illustrate step-by-step manufacture of the connection point of two adjoining net shanks;
FIGS. 4(A)-(G) illustrate braiding head and the steps toward manufacture of one braid for a four-threaded net shank;
FIGS. 5(A)-(G) illustrate two adjoining braiding heads and the steps toward manufacture of adjoining four-threaded net shanks;
FIGS. 6(A)-(F) illustrate two adjoining braiding heads and the steps toward manufacture of the connection point between the adjoining net shanks;
FIGS. 7(A)-(I) illustrate braiding head wheel and step-by-step manufacture of a six-threaded net shank;
FIGS. 8(A)-(I) illustrate two adjoining braiding heads and the step-by-step manufacture of the adjoining net shanks;
FIGS. 9(A)-(I) illustrate step-by-step manufacture of the connection point of two adjoining net shanks;
FIGS. 10(A)-(G) illustrate braiding head and the step-by-step manufacture of a six-threaded net shank;
FIGS. 11(A)-(G) illustrate two adjoining braiding heads in the step-by-step manufacture of adjoining net shanks;
FIGS. 12(A)-(G) illustrate step-by-step manufacture of the connection point of two adjoining net shanks;
FIGS. 13(A)-(I) illustrate a braiding unit comprising two braiding heads and the step-by-step manufacture of the eight-threaded net shanks; and
FIGS. 14(A)-(I) illustrate a braiding unit comprising two braiding heads and the step-by-step manufacture of the connection point.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
FIGS. 1 to 3 relate to the manufacture of three-threaded, knotlessly braided nets.
FIG. 1(A) illustrates the braiding head 20 for the manufacture of a three-threaded net shank. The braiding head 20 comprises the flyer wheels 21 and 22, each provided with four recesses 25 arranged at 90° angles for receiving and transporting bobbins 1 to 3. The bobbins 1 to 3 revolve in the figure 8-shaped path formed by the flyer wheels 21 and 22. The turning direction of the flyer wheels is marked by arrows.
FIGS. 1(B)-(I) illustrate the step-by-step preparation of the net shank by 90° revolutions of the two flyer wheels 21 and 22. Bobbins 1 to 3 are again in their starting positions after eight steps, in other words, a braid is produced in the net shank after eight steps.
FIG. 2(A) illustrates a braiding unit comprising braiding heads 20 and 30. The braiding heads border on each other with their flyer wheels 21 and 22 or 31 and 32. FIGS. 2(B)-(I) illustrate step-by-step production of the two net shanks by eight 90° revolutions of the flyer wheels.
FIG. 3 relates to the production of the connection point between adjoining net shanks. For manufacture of the connection point, it will be feasible to start with positions of the bobbins 1 to 3 and 4 to 6 concentrated in the recesses 25 or 35 between the flyer wheels of adjoining braiding heads. The most feasible starting position for the passage of the bobbins for manufacture of the connection point is illustrated in the partial FIG. 2(C). From the step-by-step illustration of the connection point according to FIG. 3 (a, b), it can be seen that the connection point is completed after two 90° revolutions of the flyer wheels, after which manufacture of the net shank can be started again.
In contrast to the known principle for manufacture of three-threaded, knotlessly braided nets, in which the flyer wheels of the braiding heads are provided with recesses arranged at 120° angles, the method according to this invention distinguishes itself by reducing the steps for manufacture of the connection point from three 120° revolutions to two 90° revolutions of the flyer wheels. In addition, the method proposed by the present invention results in more advantageous physical-textile qualities.
FIG. 4(A) illustrates the braiding head 10 which comprises squarely arranged flyer wheels 11, 12, 13 and 14. Each flyer wheel has three recesses 15 arranged at 120° angles, over which the receiving and the transporting of bobbins 1 to 4 is accomplished. Bobbins 1 and 2 revolve in the figure 8-shaped path formed by flyer wheels 11 and 13, while bobbins 3 and 4 revolve in the path formed by flyer wheels 12 and 14. By the diagonal crossing of the threads revolving with the bobbins, the so-called square cord is produced. The direction of revolution of flyer wheels 11 to 14 is marked by arrows.
FIGS. 4(B)-(G) represent the steps, i.e. 120° revolutions of the flyer wheels for manufacture of the net shank. After six steps, a braid is produced in the net shank and the bobbins have reassumed their initial position.
In contrast to the known quadruple flyer wheel principle, the proposed principle distinguishes itself by the fact that the smaller number of recesses per flyer wheel results in longer traverses and thereby in increased operating velocities.
FIG. 5 represents a braiding unit that comprises two braiding heads 10 and 20. The braiding heads are arranged adjacent one another in such a way that, in each case, two flyer wheels 13, 14 and 23, 24 contact adjoining braiding heads.
FIGS. 5(B)-(G) represent the manufacture, step-by-step, of two adjoining net shanks through six 120° revolutions of the flyer wheels.
FIG. 6 illustrates the manufacture of the connection point of two adjoining net shanks. The starting position of the bobbins in FIG. 6(A) corresponds to the starting position of the bobbins in the upper portion of FIG. 5(A). The transfer of the bobbins from one braiding head to the adjoining braiding head occurs in the figure 8-shaped paths formed by the flyer wheels. From the step-by-step representation in FIGS. 6(B) to 6(F), it can be seen that manufacture of the connection point is completed after five steps and that the sixth step already represents the first step toward the subsequent manufacture of the net shanks.
The advantage of producing the connection point according to the principle proposed in this invention is that the number of steps for the manufacture of the connection point is reduced from eight to five, as opposed to the known quadruple flyer wheel principle.
FIG. 7(A) illustrates a braiding head 20 for the manufacture of a six-threaded net shank. The braiding head 20 comprises four ilyer wheels 21 to 24, each provided with four recesses 25 at 90° angles for receiving and transporting bobbins 1 to 6. According to the method proposed by this invention, a pair of bobbins 1, 4 revolve in the figure 8-shaped path formed by the two flyer wheels 22, 23, while two pairs of bobbins 2, 5 and 3, 6 revolve in the figure 8-shaped path formed by the flyer wheels 21, 24 that crosses the first-mentioned path in a diagonal direction. The direction of revolution of the flyer wheels is marked by arrows. FIGS. 4(B)-(I) illustrate the manufacture, step-by-step, of the net shank through 90° revolutions of the flyer wheels 21 to 24. After eight steps, the bobbins 1 to 6 have reassumed their initial position to begin manufacture of a new braid in the net shank.
FIG. 8(A) illustrates a braiding unit formed of the two braiding heads 20 and 30. Braiding head 20 comprises the flyer wheels 21 to 24, and braiding head 30 comprises the flyer wheels 31 to 34. The braiding heads are arranged adjacent one another in such a way that, in each case, two flyer wheels 23, 24 and 31, 32 adjoin each other. FIGS. 8(B)-(I) illustrate the manufacture, step by step, of the two net shanks through eight 90° turns of the flyer wheels.
FIG. 9 represents the manufacture of the connection point between two adjoining net shanks. For manufacture of the connection point, it will be feasible to start with the position of the bobbins corresponding to the initial position for manufacture of the net shanks. The bobbins 1 to 6 and 7 to 12 switch over to figure 8-shaped paths that run in a diagonal direction between the braiding heads 20, 30. From the step-by-step representation of the manufacture of the connection point according to FIGS. 9(B) to 9(I), it can be seen that manufacture of the connection point is already completed after six 90° turns of the flyer wheels (FIG. 9(G)), the two subsequent 90° turns of the flyer wheels illustrated in FIGS. 9(H) and 9(I) already representing the first steps toward manufacture of the new mesh shank.
FIGS. 10 to 12 illustrate the manufacture of a six-threaded, knotlessly braided net. FIG. 10(A) illustrates the braiding head 20 for manufacture of the six-threaded net shank. Braiding head 20, in turn, comprises four flyer wheels 21 to 24, each provided with three recesses 25 arranged at angles of 120° for bobbins 1 to 6. The path of bobbins 1 to 6 corresponds to the bobbin path according to FIG. 7, in which bobbins 1, 4 revolve in the figure 8-shaped path formed by the flyer wheels 21, 24 and the two pairs of bobbins 2, 5 and 3, 6 revolve in the figure 8-shaped path formed by the flyer wheels 22, 23, diagonally crossing the first path. The direction of revolution of the flyer wheels is marked by arrows. FIG. 10(B) to (G) illustrates the manufacture, step-by-step, of the net shank through 120° turns of the flyer wheels. A braid in the net shank is completed after six steps, i.e. six 120° turns of the flyer wheels.
FIG. 11 illustrates the manufacture of two adjoining, six-threaded net shanks on braiding heads 20 and 30. The remaining steps to be taken are those enumerated for FIG. 8. The only difference is that manufacture of the net shanks is completed after six steps, corresponding to the 120° separation of the flyer wheels.
Finally, FIG. 12 again illustrates manufacture of the connection point between two adjoining net shanks. Here the initial position of bobbins 1 to 6 and 7 to 12 will be the same as that at the beginning of manufacture of the net shanks. The switching of the bobbins between the braiding heads 20, 30 occurs in diagonal figure 8-shaped paths. The step-by-step manufacture of the connection points (FIGS. 12(B) to 12(G)) illustrates that the bobbins have switched positions after five 120° turns of the flyer wheels and that the connection point has been produced.
A comparison of the two manufacturing methods illustrated in FIGS. 7 to 9 and FIGS. 10 to 12 for six-threaded, knotlessly braided nets illustrates that both net shanks have the same construction, expenditures in setup for manufacturing the connection point in the method according to FIG. 9, being, however, less than of the method according to FIG. 12, i.e. six 90° turns, as compared to five 120° turns.
FIG. 13(A) illustrates a unit comprising two braiding heads 10 and 20 for the manufacture of two eight-threaded net shanks. Braiding head 10 is provided with the bobbin pairs 1', 2' to 7', 8'.
Each braiding head comprises four squarely arranged flyer wheels 11, 12, 13, 14 (braiding head 10) and 21, 22, 23, 24 (braiding head 20) (quadruple flyer wheel principle). The diagonally opposite flyer wheels (11, 13 and 12, 14 of the braiding head 10 as well as 21, 23 and 22, 24 of braiding head 20) form the figure 8-shaped paths in which the bobbin pairs revolve on braiding. The paths cross diagonally in each braiding head. Each flyer wheel is provided with four recesses 15 or 25 at right angles for receiving and transporting the bobbins.
The arrows illustrate the direction of revolution of the flyer wheels. Step-by-step manufacture (90° turns of the flyer wheels) of the figure 8-shaped net shanks is illustrated in the partial FIGS. 13(B) to 13(I). The individual partial figures illustrate the positions of the bobbins on both braiding heads 10 and 20 after one individual 90° turn of the flyer wheels. After eight steps (FIG. 13(I)) the bobbin pairs have again reached the initial position represented in FIG. 13(A), a braid in the net shank having been produced.
The initial position of the bobbin pairs for the manufacture of the net shanks also corresponds to the initial position of the bobbins for manufacture of the connection point between two eight-threaded net shanks (FIG. 14). FIG. 14(A) corresponds to FIG. 13(A).
According to the solution proposed by this invention, the switching of the pair of bobbins occurs in such a way that each pair of bobbins crosses to the adjoining braiding head over the corresponding flyer wheel, for instance
the pairs of bobbins 1, 2 and 3, 4 cross over flyer wheel 21 and
the pairs of bobbins 5, 6 and 7, 8 cross over flyer wheel 24
the pairs of bobbins 1',2' and 3',4' cross over flyer wheel 13 and
the pairs of bobbins 5',6' and 7',8' cross over flyer wheel 12.
After each pair of bobbins has crossed to the adjoining braiding head over the corresponding flyer wheel, the braiding process is continued with the braiding head paths diagonally crossing each other.
After eight steps, manufacture of the connection point is completed (FIG. 14(I)), the pairs of bobbins having assumed the initial position illustrated in FIG. 14(A). | The present invention is directed to a method for fabricating three, four, six, or eight-threaded knotlessly woven nets, which involves aligning at least a plurality of flyer wheels to form a braiding head, and then positioning two such braiding heads against one another. Bobbins are then positioned on recesses formed at discrete intervals along the circumference of said flyer wheels, and the bobbins are then rotated about said flyer wheels in figure-eight shaped fashion to weave a net shank. Then, the bobbins are rotated between the braiding heads in figure-eight shaped fashion to form a connection point between the net shanks. | 3 |
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority from U.S. Provisional Patent Application 61/946, 377 filed 2/28/2014, which is incorporated herein by reference.
STATEMENT OF GOVERNMENT SPONSORED SUPPORT
[0002] This invention was made with Government support under contract no. DE-SC0001060 awarded by the Department of Energy. The Government has certain rights in the invention.
FIELD OF THE INVENTION
[0003] The present invention relates generally to electrodes for high-performance energy conversion and storage devices. More particularly, the invention relates to a method of controlled radio-frequency hydrogen plasma to treat graphene and other two-dimensional layered materials, such as hexagonal boron nitride (hBN) and dichalcogenides such as molybdenum sulfide (MoS 2 ) for growing crystallographically oriented nanocrytals with catalytic properties and dielectric thin films using Atomic Layer Deposition, while retaining the graphene's intrinsic properties.
BACKGROUND OF THE INVENTION
[0004] Existing challenges in electrochemical energy conversion technology electrochemical energy-conversion devices, such as fuel cells and photoelectrochemical cells, face two main obstacles: significant overpotentials arising from surface kinetics and mass transport, especially at the Oxygen Reduction Reaction (ORR) in fuel cells and the Oxygen Evolution Reaction (OER) in water-splitting cells; and high catalyst mass loading that drives up costs and impedes the widespread adoption of these devices.
[0005] State-of-the-art commercial Pt/C cathodes for Proton Exchange Membrane (PEM) fuel cells exhibit specific Pt loading of 0.5 g/kW, arising from loading-per-functioning area of 0.5 g/cm 2 . While such fuel cells exhibit a high power density of 1W/cm 2 , they suffer from quick catalyst degradation, sluggish ORR with large overpotentials, and unsustainably large catalyst mass loading.
[0006] Graphene-like materials have been widely researched for electrochemical energy conversion devices, with claimed performances better than commercial Pt/Vulcan materials on some metrics.
[0007] In such a fast-moving field it is difficult to assess which routes are most promising, but it is seen that almost all existing schemes cannot maintain the most attractive features of graphene, such as high conductivity and carrier mobility. The main graphene-derived material studied so far has been Graphene Oxide (GO), a bulk material prepared through a sequence of harsh oxidation and reduction wet chemistry reactions. GO is economical but suffers from high resistivity due to numerous oxygen-containing defects. Moreover, the wet chemistry involved is often incompatible with further processing and large scale production necessary for eventual technological applications. At the same time, it is exactly these functional groups that provide GO with the ability to bond to catalyst nanoparticles and even facilitate oxygen anion transport, which pristine graphene cannot do on its inert basal planes.
[0008] Clearly, the ideal graphene material would overcome this trade-off. Such a material would have the necessary chemical functionalization but would retain pristine graphene's unique electronic and thermal transport properties.
[0009] What is needed is a material system that provides nanosized catalysts directly grown on chemically-activated graphene in a process that is cost-effective and entirely compatible with large-scale industrial production, in addition to preserving much of pristine graphene's outstanding properties, while activating the graphene toward catalyst-growth chemistry.
SUMMARY OF THE INVENTION
[0010] To address the needs in the art, a method of growing crystals on two-dimensional layered material is provided that includes reversibly hydrogenating a two-dimensional layered material, using a controlled radio-frequency hydrogen plasma, depositing Pt atoms on the reversibly hydrogenated two-dimensional layered material, using Atomic Layer Deposition (ALD), where the reversibly hydrogenated two-dimensional layered material promotes loss of methyl groups in an ALD Pt precursor, and forming Pt—O on the reversibly hydrogenated two-dimensional layered material, using combustion by O 2 , where the Pt—O is used for subsequent Pt half-cycles of the ALD process, where growth of Pt crystals occurs.
[0011] According to one aspect of the invention, the two-dimensional layered material can include graphene, hexagonal boron nitride, or dichalcogenides. In one aspect, the dichalcogenides can include molybdenum sulfide (MoS 2 ), or tungsten selenide (WSe 2 ).
[0012] In another aspect of the invention, the reversibly hydrogenated two-dimensional layered material is dehydrogenated prior to depositing the Pt using the ALD. In one aspect the dehydrogenating is done by annealing two-dimensional layered material under argon at 300° C.
[0013] To further address the needs in the art, according to one embodiment, a method of growing crystals on a two-dimensional layered material is provided that includes reversibly hydrogenating a two-dimensional layered material, using a controlled radio-frequency hydrogen plasma, depositing crystal-forming molecules on the reversibly hydrogenated two-dimensional layered material, using atomic layer deposition (ALD), where the reversibly hydrogenated two-dimensional layered material promotes loss of methyl groups in an ALD precursor, and forming crystal-O x on the reversibly hydrogenated two-dimensional layered material, using combustion by O 2 , where the crystal-O x is used for a subsequent half-cycle of the ALD process, where growth of the crystals occurs.
[0014] According to one aspect of the current embodiment, the two-dimensional layered material can include graphene, hexagonal boron nitride, or dichalcogenides. In one aspect the dichalcogenides can include molybdenum sulfide (MoS 2 ), tungsten selenide (WSe 2 ) or others.
[0015] According to another aspect of the current embodiment, the crystal-forming molecule includes Ti, where TiO 2 crystals are formed on the reversibly hydrogenated two-dimensional layered material.
[0016] In a further aspect of the current embodiment, the crystal-forming molecule includes Al 2 , where Al 2 O 3 crystals are formed on the reversibly hydrogenated two-dimensional layered material.
[0017] In yet another aspect of the current embodiment, the reversibly hydrogenated two-dimensional layered material is dehydrogenated prior to depositing the crystal-forming molecule using the ALD. In one aspect, the dehydrogenating is done by annealing two-dimensional layered material under argon at 300° C.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] FIGS. 1A-1C show reversible hydrogenation of graphene without damage: ( FIG. 1A .) atomic force microscopy image of 1L graphene on SiO 2 substrate, and ( FIG. 1B ) Raman spectra of hydrogenated and hygrogenated+dehydrogenated 1L grapheme; ( FIG. 1C ) AFM topography of monolayer graphene treated with remote hydrogen plasma in the same chamber to create numerous hole (Left: holes with diameters of 450 nm), (Right: holes with diameters of 20 nm and less), according to one embodiment of the invention.
[0019] FIGS. 2A-2D show scanning electron microscopy (SEM) images illustrating the dependence of the density of Pt nanoparticles on layer thickness, hydrogenation time, and dehydrogenation. As shown, ALD Pt 100 cycles on ( FIG. 2A ) hydrogenated (30s), ( FIG. 2B ) hydrogenated (30s)+dehydrogenated, ( FIG. 2C ) hydrogenated (120s), and ( FIG. 2D ) hydrogenated (120s) dehydrogenated graphenes. Here, 1L represents a monolayer, 2L represents a bilayer, and Multi L represents multi-layer grapheme, according to one embodiment of the current invention.
[0020] FIGS. 3A-3C show ALD Pt nanoparticle growth on chemically activated, i.e., hydrogenated, graphene support: ( FIG. 3A ), ( FIG. 3B ) atomic force microscopy images of 1-layer (1L) graphene. ( FIG. 3C ) Raman spectra of hydrogenated 1L grapheme before and after ALD, which shows suppressed D-band after ALD, according to one embodiment of the current invention.
DETAILED DESCRIPTION
[0021] The current invention uses controlled radio-frequency hydrogen plasma to treat graphene and then epitaxially grow various nanocrystals and dielectric thin films using Atomic Layer Deposition, while retaining the graphene's intrinsic properties.
[0022] The current invention is used in energy conversion and storage devices, such as fuel cells, solar cells, and photoelectrochemical water-splitting cells; for electronic devices that require the use of dielectric spacers and top gates; and for thermal transport devices. Further, the invention provides the ability to build hierarchical chemical structures on top of a graphene substrate for biological sensing and diagnostics, and chemical sensing.
[0023] This invention may solve crucial commercial problems in the near future, as graphene materials enter the industrial realm in areas such as fuel cells, electronics and sensors.
[0024] Existing methods of using graphene for the above-mentioned purposes generally require wet chemistry, such as harsh oxidation of graphene, which results in the loss of graphene's intrinsic properties. One embodiment of the current invention circumvents this problem and retains most of graphene's outstanding properties, such as electrical conductivity.
[0025] Moreover, the current invention does not require the use of solvents, oxidizers and high temperatures and is compatible with existing industrial processes in the semiconductor, photovoltaic and electrochemical industries. Finally, in one embodiment, the invention is able to control the growth parameters of the nanocrystals, such as size and density, by suitable treatment of the graphene surface. This invention is fully compatible with exfoliated graphene, Chemical Vapor Deposition (CVD) graphene, and chemically-derived bulk graphene materials. The methods used for epitaxial growth of nanocrystals on graphene are shown to be applicable to other layered materials of industrial importance, such as hBN and MoS 2 .
[0026] Other embodiments of the invention include tuning the hydrogen plasma treatment conditions: power, plasma species temperature and density, substrate pre-treatment, substrate orientation, and also by varying the Atomic Layer Deposition methods, such as temperature, pressure, precursor type and number of cycles. The invention provides control of key features of the growth process, such as size, density, crystallographic orientation and thickness.
[0027] A key embodiment of the invention is the achievement of epitaxial growth of nanocrystals on graphene and other two-dimensional materials, as directly observed by Scanning Transmission Electron Microscopy. The epitaxial interfaces will provide an added benefit to the stability and efficiency of nanosized catalysts and nanoparticles used to modulate thermal transport.
[0028] Another embodiment is the crystallographic orientation and faceting of the nanosized catalysts grown on these substrates that is expected to result in highly enhanced catalytic activity.
[0029] The current invention provides controllable hydrogenation of graphene basal planes without apparent sputtering of carbon atoms by energetic plasma species. The invention uses the different chemical reactivities of graphene sheets of different thicknesses to achieve tunable areal coverage, size and orientation of the grown nanosized catalysts.
[0030] According to one embodiment, the hydrogenation is reversible upon annealing under argon at 300° C. Raman spectroscopy, an inelastic light scattering technique widely used in graphene characterization, reveals that the so-called Raman “defect band” (D-band), is prominent after hydrogenation due to the formation of sp3 C—H bonds, but is almost entirely suppressed after dehydrogenation, as shown in FIGS. 1A-1C .
[0031] According to the current invention, this is the first time that dehydrogenated grapheme is near pristine electrically and structurally, and is strikingly chemically reactive, as evidenced in the ability to grow high areal densities of Pt nanoparticles by Atomic Layer Deposition (ALD) on graphene basal planes. Graphene basal surfaces were previously inert toward ALD growth, and until now, it was demonstrated that platinum ALD on graphitic surfaces (HOPG) exclusively produces particles on step edges, where on pristine grapheme, nanoparticles exclusively grew on the edges of sheets and step edges of multilayer grapheme sheets, according to the current invention.
[0032] The process of the current invention results in the unusual combination of enhanced chemical reactivity and near-pristine electrical properties. Based on initial work, it is believed that this material possesses properties not found in existing graphene composites: the graphene surfaces retain their conductivity, and their functionalization can be used as a control knob that directly influences the density and shape of catalyst nanoparticles.
[0033] While the exemplary embodiment includes using high-quality exfoliated graphene as a model system, other embodiments for electrode fabrication can include use of large-area CVD graphene and high-quality graphene laminates that approximate the intrinsic properties of pristine exfoliated graphene, while offering a bridge toward manufacturability. Further embodiments include the use of other two-dimensional materials such as hexagonal Boron Nitride and molybdenum disulfide, layered materials of great industrial importance.
[0034] The current invention provides a material system can overcome key challenges in fuel cell performance by allowing:
[0035] 1) nanodispersion of catalysts, and mass loading reduced by up to a factor of 10;
[0036] 2) reduction in device component sizes, leading to further cost savings; and
[0037] 3) mechanically robust, electrically conducting graphene supports that also offer chemical anchor sites for nanosized catalysts.
[0038] State-of-the-art commercial Pt/C cathodes for Proton Exchange Membrane (PEM) fuel cells exhibit specific Pt loading of 0.5 g/kW, arising from loading-per-functioning area of 0.5 g/em 2 . While such fuel cells exhibit a high power density of 1 W/cm 2 , they suffer from quick catalyst degradation, sluggish ORR with large overpotentials, and unsustainably large catalyst mass loading.
[0039] The current invention provides a method of cathode engineering that is capable of platinum mass activity of 0.1 g/kW or below, while maintaining high power density of ˜1 W/cm 2 , This method is further applied to cathode engineering in photoelectrochemical cells for watersplitting.
[0040] The resulting engineered graphene material according to one embodiment of the current invention possesses near-pristine properties and high chemical reactivity for nanosized catalyst growth and attachment. This combination makes the material an excellent candidate for electrochemical device electrode assembly.
[0041] In one embodiment, the invention uses process parameters to tune the surface properties and directly influence nanoparticle properties, such as density and size. The invention reveals a dependence of particle density and size on graphene layer thickness and degree of hydrogenation, as shown in FIGS. 2A-2D . Here, nanoparticle growth proceeds through a hydroxide-containing functional group tethered to the activated graphene, Where the Pt nanoparticles chemically bond to the graphene support. The molecular linker between the graphene plane and the platinum nanoparticles by are investigated by tip-enhanced Raman spectroscopy with a 10-n. resolution, The ability to allow passage of ions through the support is crucial in fuel cell applications, but pristine graphene membranes block almost all atoms and ions. The current invention uses a RF hydrogen plasma treatment that results in a range of hole sizes, including sub-10 nm pores in the graphene sheets.
[0042] Crucially, the pore formation retains the graphene sheets' physical integrity and the conductive path for carriers to be collected. The pores allow ion passage, while the graphene sheet collects carriers and serves as stable anchoring support for catalyst growth. Early calculations indicate that negatively charged oxide-ions can penetrate through the carbon rings of graphene and incorporate into positively charged vacancies at the electrolyte surface with a negligible activation energy barrier.
[0043] FIGS. 2A-2D show scanning electron microscopy (SEM) images illustrating the dependence of the density of Pt nanoparticles on layer thickness, hydrogenation time, and dehydrogenation. As shown, ALD Pt 100 cycles on (see FIG. 2A ) hydrogenated (30 s), (see FIG. 29 ) hydrogenated (30 s)+dehydrogenated, (see FIG. 2C ) hydrogenated (120 s), and (see FIG. 2D ) hydrogenated (120 s)+dehydrogenated graphenes. Here, 1L represents a monolayer, 2L represents a bilayer, and Multi L represents multi-layer grapheme, according to one embodiment of the current invention.
[0044] FIGS. 3A-3C show ALD Pt nanoparticle growth on chemically activated, i.e., hydrogenated, graphene support: (see FIG. 3A ), (see FIG. 3B ) atomic force microscopy images of 1-layer (1L) graphene. (see FIG. 3C ) Raman spectra of hydrogenated 1L grapheme before and after ALD, which shows suppressed D-band after ALD, according to one embodiment of the current invention.
[0045] The current invention benefits two classes of electrochemical devices: fuel cells and photoelectrochemical cells (PEC). Regarding fuel cells, one of the main challenges in fuel cells, especially those working at low temperatures, such as polymer electrolyte membrane fuel cells (PEMFC) and low-temperature solid-oxide fuel cells (SOFC), is the sluggish Oxygen Reduction Reaction (ORR) at the cathode. To compensate for the slow reaction kinetics of the ORR, a major effort is underway to increase the density of the so-called triple phase boundary (TPB), where the electrode, electrolyte and oxygen form an interface and where the reaction occurs. At the same time, Pt is the most efficient and most costly catalyst for ORR. Therefore, an efficient cathode structure formed by the current invention fulfills the following requirements: 1) large TPB density for fast electrochemical reaction rate; 2) large electrical conductivity for electron transport; 3) low Pt material loading and 4) good chemical/mechanical stability to be economically viable and stable for long-term operation. While a complete electrode made of Pt only is attainable by forming a continuous film structure, there is an inherent trade-off in such a structure between TPB density and electrical conductivity: increasing TPB, through formation of discrete particles, can only come at the expense of electrical conductivity. The current invention satisfies all these requirements with the graphene-Pt composites.
[0046] First, the TPB density on the graphene of the current invention can be as high as 0.4 nm/nm 2 , which is 8 times larger than that of a sputtered Pt electrode (0.05 nm/nm 2 , Pt-only electrode) for a low-temperature SOFC. Also, the electrochemical active surface areas (ECSA) of this graphene-Pt composite is higher than that of commercial Pt/C electrodes (26-55 m 2 /g for PEMFC) and higher than published ECSA of graphene oxide-Pt composites, given the fact that very high areal densities of Pt nanoparticles on graphene basal planes are achieved (more than 50% for single-layer graphene and more than 80% for multilayer graphene, figures that are remarkably high compared to that of commercial Pt-C electrodes). Second, the electrical sheet resistance can be still maintained at <300 Ω/, which is significantly lower than that of graphene oxide (>10 kΩ/), where (Ω/) is Ω/sq. Moreover, significant benefits from the reduced Pt mass loading are provided, which remains a challenge to fuel cell adoption due to the prohibitive cost of the Pt catalyst (˜50 /g). In a previous study, it was demonstrated that the Pt mass loading decreases by 8 times (0.16→0.02 mg/cm2, active cathode area) without sacrificing performance, by using ALD on low-temperature SOFCs. Pt mass loading can be further decreased down to less than 0.005 mg/cm2 with the use of our graphene-Pt composites with ALD Pt cycles of less than 50 cycles. This is also significantly lower than the Pt loading of commercial 100 kW-PEMFC for small-to-medium size vehicles (50 g/100 kW, ˜0.25 mg/cm 2 (active cathode area). By combining these advantages, PEMFC and low temperature SOFC are fabricated with extremely low
[0047] Pt loading of 0.005 mg/cm 2 , which means that the Pt loading of 100 kW-fuel cell could be as low as 1 g, compared with the current 50 g. Such a reduction, coupled with maintaining comparable energy densities as those of conventional automotive fuel cells today, leads to substantial cost savings.
[0048] In addition to fuel cells, an application for our graphene-Pt composite material in solar photoelectrochemical (PEC) hydrogen production exists. TiO 2 is considered one of the best photocatalytic materials due to its thermodynamic stability, strong oxidizing power, and relative non-toxicity. Under the UV irradiation, photo-induced electron-hole pairs are generated and the electrons then drive the watersplitting reaction to produce hydrogen. In water-splitting, the challenges include: 1) reducing the rapid recombination rate of electrons and holes in TiO 2 , and 2) reducing the large overpotential for the oxygen evolution reaction (OER). The current invention allows for fabricating dense TiO 2 nanoparticles via ALD on the functionalized graphene to address these issues.
[0049] First, the supporting graphene is an efficient electron transfer channel, which reduces the recombination of the photogenerated electron holes, and eventually leads to enhanced photoconversion efficiency compared to the graphene-oxide. The current invention provides for achieving a recombination rate comparable to that achieved on widely used transparent conducting oxide (TCO) substrates. Second, the overpotential for OER at the photoanode interface is reduced by the large density of TiO 2 nanoparticles on the chemically activated graphene. Commercial Pt—TiO 2 with surface area of 320 m 2 /g shows an H 2 production rate of 20 mol/h. According to the invention, the H 2 production rate >100μmol/h (1 g catalyst, in 40 mmol NaI) with ALD TiO 2 nanoparticles on the functionalized graphene supports.
[0050] Furthermore, as with Pt ALD on graphene, an enhanced mechanical and chemical stability of TiO 2 nanoparticles is provided due to chemical bonding to the graphene support.
[0051] The present invention has now been described in accordance with several exemplary embodiments, which are intended to be illustrative in all aspects, rather than restrictive. Thus, the present invention is capable of many variations in detailed implementation, which may be derived from the description contained herein by a person of ordinary skill in the art. All such variations are considered to be within the scope and spirit of the present invention as defined by the following claims and their legal equivalents. | A method of growing crystals on two-dimensional layered material is provided that includes reversibly hydrogenating a two-dimensional layered material, using a controlled radio-frequency hydrogen plasma, depositing Pt atoms on the reversibly hydrogenated two-dimensional layered material, using Atomic Layer Deposition (ALD), where the reversibly hydrogenated two-dimensional layered material promotes loss of methyl groups in an ALD Pt precursor, and forming Pt—O on the reversibly hydrogenated two-dimensional layered material, using combustion by O 2 , where the Pt—O is used for subsequent Pt half-cycles of the ALD process, where growth of Pt crystals occurs. | 7 |
BACKGROUND OF THE INVENTION
This invention is generally directed to photoconductive imaging members, and more specifically to imaging members with polycarbonate binders. The present invention in one embodiment is directed to layered imaging members comprised of charge transport layers with charge transport molecules dispersed in polycarbonate binder, which novel polycarbonates contain telechelic polysiloxane macromers. In a specific embodiment, the present invention relates to layered imaging members comprised of a photogenerating layer and a hole transport layer wherein the transport molecules thereof are dispersed in a polycarbonate resinous binder, which polycarbonates have incorporated therein polysiloxane telomers during, for example, a polyesterification reaction. Further, in another embodiment of the present invention the imaging member is comprised of a supporting substrate, a photogenerating layer, and in contact therewith a charge, especially a hole transport layer comprised of hole transport molecules dispersed in the aforementioned polycarbonate resinous binder. The charge transport layer can be located as the top layer of the imaging member, or alternatively it may be situated between a supporting substrate and the photogenerating layer. The aforementioned polycarbonate binders can possess a number of advantages including, for example, resistance to abrasion, increased tensile toughness of up to fifty fold times more relative to polycarbonate Z, from about 2 Joules/cm 3 to about 100 Joules/cm 3 , increased elongation to break of five to ten times more relative to polycarbonate Z, the solubility thereof in a number of solvents such as aromatic solvents including toluene, tetrahydrofuran, xylene, and benzene, and aliphatic solvents such as halogenated hydrocarbons thus permitting, for example, and improved coatability thereof with organic charge transport components utilizing various known processes such as spray, dip, and draw-down coating. Another advantage associated with many of the imaging members of the present invention resides in the ability to modify the substituents, or side groups present on the polycarbonates thereby providing, for example, substantial latitude in improving the mechanical and surface properties of the charge transport layers including, for example, environmental stability, abrasion resistence, elimination of a protective top coating, and/or excellent paper stripping characteristics for the imaging member.
The tensile toughness represents the area of a stress strain curve when a sample of the material is strained to its breaking point, this phrase being well known in the art, and moreover there can be selected a known tensile test for films and coatings of the polycarbonate binders, which tests are capable of enabling the calculation of the Young's modulus, tensile strength, yield strength, percent elongation, and tensile toughness.
The novel polycarbonates binders illustrated herein may also be selected in an embodiment of the present invention as a resin binder for the charge generating layer, particularily since it is believed that such a binder may enable improved photogenerating pigment dispersion stability, and increased photosensitivity for the resulting imaging member.
The imaging members of the present can be selected for a number of imaging and printing processes including electrophotographic imaging and printing processes for an extended number of imaging cycles, exceeding 200,000, for example, while substantially avoiding or minimizing abrasion thereof. Also, the imaging members of the present invention can be selected for a number of color imaging and printing processes.
The formation and development of electrostatic latent images on the imaging surfaces of photoconductive materials by electrostatic means is well known. Numerous different photoconductive members for use in xerography are known such as selenium, alloys of selenium, layered imaging members comprised of aryl amine charge transport layers, reference U.S. Pat. No. 4,265,990, and imaging members with charge transport layers comprised of polysilylenes, reference U.S. Pat. No. 4,618,551. The disclosures of the aforementioned patents are totally incorporated herein by reference. With the aforementioned imaging members, especially those of the '990 patent, there are selected aryl amine charge transport layers, which aryl amines are soluble in halogenated hydrocarbons such as methylene chloride. Further, the polycarbonates of the present invention can also be selected as resinous binders for imaging members with electron transport layers, reference U.S. Pat. No. 4,474,865, the disclosure of which is totally incorporated herein by reference.
In U.S. Pat. No. 4,869,988 and U.S. Pat. No. 4,946,754, the disclosures of which are totally incorporated herein by reference, there are described layered photoconductive imaging members with transport layers incorporating, for example, biarylyl diarylamines, N,N-bis(biarylyl)anilines, and tris(biarylyl)amines as charge transport compounds. In the above-mentioned patents, there are disclosed improved layered photoconductive imaging members comprised of a supporting substrate, a photogenerating layer optionally dispersed in an inactive resinous binder, and in contact therewith a charge transport layer comprised of the above-mentioned charge transport compounds, or mixtures thereof dispersed in resinous binders.
Examples of specific hole transporting components disclosed in U.S. Pat. No. 4,869,988 include N,N-bis(4-biphenylyl)-3,5-dimethoxyaniline (Ia); N,N-bis(4-biphenylyl)-3,5-dimethylaniline (Ib); N,N-bis(4-methyl-4'-biphenylyl)-3-methoxyaniline (Ic); N,N-bis(4-methyl-4'-biphenylyl)-3-chloroaniline (Id); N,N-bis(4-methyl-4'-biphenylyl)-4-ethylaniline (Ie); N,N-bis(4-chloro-4'-biphenylyl)-3-methylaniline (If); N,N-bis(4-bromo-4'-biphenylyl)-3,5-dimethoxy aniline (Ig); 4-biphenylyl bis(4-ethoxycarbonyl-4'-biphenylyl)amine (IIa); 4-biphenylyl bis(4-acetoxymethyl-4'-biphenylyl)amine (IIb); 3-biphenylyl bis(4-methyl-4'-biphenylyl)amine (IIc); 4-ethoxycarbonyl-4'-biphenylyl bis(4-methyl-4'-biphenylyl)amine (IId); and the like.
Examples of specific hole transporting compounds disclosed in U.S. Pat. No. 4,946,754 include bis(p-tolyl)-4-biphenylylamine (IIa); bis(p-chlorophenyl)-4-biphenylylamine (IIb); N-phenyl-N-(4-biphenylyl)-p-toluidine (IIc); N-(4-biphenylyl)-N-(p-chlorophenyl)-p-toluidine (IId); N-phenyl-N-(4-biphenylyl)-p-anisidine (IIe); bis(m-anisyl)-4-biphenylylamine (IIIa); bis(m-tolyl)-4-biphenylylamine (IIIb); bis(m-chlorophenyl)-4-biphenylylamine (IIIc); N-phenyl-N-(4-biphenylyl)-m-toluidine (IIId); N-phenyl-N-(4-bromo-4'-biphenylyl)-m-toluidine (IVa); diphenyl-4-methyl-4'-biphenylylamine (IVb); N-phenyl-N-(4-ethoxycarbonyl-4'-biphenylyl)-m-toluidine (IVc); N-phenyl-N-(4-methoxy-4'-biphenylyl)-m-toluidine (IVd); N-(m-anisyl)-N-(4-biphenylyl)-p-toluidine (IVe); bis(m-anisyl)-3-biphenylylamine (Va); N-phenyl-N-(4-methyl-3'-biphenylyl)-p-toluidine (Vb); N-phenyl-N-(4-methyl-3'-biphenylyl)-m-anisidine (Vc); bis(m-anisyl)-3-biphenylylamine (Vd); bis(p-tolyl)-4-methyl-3'-biphenylylamine (Ve); N-p-tolyl-N-(4-methoxy-3'-biphenylyl)-m-chloroaniline (Vf), and the like. The aforementioned charge, especially hole transport components, can be selected for the imaging members of the present invention in embodiments thereof.
It is also indicated in the aforementioned patents that there may be selected as resin binders for the charge transport molecules those components as illustrated in U.S. Pat. No. 3,121,006 including polycarbonates, polyesters, epoxy resins, polyvinylcarbazole; and also wherein for the preparation of the charge transport layer with a polycarbonate there is selected methylene chloride as a solvent.
There is also mentioned as prior art U.S. Pat. Nos. 4,657,993, the disclosure of which is totally incorporated herein by reference, directed to polyphosphazene homopolymers and copolymers of the formula as recited, for example, in the Abstract of the Disclosure, which components may be selected as photoconductive materials and for other uses, see column 1, and continuing on to column 2; and as background interest directed to processes for the preparation of phosphonitrilic polymer mixtures, reference the Abstract of the Disclosure; 3,515,688 related to phosphonitrile elastomers, reference for example the Abstract of the Disclosure; 3,702,833 directed to curable fluorophosphazene polymers, see for example column 1; and 3,856,712 directed to polyphosphazene copolymers which are elastomers. The disclosures of each of the aforementioned patents are totally incorporated herein by reference.
While imaging members with various charge transporting substances, especially hole transports, including the aryl amines disclosed in the prior art, are suitable for their intended purposes, there continues to be a need for improved imaging members, particularly layered members, with abrasion resistant resin binders. Another need resides in the provision of layered imaging members that are compatible with liquid developer compositions. Further, there continues to be a need for layered imaging members wherein the layers are sufficiently adhered to one another to allow the continuous use of such members in repetitive imaging systems. Also, there continues to be a need for improved layered imaging members comprised of hole transport layers wherein the problems of transport molecule crystallization, bleeding and leaching are avoided or minimized. Furthermore, there is a need for imaging members with charge transport compounds or polymers dispersed in certain polycarbonate resin binders that are soluble in nontoxic solvents, and wherein the resulting imaging members are inert to the users thereof. A further need resides in the provision of photoconductive imaging members with desirable mechanical characteristics.
SUMMARY OF THE INVENTION
It is therefore a feature of the present invention to provide layered photoresponsive imaging members with many of the advantages indicated herein.
Also, it is a feature of the present invention to provide binders for charge transport molecules contained in layered photoconductive imaging members.
It is yet another feature of the present invention to provide layered photoresponsive imaging members with charge, especially hole transport layers in contact with a photogenerating layer, which members are suitable for use with liquid and dry developers.
In a further feature of the present invention there is provided a layered photoresponsive imaging member with a photogenerating layer situated between a supporting substrate, and a hole transport layer with a polycarbonate resin binder.
In yet another feature of the present invention there is provided a photoresponsive imaging member comprised of a hole transporting layer situated between a supporting substrate and a photogenerating layer.
In another feature of the present invention there are provided imaging and printing methods with the layered imaging members disclosed herein.
Another feature of the present invention resides in the provision of novel polycarbonates and processes thereof.
A further feature of the present invention is to provide improved layered imaging members wherein the problems of transport molecule crystallization, hole charge transport molecule, bleeding and leaching, and the like are eliminated or minimized enabling their selection, for example, in imaging apparatuses with liquid developer compositions and which members are insensitive to changes in environmental conditions.
Further, in another feature of the present invention there are provided imaging members with charge, especially hole, transport layers that can be fabricated from solvents other than halogenated materials such as methylene chloride.
Also, in another feature of the present invention there are provided imaging members with charge transport layers that are free or substantially free of charge trapping.
Another feature of the present invention resides in the provision of imaging members with electrical stability for an extended number of imaging cycles, for example exceeding 200,000 in some instances.
Moreover, in another feature of the present invention there are provided charge transport layers for imaging members, which layers can be prepared with nontoxic solvents.
Furthermore, in another feature of the present invention there are provided polycarbonates with increased tensile strength, tensile toughness and improved elongation to break.
Another feature of the present invention resides in the provision of imaging members wherein the polycarbonates illustrated herein can be selected as a resin binder for the photogenerating pigments.
Another feature of the present invention resides in the provision of copolycarbonates which can be selected as resin binders, which copolycarbonates are obtained from the reaction, for example, of a bisphenol and a difunctional phenylsilanol.
These and other features of the present invention can be accomplished in embodiments thereof by the provision of layered imaging members comprised, for example, of a photogenerating layer and a charge transport layer. More specifically, the present invention is directed to layered imaging members comprised of photogenerating layers, and in contact therewith hole transport layers comprised of, for example, hole transporting aryl amines, the amines of U.S. Pat. No. 4,299,897, the disclosure of which is totally incorporated herein by reference, and the like dispersed in a polycarbonate resin binder, which polycarbonate is comprised of block copolycarbonates of bisphenols and polydiphenylsiloxane.
In one embodiment, the present invention is directed to a layered photoconductive imaging member comprised of a supporting substrate, a photogenerating layer comprised of organic or inorganic photoconductive pigments optionally dispersed in an inactive resinous binder, and in contact therewith a hole transport layer comprised of the aryl amines as illustrated in U.S. Pat. No. 4,265,990, the disclosure of which is totally incorporated herein by reference, and the aforementioned '897 patent, which amines are dispersed in a polycarbonate resin binder of the formula: ##STR2## wherein k corresponds to the degree of polymerization and, for example, is a number of from about 4 to about 12; j and n correspond to the degree of polymerization and are, for example, numbers of from about 4 to about 200; R 1 and R 2 are independently selected from the group consisting of hydrogen, alkyl, substituted alkyl, aryl, substituted aryl, and the like, wherein alkyl can be substituted with, for example, halogen such as fluoro, chloro and bromo, and aryl can contain substituents such as alkyl including methyl, ethyl, propyl, butyl, pentyl, hexyl, heptyl, octyl, nonyl, decyl, and the like; R 3 is alkyl, such as methyl, hydrogen or halogen such as chlorine or bromine; and m represents the number of repeating segments. Alkyl can be branched, for example, with alkyl groups or contain aryl substituents; and the R 1 -C-R 2 can be a sulfonyl group, a carbonyl, oxygen, and the like; and this central substituent need not be 1,4 or para to the oxygen but could be 1,3 or meta to the oxygen. Alkyl contains, for example, from 1 to about 25 carbon atoms, and aryl contains, for example, from 6 to about 24 carbon atoms, such as methyl, ethyl, and the like, phenyl, benzyl, napthyl, cyclohexyl, t-butylcyclohexyl, phenylcyclohexyl, cycloheptyl and the like; R 1 -C-R 2 can also be replaced by groups such as 1,2-phenylenebisisopropylidene or 1,4-phenylenebisisopropylidene. The aforementioned polymer in embodiments of the present invention possesses a number average molecular weight of from about 7,000 to about 100,000, and a weight average molecular weight of from about 15,000 to about 300,000, and a M w /M n ratio of from about 2.0 to about 4.0 as determined by a Waters Gel Permeation Chromatograph employing four Ultrastyragel® columns with pore sizes of 100, 500, 500, and 104 Angstroms and using THF (tetrahydrofuran) as a solvent. It is believed that up to some maximum molecular weight polymer mechanical properties improve with increasing molecular weight. However, it is also believed that the coating technique chosen for photoreceptor fabrication can determine the choice of molecular weight since with spray coating usually lower molecular weight polymer is selected as compared to dip coating wherein a lower molecular weight is selected as compared to drawn film coating.
The polycarbonates of the present invention are named herein according to the conventions of the International Union of Pure and Applied Chemistry as found in Source-Based Nomenclature for Copolymers, Pure & Appl. Chem., Vol. 57, No. 10, pages 1427 to 1440, 1985, the disclosure of which is totally incorporated herein by reference. Specifically, block polymers of the present invention include, for example, poly(4,4'-(1-phenylethylidene)bisphenol)carbonate with 10 weight percent of polydiphenylsiloxane blocks which can named according to the above conventions as poly(poly(4,4'-(1phenylethylidene)bisphenol)carbonate-block-polydiphenylsiloxane-block-poly(4,4'-(1-phenylethylidene)bisphenol)carbonate) (a:10:c mass percent) the polymer contains 10 percent by weight polysiloxane. Examples of polycarbonates of the present invention include poly(poly(4,4'-(1-phenylethylidene)bisphenol)carbonate-block-polydiphenylsiloxane-block-poly(4,4'-(1-phenylethylidene)bisphenol)carbonate) (a:5:c mass percent), poly(poly(4,4'-(1-phenylethylidene)bisphenol)carbonate-block-polydiphenylsiloxane-block-poly(4,4'-(1-phenylethylidene)bisphenol)carbonate) (a:15:c mass percent), poly(poly(4,4'-(1-phenylethylidene)bisphenol)carbonate-block-polydiphenylsiloxane-block-poly(4,4'-(1-phenylethylidene)bisphenol)carbonate) (a:20:c mass percent), poly(poly(4,4'-cyclohexylidenebisphenol)carbonate-block-polydiphenylsiloxane-block-poly(4,4'-cyclohexylidenebisphenol)carbonate), poly(poly(4,4'-cyclohexylidene-2,2'-dimethylbisphenol)carbonate-block-polydiphenylsiloxane-block-poly( 4,4'-cyclohexylidene-2,2'-dimethylbisphenol)carbonate), poly(poly(4,4'-(1,4-phenylenebisisopropylidene)bisphenol)carbonate-block-polydiphenylsiloxane-block-poly(4,4'-(1,4-phenylenebisisopropylidene)bisphenol)carbonate), poly(poly(4,4'-isopropylidenebisphenol)carbonate-block-polydiphenylsiloxane-block-poly(4,4'-isopropylidenebisphenol)carbonate), poly(poly(4,4'-cycloheptylidenebisphenol)carbonate-block-polydiphenylsiloxane-block-poly(4,4'-cycloheptylidenebisphenol)carbonate), poly(poly(4,4'-diphenylmethylidenebisphenol)carbonate-block-polydiphenylsiloxane-block-poly(4,4'-diphenylmethylidenebisphenol)carbonate), poly(poly(4,4'-(1-naphthylethylidene)bisphenol)carbonate-block-polydiphenylsiloxane-block-poly(4,4'-(1-napthylethylidene)bisphenol)carbonate), poly(poly(4,4'-(1,2-phenylenebisisopropylidene)bisphenol)carbonate-block-polydiphenylsiloxane-block-poly(4,4'-(1,2-phenylenebisisopropylidene)bisphenol)carbonate), poly(poly(4,4'-(4-t-butylcyclohexylidene)bisphenol)carbonate-block-polydiphenylsiloxane-block-poly(4,4'-(4-t-butylcyclohexylidene)bisphenol)carbonate), poly(poly(4,4'-(1,2-diphenylethylidene)bisphenol)carbonate-block-polydiphenylsiloxane-block-poly(4,4'-(1,2-diphenylethylidene)bisphenol)carbonate), poly(poly(4,4'-(1,3-diphenylisopropylidene)bisphenol)carbonate-block-polydiphenylsiloxane-block-poly(4,4'-(1,3-diphenylisopropylidene)bisphenol)carbonate), poly(poly(4,4'-(4-phenylcyclohexylidene)bisphenol)carbonate-block-polydiphenylsiloxane-block-poly(4,4'-(4-phenylcyclohexylidene)bisphenol)carbonate), poly(poly(4,4'-cyclohexylidene-2,2'-dichlorobisphenol)carbonate-block-polydiphenylsiloxane-block-poly(4,4'-cyclohexylidene-2,2'-dichlorobisphenol)carbonate), poly(poly(4,4'-cyclohexylidene-2,2'-dibromobisphenol)carbonate-block-polydiphenylsiloxane-block-poly(4,4'-cyclohexylidene-2,2'-dibromobisphenol)carbonate), poly(poly(4,4'-isopropylidene-2,2'-dichlorobisphenol)carbonate-block-polydiphenylsiloxane-block-poly(4,4'-isopropylidene-2,2'-dichlorobisphenol)carbonate), poly(poly(4,4'-(1-phenylethylidene)-2,2'-dibromobisphenol)carbonate-block-polydiphenylsiloxane-block-poly(4,4'-(1-phenylethylidene)-2,2'-dibromobisphenol)carbonate), poly(poly(4,4'-sulfonyldiphenol)carbonate-block-polydiphenylsiloxane-block-poly(4,4'-sulfonyldiphenol)carbonate), and the like. Other examples include block copolymers of different polysiloxane structures such as poly(poly(4,4'-(1-phenylethylidene)bisphenol)carbonate-block-poly(diphenylsiloxane-co-dimethylsiloxane)-block-poly(4,4'-(1-phenylethylidene)bisphenol)carbonate), poly(poly(4,4'-isopropylidene)bisphenol)carbonate-block-poly(diphenylsiloxane-co-dimethylsiloxane)-block-poly(4,4'-isopropylidene)bisphenol)carbonate), poly(poly(4,4'-diphenylmethylidenebisphenol)carbonate-block-poly(diphenylsiloxane-co-dimethylsiloxane)-block-poly(4,4'-diphenylmethylidenebisphenol)carbonate), poly(poly(4,4'-cyclohexylidenebisphenol)carbonate-block-poly(diphenylsiloxane-co-dimethylsiloxane)-block-poly(4,4'-cyclohexylidenebisphenol)carbonate), poly(poly(4,4'-(1-phenylethylidene)bisphenol)carbonate-block-polydimethylsiloxane-block-poly(4,4'-(1-phenylethylidene)bisphenol)carbonate), poly(poly(4,4'-isopropylidene)bisphenol)carbonate-block-polymethylsiloxane-block-poly(4,4'-isopropylidene)bisphenol)carbonate), poly(poly(4,4'-diphenylmethylidenebisphenol)carbonate-block-polymethylsiloxane-block-poly(4,4'-diphenylmethylidenebisphenol)carbonate), poly(poly(4,4'-cyclohexylidenebisphenol)carbonate-block-polydimethylsiloxane-block-poly(4,4'-cyclohexylidenebisphenol)carbonate), poly(poly(4,4'-(1-phenylethylidene)bisphenol)carbonate-block-polydiethylsiloxane-block-poly(4,4'-(1-phenylethylidene)bisphenol)carbonate), poly(poly(4,4'-isopropylidene)bisphenol)carbonate-block-polyethylsiloxane-block-poly(4,4'-isopropylidene)bisphenol)carbonate), poly(poly(4,4'-diphenylmethylidenebisphenol)carbonate-block-polyethylsiloxane-block-poly(4,4'-diphenylmethylidenebisphenol)carbonate), poly(poly(4,4'-cyclohexylidenebisphenol)carbonate-block-pol ydiethylsiloxane-block-poly(4,4'-cyclohexylidenebisphenol)carbonate), and the like. Additional examples include block copolymers where the polycarbonate blocks are prepared from more than one bisphenol structure, such as poly(poly(4,4'-cyclohexylidene-2,2'-dimethylbisphenol)-co-(4,4'-cyclohexylidenebisphenol)carbonate-block-polydiphenylsiloxane-block-polypoly(4,4'-cyclohexylidene-2,2'-dimethylbisphenol)-co-(4,4'-cyclohexylidenebisphenol)carbonate), poly(poly(4,4'-isopropylidenebisphenol)-co-(4,4'-cyclohexylidenebisphenol)carbonate-block-polydiphenylsiloxane-block-polypoly(4,4'-isopropylidenebisphenol)-co-(4,4'-cyclohexylidenebisphenol)carbonate), poly(poly(4,4'-hexafluoroisopropylidenebisphenol)-co-(4,4'-cyclohexylidenebisphenol)carbonate-block-polydiphenylsiloxane-block-polypoly(4,4'-hexafluoroisopropylidenebisphenol)-co-(4,4'-cyclohexylidenebisphenol)carbonate), poly(poly(4,4'-hexafluoroisopropylidenebisphenol)-co-(4,4'-(1,4-phenylenebisisopropylidene)bisphenol)carbonate-block-polydiphenylsiloxane-block-polypoly(4,4'-hexafluoroisopropylidenebisphenol)-co-(4,4'-(1,4-phenylenebisisopropylidene)bisphenol)carbonate), poly(poly(4,4'-(1-phenylethylidene)bisphenol)-co-(4,4'-(1,4-phenylenebisisopropylidene)bisphenol)carbonate-block-polydiphenylsiloxane-block-polypoly(4,4'-(1-phenylethylidene)bisphenol)-co-(4,4'-(1,4-phenylenebisisopropylidene)bisphenol)carbonate), and the like.
Examples of polycarbonate block segments selected for the process of the present invention include the polymer structures as illustrated in U.S. Pat. No. 4,921,940 (D/88100), the disclosure of which is totally incorporated herein by reference, which blocks are obtained from the reaction of diphenylcarbonate with 4,4'-dihydroxydiphenyl-1,1-ethane, 4,4'-dihydroxydiphenyl-1,1-isobutane,4,4'-dihydroxydiphenyl-2,2-propane, 4,4'-dihydroxydiphenyl-4,4-heptane, 4,4'-dihydroxydiphenyl-1,1-cyclohexane, 4,4'-dihydroxy-3,3'-dimethyldiphenyl-2,2-propane, 4,4'-dihydroxy-3,3',5,5'-tetrachlorodiphenyl-2,2-propane, 4,4'-dihydroxydiphenylsulfone, 4,4'-dihydroxydiphenylether, copolymers thereof, and the polycarbonates as illustrated in the aforementioned copending application. Many of the structures thereof may be located in Hermann Schnell's Chemistry and Physics of Polycarbonates, Polymer Reviews, V. 9, Interscience Publishers, principally the structures found in Tables IV-1 pages 86 to 90 and also Tables IV-2, V-1, V-2, V-3, V-4, V-5, and V-6, the disclosure of which is totally incorporated herein by reference.
The polycarbonates of the present invention can be prepared by known polyesterification methods with the primary exception that polysiloxane telomers are incorporated therein during the polyesterification reaction. Examples of polysiloxane telomers present in effective amounts of, for example, from about 1 weight percent to about 20 weight percent and preferably from about 5 weight percent to about 15 weight percent include polydiphenyl siloxanes terminated with silanol end groups, polydimethyl siloxanes terminated with silanol end groups, silanol terminated siloxanes mixtures containing both methyl and phenyl groups attached to the silicon atom where the amounts of components in the mixture vary from about 5 to about 95 percent, respectively.
More specifically, the polycarbonates of the present invention can be prepared by the reaction of one or more, for example up to 5, preferably 3, and more preferably 2, in an embodiment bisphenols with a diaryl carbonate, especially bis(aryl)carbonates, reference U.S. Pat. No. 4,345,062, the disclosure of which is totally incorporated herein by reference, such as diphenyl carbonate; the bis(aryl)carbonates reactants are also commonly referred to as carbonic acid aromatic diesters and include those described by Formula III in U.S. Pat. No. 3,163,008, the disclosure of which is totally incorporated herein by reference, column 2, lines 23 to 72, and column 3, lines 1 to 42, with preferred bis(aryl)carbonates being diphenyl carbonate, dicresyl carbonate, bis(2-chlorophenyl)carbonate, the bis-phenyl-carbonates of hydroquinone, resorcinol and 4,4'-dihydroxydiphenyl, the bisphenyl carbonates of the bis(4-hydroxyaryl)alkanes, cycloalkanes, ethers, sulfides, sulfones, and the like; and a silanol terminated polysiloxane telomer, such as polydiphenyl siloxane in the presence of a catalyst, such as metal alkoxides, such as titanium butoxide, titanium isopropoxide, zirconium isopropoxide; metal acetates, such as magnesium acetate, zinc acetate; tin compounds, such as dibutyltin oxide, di-n-butyltin dimethoxide, tetraborate compounds, such as tetramethyl ammonium tetraphenyl borohydride, a titanium or zirconium alkoxides, metal diacetates, organotin compounds or borohydride based compounds. The diphenylcarbonate is, in an embodiment, used in molar excess with respect to the total number of moles of bisphenol and polysiloxane telomer employed; this excess being in the range of from about 5 percent to about 30 percent and preferentially about 10 percent. The catalyst is employed in an effective amount of, for example, from about 0.01 percent to about 1.0 percent molar relative to the bisphenol content, and preferentially in an amount of from about 0.1 to about 0.3 based on the bisphenol. This mixture is heated with stirring in a one liter steel reactor capable of maintaining a vacuum of at least as low as 1.0 mbar. The reactor should also be capable of heating to a temperature at least as high as 300° C. and be equipped with a condenser for the collection of the byproducts, such as phenol, of the polymerization and the molar excess of diphenylcarbonate. Specifically, such a reaction can be conducted as follows: there can be added to a one liter reactor 1-phenylethylidenebisphenol, about 270 grams, or approximately one mole, together with a molar excess of diphenyl carbonate of about 10 percent or 273.4 grams. To this mixture is added about 30 grams of a silanol terminated polydiphenyl siloxane, such as Huls Petrarch Systems product PS080. A catalyst, such as titanium butoxide, can be added in the amount of about 0.5 milliliter as the solid bisphenols and diphenylcarbonate melt with heating. Heating is accomplished by electric element heater that surrounds the reactor vessel. The monomer mixture comprised of the bisphenols and diphenylcarbonate melts in the temperature range of about 80° C. to about 140° C. Upon melting, the reactor is sealed, stirring initiated, and a continuous stream of dry nitrogen gas is flushed through the reactor for 50 minutes. The reactor temperature is raised to about 220° C. over a period of about 50 minutes. This temperature is maintained while the pressure in the reactor is lowered by means of a mechanical vacuum pump. The pressure is lowered from about 1,000 mbar to about 500 mbar over a period of about 10 minutes. The pressure is then further reduced to about 0 mbar over a period of about 80 minutes. After the temperature has been maintained at 220° C. for about 100 to about 160 minutes, the temperature is increased to about 260° C. over a period of about 20 minutes. This temperature is maintained for about 90 minutes. The progress of the reaction may be monitored by the rise in the stirrer torque, the stirrer torque increases as the melt viscosity increases and the rise in the viscosity is caused by the increase in the polymer molecular weight as the reaction progresses or by the collection of the phenol byproduct, since 2 moles of phenol are produced by every mole of bisphenol that polymerizes, the extent of the polymerization can be directly followed. The temperature is then increased to about 280° C. in about 10 minutes. This temperature is maintained for about 120 minutes. The temperature is then increased to about 300° C. in about 10 minutes. This temperature is maintained for about 120 minutes. The reactor is then repressurized with dry nitrogen gas to atmospheric pressure and the molten polymer is drawn with large forceps from the reactor bottom into a dry inert atmosphere and cut with wire cutters where it is permitted to cool to room temperature, about 25° C., to provide the product poly(poly(4,4'-(1-phenylethylidene)bisphenol)carbonate-block-polydiphenylsiloxane-block-poly(4,4'-(1-phenylethylidene)bisphenol)carbonate) (a:10:c mass percent). Subsequent to effecting purification of the product, it can be treated by the process outlined in U.S. Pat. No. 4,921,940, the disclosure of which is totally incorporated herein by reference, whereby, for example, 10 grams of the polycarbonate product was added to 100 milliliters of dimethylformamide as the polymer solvent containing 0.25 gram of tartaric acid as the complexing component. Following stirring of the mixture for 16 hours, the resulting polymer solution was precipitated into 3 liters of rapidly stirring deionized water. The polymer was recovered by filtration and dried overnight in a vacuum oven at about 80 degrees Celsius. The polymer obtained may be characterized by GPC to confirm siloxane incorporation into a high molecular weight polymer. Siloxane incorporation into the polymer backbone was determined by both NMR and by Supercritical Fluid Extraction of the polymer.
Examples of specific hole transporting molecules in addition to the aryl amines disclosed herein include, but are not limited to, those molecules of the following formulas wherein X is independently selected from halogen or alkyl, and preferably N,N'-diphenyl-N,N'-bis(3-methylphenyl)-(1,1'-biphenyl)-4,4'-diamine. ##STR3##
The photoresponsive imaging members of the present invention can be prepared by a number of known methods, the process parameters and the order of the coating of the layers being dependent on the member desired. Thus, for example, the photoresponsive members of the present invention can be prepared by providing a conductive substrate with an optional charge blocking layer and an optional adhesive layer, and applying thereto a photogenerating layer, and overcoating thereon a charge transport layer dispersed in the polycarbonate resinous binder illustrated herein. The photoresponsive imaging members of the present invention can be fabricated by common known coating techniques such as by dip coating, draw-bar coating, or by spray coating process, depending mainly on the type of imaging devices desired. Each coating, however, can be usually dried, for example, in a convection or forced air oven at a suitable temperature before a subsequent layer is applied thereto. In one embodiment of the present invention, the transport layer can be fabricated from a 10 weight percent solution of the charge transporting molecules, which molecules are usually present in an amount of from about 35 to about 60 weight percent, and preferably 40 weight percent, and are dispersed in the polycarbonate resinous binder illustrated herein, preferably in an amount of 60 weight percent. The aforementioned solution can be obtained by stirring 6 grams of the selected polycarbonate and 4 grams of the charge transport molecule in 100 milliliters of toluene at ambient temperature. The resulting solution can then be draw bar coated on the photogenerating layer and thereafter dried. The drying temperature is dependent on a number of factors including the components selected, particularly the photogenerating component, but generally drying is accomplished at about 130° C., especially in situations wherein trigonal selenium is selected as the photogenerating pigment dispersed in a polyvinyl carbazole binder.
In a illustrative embodiment, the photoconductive imaging member of the present invention is comprised of (1) a conductive supporting substrate of Mylar with a thickness of 75 microns and a conductive vacuum deposited layer of titanium with a thickness of 0.02 micron; (2) a hole blocking layer of N-methyl-3-aminopropyltrimethoxy silane with a thickness of 0.1 micron; (3) an adhesive layer of 49,000 Polyester (obtained from E. I. DuPont Chemical) with a thickness of 0.05 micron; (4) a photogeneration layer of trigonal selenium with a thickness of 1 micron; and (5) a charge transport layer with a thickness of 20 microns of an aryl amine dispersed in a resin binder of a block copolycarbonate of bisphenol and polydiphenyl siloxane.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 represents a partially schematic cross-sectional view of a photoresponsive imaging member of the present invention;
FIGS. 2 and 3 represent partially schematic cross-sectional views of photoresponsive imaging members of the present invention; and
FIG. 4 represents a partially schematic cross-sectional view of a photoresponsive imaging member of the present invention wherein the hole transporting layer is situated between a supporting substrate and the photogenerating layer.
DETAILED DESCRIPTION OF THE INVENTION
Illustrated in FIG. 1 is a photoresponsive imaging member of the present invention comprising a supporting substrate 3 of a thickness of from about 50 microns to about 5,000 microns, a charge carrier photogenerating layer 5 of a thickness of from about 0.5 micron to about 5 microns comprised of photogenerating pigment s6 optionally dispersed in a resinous binder composition 7, and a hole transport layer 9 of a thickness of from about 10 microns to about 60 microns comprised of an aryl amine dispersed in the polycarbonate illustrated herein resin binder 8.
Illustrated in FIG. 2 is a photoresponsive imaging member of the present invention comprised of about a 25 micron to about a 100 micron thick conductive supporting substrate 15 of aluminized Mylar, a 0.5 micron to about a 5 micron thick photogenerating layer 17 comprised of trigonal selenium photogenerating pigments 19 dispersed in a resinous binder 21 in the amount of 10 percent to about 80 percent by weight, and a 10 micron to about a 60 micron thick hole transport layer 23 comprised of the aryl amine charge transport N,N'-diphenyl-N,N'-bis(3-methylphenyl)1,1'-biphenyl-4,4'-diamine dispersed in the polycarbonate resin binder 24 poly(4,4'-(1-phenylethylidene)bisphenol carbonate with 10 weight percent of polydiphenyl siloxane blocks, based on the amount of polydiphenyl siloxane added to the polymerization, and confirmed by NMR integration; additionally, covalent incorporation of the polysiloxane blocks is supported by the absence of a separate low molecular weight peak in GPC studies of the polymer and by the low amount of free polysiloxane extracted by SFE/SFC studies, which polycarbonate has a number average molecular weight of about 21,000, and a weight average molecular weight of about 67,500, and a dispersity of about 3.25 as determined by a Waters Gel Permeation Chromatograph employing four Ultrastyragel© columns with pore sizes of 100, 500, 500, 10 4 Angstroms and using THF as solvent. The polydiphenyl siloxane blocks are believed to be incorporated randomly along the polymer chain length.
Another photoresponsive imaging member of the present invention, reference FIG. 3, is comprised of a conductive supporting substrate 31 of aluminum of a thickness of 50 microns to about 5,000 microns, a photogenerating layer 33 comprised of amorphous selenium or an amorphous selenium alloy, especially selenium arsenic alloy (99.5/0.5) or a selenium tellurium alloy (75/25), of a thickness of 0.1 micron to about 5 microns, and a 10 micron to about 60 micron thick hole transport layer 37 comprised of the aryl amine hole transport N,N'-diphenyl-N,N'-bis(3-methylphenyl)1,1'-biphenyl-4,4'-diamine, 55 weight percent, dispersed in the polycarbonate resin binder 39 of FIG. 2.
Illustrated in FIG. 4 is another photoresponsive imaging member of the present invention comprised of a 25 micron to 100 micron thick conductive supporting substrate 41 of aluminized Mylar, a 10 micron to about 70 micron thick hole transport layer 47 comprised of N,N'-diphenyl-N,N'-bis(3-methylphenyl)1,1'-biphenyl-4,4'-diamine hole transport molecules, 55 weight percent, dispersed in the polycarbonate resin binder poly(4,4'-(1-phenylethylidene)bisphenol carbonate 48 with 10 weight percent of polydiphenylsiloxane blocks, and a 0.1 micron to about 5 micron thick photogenerating layer 50 comprised of vanadyl phthalocyanine photogenerating pigments 53 optionally dispersed in a polyester resinous binder 55 in an amount of about 10 percent to about 80 percent by weight.
The supporting substrate layers may be opaque or substantially transparent and may comprise any suitable material possessing, for example, the requisite mechanical properties. The substrate may comprise a layer of an organic or inorganic material having a conductive surface layer arranged thereon or a conductive material such as, for example, aluminum, chromium, nickel, indium, tin oxide, brass or the like. The substrate may be flexible, seamless, or rigid and can be comprised of various different configurations such as, for example, a plate, a cylindrical drum, a scroll, and the like. The thickness of the substrate layer is dependent on many factors including, for example, the components of the other layers, and the like; generally, however, the substrate is generally of a thickness of from about 50 microns to about 5,000 microns.
Examples of photogenerating layers, especially since they permit imaging members with a photoresponse of from about 400 to about 700 nanometers, for example, include those comprised of known photoconductive charge carrier generating materials, such as amorphous selenium, selenium alloys, halogen doped amorphous selenium, doped amorphous selenium alloys doped with chlorine in the amount of from about 50 to about 200 parts per million, and trigonal selenium, cadmium sulfide, cadmium selenide and cadmium sulfur selenide, and the like, reference U.S. Pat. Nos. 4,232,102 and 4,233,283, the disclosures of each of these patents being totally incorporated herein by reference. Examples of specific alloys include selenium arsenic with from about 95 to about 99.8 weight percent selenium; selenium tellurium with from about 70 to about 90 weight percent of selenium; the aforementioned alloys containing dopants, such as halogens, including chlorine in amounts of from about 100 to about 1,000 parts per million, ternary alloys, and the like. The thickness of the photogenerating layer is dependent on a number of factors, such as the materials included in the other layers, and the like; generally, however, this layer is of a thickness of from about 0.1 micron to about 5 microns, and preferably from about 0.2 micron to about 2 microns, depending on the photoconductive volume loading, which may vary from about 5 percent to about 100 percent by weight. Generally, it is desirable to provide this layer in a thickness which is sufficient to absorb about 90 percent or more of the incident radiation which is directed upon it in the imagewise exposure step. The maximum thickness of this layer is dependent primarily upon factors such as mechanical considerations, for example, whether a flexible photoresponsive device is desired. Also, there may be selected as photogenerators organic components such as squaraines, perylenes, reference for example U.S. Pat. No. 4,587,189, the disclosure of which is totally incorporated herein by reference, metal phthalocyanines, metal free phthalocyanines, vanadyl phthalocyanine, dibromoanthanthrone, and the like.
The hole transport layer can be comprised of one or a mixture of hole transporting molecules in the amount of from about 10 percent to about 60 percent by weight thereof in some embodiments of the transport molecules illustrated herein, and preferably the aryl amines of the formula illustrated herein. The thickness of the transport layer is, for example, from about 5 microns to about 50 microns with the thickness depending predominantly on the nature of intended applications. In addition, a layer of adhesive material located, for example, between the transport layer and the photogenerating layer to promote adhesion thereof can be utilized. This layer may be comprised of known adhesive materials such as polyester resins, reference 49,000 polyester available from E. I. DuPont Chemical Company, polysiloxane, acrylic polymers, and the like. A thickness of from about 0.001 micron to about 0.1 micron is generally employed for the adhesive layer. Hole blocking layers usually situated between the substrate and the photogenerating layer, and preferably in contact with the supporting substrate include, for example, those derived from the polycondensation of aminopropyl trialkoxysilane or aminobutyl trialkoxysilane, such as 3-aminopropyltrimethoxy silane, 3-aminopropyltriethoxy silane, or 4-aminobutyltrimethoxy silane thereby improving in some embodiments the dark decay characteristics of the imaging member. Typically, this layer has a thickness of from about 0.001 micron to about 5 microns or more in thickness, depending on the desired effectiveness for preventing or minimizing the dark injection of charge carriers into the photogenerating layer.
With the layered imaging members of the present invention, wherein the photogenerating layer is comprised of trigonal selenium, this member when charged to a negative voltage of 800 volts with a corotron had a photosensitivity of 2.0 ergs per square centimeter. The residual voltage buildup for this imaging member was negligible as determined, for example, with a volt meter (about 8 volts) after 1,000 imaging cycles in a xerographic imaging test fixture. The overall electrical performance (photosensitivity, cyclic stability, and dark decay) was superior to a similar imaging member fabricated with a polycarbonate (Lexan), 45 weight percent, as resin binder for the charge transport molecule. The aforementioned imaging member of the present invnetion exhibited an increase in yield strength and tensile toughness compared to a similar imaging member compared with a polycarbonate such as polycarbonate Z.
The imaging members of the present invnetion can be selected for electrostatographic, especially xerographic, imaging and printing processes wherein, for example, a positively, or negatively charged imaging member is selected, and developing the image with toner comprised of resin, such as styrene acrylates, styrene methacrylates, styrene butadienes, and the like, pigment, such as carbon black, and a charge additive such as distearyl dimethyl ammonium methyl sulfate.
The following examples, except for any comparative examples, are being supplied to further define specific embodiments of the present invention, it being noted that these examples are intended to illustrate and not limit the scope of the present invention. Also, parts and percentages are by weight unless otherwise indicated.
EXAMPLE I
In the following Examples, unless otherwise noted, there was selected a one liter stainless steel reactor equipped with a helical coil stirrer and a double mechanical seal. The stirrer was driven by a one-half horse power motor with a 30:1 gear reduction, and a torque meter was included on the stirrer drive. The reactor was heated electrically, and the pressure was monitored by both a pressure transducer, and a pirani gauge, while the temperature was determined by a platinum RTD. A specifically designed condensor ensures the efficient condensation of phenol and diphenylcarbonate; these materials are both solids at room temperature and the condenser design ensures that when they solidify they do not plug a line between the reactor and the vacuum pump which would cause the reaction to cease. In addition, at the low pressures below from 0.1 to 100 mbar used at the reaction end phenol has sufficient vapor pressure at room temperature and above that it can interfere with the polymerization by either raising the lowest pressure achievable by the system or by subliming to other parts of the condenser and plugging a line. In this condenser, the diameter of the pipe from the reactor to the condenser was 3/8". The major fraction of the line consists of flexible steel piping to avoid having to exactly position both reactor and condenser. A heating mantle was used to wrap this line. The condensation takes place in a 6 inch diameter stainless steel pipe about 16 inches long. The condensing surface itself consists of five 12 inch flexible steel tubes running parallel to each other, hung vertically, with four tubes arranged around the central one. To cool the condensing surface, there was used cold nitrogen gas. The cold nitrogen enters the four outer tubes, descends to the bottom, then rises up the central tube. The nitrogen flow is controlled by a flow meter with a typical flow rate in the range of 20 to 30 liters minute -1 . This tube assembly was hung from a weigh cell by a small universal joint. The inlet and outlet are long flexible steel tubes. This length along the horizontal axis should minimize the vertical force. Since the load cell deflection is quite small, a uniform, consistent force shunt occurs that can be corrected for by calibrating the cell. The byproducts such as phenol, cresol, chlorophenol, a mixture of phenol and hydroquinone, a mixture of phenol and resorcinol, a mixture of phenol and biphenol, or a mixture of phenol with one of 4,4'-dihydroxyarylalkanes, 4,4'-dihydroxycycloalkanes, 4,4'-dihydroxyethers, 4,4'-dihydroxysulfides, 4,4'-dihydroxysulfones, and the like drips as a liquid into the glass bottom portion of the condenser which was joined to the upper stainless steel portion by a ball valve. This glass piece at the bottom is a 250 milliliters graduated cylinder. Through this glass the amount and rate of phenol condensation can be monitored. When the reaction pressure was low enough, usually between 10 about 100 mbars, that the vapor pressure of the phenol becomes a significant contribution to the reactor pressure, the ball valve is closed to isolate the bulk of the phenol and the temperature of the ntrogen gas in the condensing element is lowered to below -80° C. In this manner, solid phenol was collected, and the rate and amount of collection can be monitored by the weigh cell electronic signal. The line leaving the condenser to the vacuum pump is 1/2 inch in diameter to further reduce any chance of plugging. Since the polymerization is driven by the removal of phenol, which in turn is driven by pressure and temperature, control of these variables is most important. A series of valves, a rotary oil pump, and a surge tank provided controlled variations in reactor pressure.
There was added to the above reactor 270.0 grams of bisphenol (z) (4,4'-cyclohexylidenediphenol) as obtained by the process as illustrated in Example I of U.S. Pat. No. 4,766,255, the disclosure of which is totally incorporated herein by reference; 30 grams of polydiphenylsiloxane, silanol terminated, obtained from Petrarch Systems (now Huls); 273.4 grams of diphenylcarbonate and 0.50 milliliter of titanium (IV) butoxide. The reactor was then sealed and heated to 220° C., and the pressure lowered from 1,000 millibar (atmospheric pressure) to about 500 mbar in a period of about 15 minutes. Phenol began to collect in the condenser and the amount was observed through the lower glass portion of the condenser. The rate of pressure decrease was then slowed so that about 80 minutes were required to reach a pressure of 5 mbar. During the slow pressure drop about 110 to 130 milliliters of phenol was observed to collect in the lower glass portion of the condenser. When the pressure reached about 100 mbar, the temperature of the nitrogen gas cooling the condensing element was lowered from about 16° C. to about -84° C. After 150 minutes at 220° C. the temperature was increased to 260° C. and heating was continued for 90 minutes. Thereafter, the temperature was increased to 280° C. and heating was continued for 120 minutes. Thereafter, the temperature was increased to 300° C. and heating was continued for 120 minutes, and the molten polymer resulting was drawn from the reactor by pulling with large forceps into a dry nitrogen atomsphere to prevent hydrolysis or oxidation of the heated polymer, which after cooling had a weight average molecular weight in polystyrene equivalents of 37,000 as determined by GPC. Ten (10) grams of the obtained polycarbonate product was added to 100 milliliters of dimethylformamide as the polymer solvent containing 0.25 gram of tartaric acid as the complexing component. Following the stirring of the mixture for 16 hours, the resulting polymer solution was precipitated into 3 liters of rapidly stirring deionized water. The polymer poly(poly(4,4'-cyclohexylidenebisphenol)carbonate-block-polydiphenylsiloxane-block-poly(4,4'-cyclohexylidenebisphenol)carbonate) with a GPC weight molecular weight of 55,300 and Tg of 152° C. was recovered by filtration and dried overnight (18 hours) in a vacuum oven at about 80 degrees Celsius. This polymer was tested as a free standing film in an Instron materials testing system (Model #1123) and found to have a yield strength of 71.1 Megapascals and a modulus of 2.4 Gigapascals. This can be compared to a polymer without polysiloxane blocks, such as the homopolymer, poly(4,4'-cyclohexylidenebisphenol)carbonate with a GPC weight molecular weight of 57,400 prepared by the same polyesterification process of this example, that displayed, as a free standing film, a yield strength of 59.7 Megapascals and a modulus of 2.0 Gigapascals.
EXAMPLE II
The processes of Example I were repeated with the exceptions that there were selected 270 grams of bisphenol (z) (4,4'-cyclohexylidenediphenol); 31.2 grams of (85 to 88 percent) dimethyl-(12 to 15 percent)-diphenyl siloxane, silanol terminated (Petrarch Systems PS085); and 273.4 grams of diphenylcarbonate. There resulted a block copolymer poly(poly(4,4'-cyclohexylidenebisphenol)carbonate-block-poly(diphenylsiloxane-co-dimethylsiloxane)-block-poly(4,4'-cyclohexylidenebisphenol)carbonate) with a GPC weight molecular weight of 39,000.
EXAMPLE III
The processes of Example I were repeated with the exceptions that there were selected 270 grams of bisphenol (AP) (4,4'-(1-phenylethylidene)bisphenol); 30 grams of diphenyl siloxane, silanol terminated (Petrarch Systems PS080); and 273.4 grams of diphenylcarbonate. There resulted a block copolymer poly(poly(4,4'-(1-phenylethylidene)bisphenol)carbonate-block-polydiphenylsiloxane-block-poly(4,4'-(1-phenylethylidene)bisphenol)carbonate) (a:10:c mass percent) with a GPC weight molecular weight of 68,000.
EXAMPLE IV
The processes of Example I were repeated with the exceptions that there were selected 285 grams of bisphenol (AP) (4,4'-(1-phenylethylidene)bisphenol); 15 grams of diphenyl siloxane, silanol terminated (Petrarch Systems PS080); and 273.4 grams of diphenylcarbonate. There resulted a block copolymer poly(poly(4,4'-(1-phenylethylidene)bisphenol)carbonate-block-polydiphenylsiloxane-block-poly(4,4'-(1-phenylethylidene)bisphenol)carbonate) (a:5:c mass percent) with a GPC weight molecular weight of 44,000.
EXAMPLE V
The processes of Example I were repeated with the exceptions that there were selected 255 grams of bisphenol (AP) (4,4'-(1-phenylethylidene)bisphenol); 45 grams of diphenyl siloxane, silanol terminated (Petrarch Systems PS080); and 273.4 grams of diphenylcarbonate. There resulted a block copolymer poly(poly(4,4'-(1-phenylethylidene)bisphenol)carbonate-block-polydiphenylsiloxane-block-poly(4,4'-(1-phenylethylidene)bisphenol)carbonate) (a:15:c mass percent) with a GPC weight molecular weight of 68,000 and a Tg of 157° C.
EXAMPLE VI
The processes of Example I were repeated with the exceptions that there were selected 240 grams of bisphenol (AP) (4,4'-(1-phenylethylidene)bisphenol); 60 grams of diphenyl siloxane, silanol terminated (Petrarch Systems PS080); and 273.4 grams of diphenylcarbonate. There resulted a block copolymer poly(poly(4,4'-(1-phenylethylidene)bisphenol)carbonate-block-polydiphenylsiloxane-block-poly(4,4'-(1-phenylethylidene)bisphenol)carbonate) (a:20:c mass percent) with a GPC weight molecular weight of 52,000 and a bimodal distribution.
EXAMPLE VII
The processes of Example I were repeated with the exceptions that there were selected 270 grams of bisphenol (AP) (4,4'-(1-phenylethylidene)bisphenol); 30 grams of diphenyl siloxane, silanol terminated (Petrarch Systems PS080); and 273.4 grams of diphenylcarbonate and the catalyst employed was tetramethyl ammonium tetraphenyl borohydride. There resulted a block copolymer poly(poly(4,4'-(1-phenylethylidene)bisphenol)carbonate-block-polydiphenylsiloxane-block-poly(4,4'-(1-phenylethylidene)bisphenol)carbonate) (a:20:c mass percent) with a GPC weight molecular weight of 9,000.
EXAMPLE VIII
The processes of Example I were repeated with the exceptions that there were selected 270 grams of bisphenol (P) (4,4'-(1,2-phenylenebisisopropylidene)bisphenol); 30 grams of diphenyl siloxane, silanol terminated (Petrarch Systems PS080); and 273.4 grams of diphenylcarbonate. There resulted a block copolymer, poly(poly(4,4'-(1,4-phenylenebisisopropylidene)bisphenol)carbonate-block-polydiphenylsiloxane-block-poly(4,4'-(1,4-phenylenebisisopropylidene)bisphenol)carbonate) with a GPC weight molecular weight of 68,900.
EXAMPLE IX
The polymer of Example III and a polycarbonate Z comparative polymer obtained from Mitsubishi Chemical with viscosity average molecular weight of 26,000 of the same bisphenol structure but without the siloxane incorporation (poly(4,4'-(1-phenylethylidene)bisphenol)carbonate were comparatively tested as follows: two layered photoresponsive imaging members containing the hole transport molecule, N,N'-diphenyl-N,N'-bis(3-methylphenyl)-1,1'-biphenyl-4,4'-diamine in the above polycarbonate binders respectively as the charge transport layer and trigonal selenium as the photogenerator was prepared as follows:
A solution for the charge transport layer was prepared by dissolving 1.0 gram of N,N'-diphenyl-N,N'-bis(3-methylphenyl)-1,1'-biphenyl-4,4'-diamine and 1.0 gram of the above polycarbonates, respectively, in 10 milliliter of methylene chloride. This solution was coated on top of a trigonal selenium generator layer by means of a Bird film applicator. The resulting photoreceptor devices with an aluminized Mylar substrate with a thickness of 75 microns was dried in a forced air oven at 135° C. for 20 minutes resulting in an 24 micron thick hole transport layer. Mechanical testing was done with samples of the above prepared photoreceptor devices with a sample size of 5 centimeters in length and with a width of 1.5 centimeters. Tensile tests were then conducted on an Instron materials testing system (Model #1123) employing a strain rate of 0.20 minute. The type of test used was a tensile test for films and coatings, ASTM test method D 882, capable of calculating the Young's modulus, tensile strength, yield strength, percent elongation and tensile toughness. The tensile toughness is the area of the stress-strain curve when the sample is strained to the breaking point. The results are contained in the following table. The Young's modulus is the ratio of the tensile stress to the strain in the linear portion of the stress-strain curve. The result is expressed in force per unit area usually gigapascals (GPa) or pounds force per square inch (psi). The tensile strength is calculated by deviding the load at breaking point by the original cross-sectional area of the test specimen. The result is expressed in force per unit area usually megapascals (MPa) or pounds-force per square inch (psi). The yield strength is calculated by dividing the load at the yield point by the original cross-sectional area of the test specimen. The result is expressed in force per unit area, usually megapascals (MPa) or pounds-force per square inch (psi). The percentage elongation at break is calculated by dividing the elongation at the moment of rupture of the test specimen by the initial gauge length (for example 5 centimeters in this example) of the specimen and multiplying by 100. The tensile toughness is the total energy absorbed per unit volume of the specimen up to the point of rupture. The result is expressed in units of Joules cm -3 .
TABLE 1______________________________________MECHANICAL PROPERTIES OFPOLYMER BINDERS FOR P/R Tensile Tough- Young's Tensile Yield Percent nessPolymer Modulus Strength Strength Elon- Joules/Structure GPa MPa MPa gation cm.sup.3______________________________________Comparative 3.73 94.74 87.85 4.58 2.67PolymerExample III 4.24 165.64 68.51 85.08 93.22Polymer______________________________________
EXAMPLE X
A photoresponsive imaging member was prepared by providing an aluminized Mylar substrate in a thickness of 75 microns, followed by applying thereto with a multiple-clearance film applicator a solution of N-methyl-3-aminopropyl-trimethoxy silane (obtained from PCR Research Chemicals) in ethanol (1:20 volume ratio). This hole blocking layer, 0.1 micron, was dried for 5 minutes at room temperature, and then cured for 10 minutes at 110° C. in a forced air oven. There was then applied to the above silane layer a solution of 0.5 percent by weight of 49,000 polyester (obtained from E. I. DuPont Chemical) in a mixture of methylene chloride and 1,1,2-trichloroethane (4:1 volume ratio) with a multiple-clearance film applicator. The layer was allowed to dry for one minute at room temperature, and 10 minutes at 100° C. in a forced air oven. The resulting adhesive layer had a dry thickness of 0.05 micron.
A dispersion of trigonal selenium and poly(N-vinylcarbazole) was prepared by ball milling 1.6 grams of trigonal selenium and 1.6 grams of poly(N-vinylcarbazole) in 14 milliliters each of tetrahydrofuran and toluene. A 1.0 micron thick photogenerator layer was then fabricated by coating the above dispersion onto the above adhesive layer present on the Mylar substrate with a multiple-clearance film applicator, followed by drying in a forced air oven at 135° C. for 5 minutes.
A solution of 4.0 grams of the aryl amine N,N'-diphenyl-N,N'-bis(3-methylphenyl)1,1'-biphenyl-4,4'-diamine and 6 grams of a block copolycarbonate of bisphenol and polydiphenylsiloxane, obtained from Example I, resin binder in 100 milliliters of methylene chloride was then coated over the photogenerator layer by means of a multiple-clearance film applicator. The resulting member was subsequently dried in a forced air oven at 130° C. for 30 minutes resulting in a 22 micron thick hole transport layer with 60 weight percent of the resin binder comprised of a block copolycarbonate of bisphenol and polydiphenyl siloxane of Example II.
The above fabricated imaging member was electrically tested by negatively charging it with a corona, and discharged by exposing it to white light of wavelengths of from 400 to 700 nanometers. Charging was accomplished with a single wire corotron in which the wire was contained in a grounded aluminum channel and was strung between two insulating blocks. The acceptance potential of this imaging member after charging, and its residual potential after exposure were recorded. The procedure was repeated for different exposure energies supplied by a 75 watt Xenon arc lamp of incident radiation, and the exposure energy required to discharge the surface potential of the member to half of its original value was determined. This surface potential was measured using a wire loop probe contained in a shielded cylinder, and placed directly above the photoreceptor member surface. This loop was capacitively coupled to the photoreceptor surface so that the voltage of the wire loop corresponds to the surface potential. Also, the cylinder enclosing the wire loop was connected to the ground.
The above imaging member was negatively charged to a surface potential of 800 volts, and discharged to a residual potential of 15 volts. The dark decay of this device was about 20 volts/second. Further, the electrical properties of the above prepared photoresponsive imaging member remained essentially unchanged for 10,000 cycles of repeated charging and discharging.
EXAMPLE XI
A layered photoresponsive imaging member was fabricated by repeating the procedure of Example VIII with the exceptions that a 0.5 micron thick layer of amorphous selenium photogenerating components on a ball grained aluminum plate of a thickness of 7 mils (175 microns) was utilized, and wherein conventional vacuum deposition techniques were selected. Vacuum deposition of the selenium photogenerating layer was accomplished at a vacuum of 10 -6 Torr, while the substrate was maintained at about 50° C. Thereafter, the resulting imaging device was dried in a forced air oven at 40° C. for 1 hour to form a 20 micron thick hole transport layer. Subsequently, the imaging member was cooled to room temperature, followed by electrical testing by repeating the procedure of Example VIII with the exception that a 450 nanometer monochromatic light was selected for irradiation. This imaging member was negatively charged to 850 volts and discharged to a residual potential of 30 volts. The dark decay of this device was 5 volts/second.
EXAMPLE XII
A layered photoresponsive imaging member was prepared by repeating the procedure of Example VIII by depositing a 0.5 micron thick layer of amorphous selenium on a ball grained aluminum plate of a thickness of 7 mils with the exception that the polycarbonate polymer resin binder of Example III was selected in place of the polymer resin binder of Example II. Thereafter, the resulting device or imaging member was dried in a forced air oven at 40° C. for 1 hour to form a 25 micron thick hole transport layer. Subsequently, the imaging member was cooled to room temperature, followed by electrical testing by repeating the procedure of Example III with the exception that a 450 nanometer monochromatic light was selected for irradiation. Specifically, this imaging member was negatively charged to 800 volts and discharged to a residual potential of 90 volts. The electrical performance as indicated by photosensitivity, dark decay, and residual voltage of this imaging member remained essentially the same after 1,000 cycles of repeated charging and discharging.
It is believed that images with excellent resolution with substantially no background deposits can be obtained with the imaging members of the present invention subsequent to development with known toner compositions comprised, for example, of styrene n-butyl methacrylate copolymer resin, 88 weight percent, 10 weight percent of carbon black, and 2 weight percent of the charge additive distearyl dimethyl ammonium methyl sulfate, reference U.S. Pat. No. 4,560,635, the disclosure of which is totally incorporated herein by reference.
Although the invention has been described with reference to specific preferred embodiments, it is not intended to be limited thereto, rather those skilled in the art will recognize variations and modifications may be made therein which are within the spirit of the invention and within the scope of the following claims. | Block copolymers of the formula ##STR1## wherein R 1 , R 2 , and R 3 are independently selected from the group consisting of hydrogen, alkyl and aryl; k, j, m and n represent the number of repeating segments, and imaging members thereof. | 2 |
CROSS-REFERENCE TO RELATED APPLICATION
This application claims benefit of U.S. Provisional application Ser. No. 61/187,532 filed Jun. 16, 2009, the entire disclosure of which is hereby incorporated herein by reference for all purposes.
BACKGROUND OF THE INVENTION
This invention relates to a pulp lifter for installation in a grinding mill.
A conventional pulp lifter for a grate discharge mill comprises a plurality of chambers radially arranged to rotate against the downstream side of a vertical or sloped grate. Each pulp lifter chamber is defined between a trailing edge wall and a leading edge wall, relative to the direction of rotation of the mill. In the conventional pulp lifter, the trailing edge wall and leading edge wall are radial, and the trailing edge wall of a leading pulp lifter chamber is the leading edge wall of the next following pulp lifter chamber. The pulp lifter chambers are open towards the axis of the mill.
A mill charge of mineral or mixture of mineral and any grinding media on the upstream side of the grate tumbles as the mill rotates. Water is fed to the mill and as the mineral is comminuted by the tumbling action, the fine particles and the water form a slurry in the interstices of the mineral. Some of the slurry passes through the apertures in the grate. During a portion of each rotation of the mill, each pulp lifter chamber in turn passes against the mill charge on the upstream side of the grate and slurry passes through the grate to a collecting region of the pulp lifter chamber.
As the mill rotates, the material in the pulp lifter chamber is lifted upward. The orientation of the pulp lifter chamber changes until ultimately the chamber is open downwards and material may fall downward from the chamber onto a discharge cone, which directs the material towards a discharge opening of the mill.
Developments of the conventional pulp lifter are described in U.S. Pat. No. 7,566,017 issued Jul. 28, 2009 and International Publication No. WO 98/01226, the entire disclosure of each of which is hereby incorporated by reference herein for all purposes. The pulp lifter disclosed in U.S. Pat. No. 7,566,017 is partially modular, in that each pulp lifter chamber is formed by a separate pulp lifter module, and the separate modules are assembled in a support structure. Moreover, the grate is integrated into the pulp lifter modules.
The material that enters a pulp lifter chamber through the grate has two principal fractions, namely a slurry fraction, composed of water and particles that are smaller than about few millimeters, and a pebble fraction, composed principally of stones that are larger than about few centimeters. The discharge position of the slurry depends on the mill rotational speed and the effective mill diameter. When the mill is viewed as rotating in the counterclockwise direction, the slurry fraction in a pulp lifter chamber starts flowing toward the discharge cone when the pulp lifter chamber is at about the 2:00 o'clock position and is discharged almost completely by the time that the pulp lifter chamber attains the 10:30 to 11:00 o'clock position. The pebble fraction on the other hand moves much less easily and does not start to fall toward the discharge cone of the pulp lifter until the pulp lifter chamber reaches about the 1:00 o'clock position, depending on the mill speed. For a short interval of rotation about the 12:00 o'clock position, the pebbles fall freely but from about 11:00 o'clock to the 10:00 o'clock position they strike the leading edge wall of the pebble lifter chamber and slide down the leading edge wall. After 10:00 o'clock, the sliding movement of the pebble fraction slows down and in any event any pebbles that fall from the pulp lifter chamber might not be discharged by the discharge cone but fall into another chamber of the pulp lifter. Thus, a large proportion of the pebble fraction is not discharged but remains in the pulp lifter over several rotations. This operation of the conventional pulp lifter is illustrated in FIG. 1 .
The recycling pebbles form a dead load behind the grate, which reduces the volumetric capacity of the pulp lifters by partially occupying the effective volume of the pulp lifters and increases the mass of the mill. In addition, the recycling pebbles may block the grate openings, and the presence of a quantity of pebbles in the pulp lifter reduces the flow gradient through the grate, and may cause a slurry pool to be formed in the mill. It is therefore desirable to reduce the proportion of the pebble fraction that remains in the pebble lifter over multiple rotations of the mill.
The object of the present invention is to eliminate drawbacks of the prior art and to achieve a more effective apparatus for discharging material from a mill, which is used for grinding or comminution, even at the higher rotating speeds of the mill.
SUMMARY OF THE INVENTION
In accordance with a first aspect of the disclosed subject matter there is provided a pulp lifter for installation in a rotary grinding mill, the pulp lifter comprising a leading edge wall and a trailing edge wall with respect to rotation of the mill, wherein the leading edge wall and the trailing edge wall define a pulp lifter chamber, the pulp lifter including a grate that allows slurry to pass to a radially outward collecting region of the pulp lifter chamber for removal from the mill by way of a radially inward discharge region of the pulp lifter chamber, and the pulp lifter further comprises a gate positioned between the collecting region and the discharge region, the gate being movable between an open position, in which the gate permits solid material to pass from the collecting region to the discharge region, and a closed position, in which the gate prevents return movement of solid material from the discharge region to the collecting region.
In accordance with a second aspect of the disclosed subject matter there is provided a pulp lifter for installation in a rotary grinding mill, the pulp lifter comprising a leading edge wall and a trailing edge wall with respect to rotation of the mill, wherein the leading edge wall and the trailing edge wall define a pulp lifter chamber, the pulp lifter including a grate that allows slurry to pass to the pulp lifter chamber for removal from the mill by way of a radially inward discharge region of the pulp lifter chamber, and wherein the trailing edge wall has a radially outer end and a radially inner end and is inclined relative to a radius of the pulp lifter such that the radially inner end of the trailing edge wall lags rotationally relative to the radially outer end of the trailing edge wall.
In accordance with a third aspect of the disclosed subject matter there is provided a pulp lifter for installation in a rotary grinding mill, the pulp lifter comprising a leading edge wall and a trailing edge wall with respect to rotation of the mill, wherein the leading edge wall and the trailing edge wall define a pulp lifter chamber, the pulp lifter including a grate that allows slurry to pass to a radially outward collecting region of the pulp lifter chamber for removal from the mill by way of a radially inward discharge region of the pulp lifter chamber, and wherein the trailing edge wall has an S-shaped curvature between a radially outer end and a radially inner end whereby the radial position of maximum slope of the trailing edge wall varies during rotation of the pulp lifter.
In accordance with a fourth aspect of the disclosed subject matter there is provided a pulp lifter for installation in a grinding mill, the pulp lifter comprising a leading edge wall and a trailing edge wall with respect to rotation of the mill, wherein the leading edge wall and the trailing edge wall define a pulp lifter chamber, the pulp lifter including a grate that allows slurry to pass to a radially outward collecting region of the pulp lifter chamber for removal from the mill by way of a radially inward discharge region, and wherein the leading edge wall is provided with a projection between a radially outer end and a radially inner end of the leading edge wall, the projection being configured to form a pocket for receiving pebbles that land on the leading edge wall during rotation of the pulp lifter, to prevent the pebbles that enter the pocket from passing to the collecting region of the pulp lifter chamber.
In accordance with a fifth aspect of the disclosed subject matter there is provided a pulp lifter for installation in a rotary grinding mill, the pulp lifter comprising a leading edge wall and a trailing edge wall with respect to rotation of the mill, wherein the leading edge wall and the trailing edge wall define a pulp lifter chamber, the pulp lifter including a grate that is formed with openings that allow slurry to pass to a radially outward collecting region of the pulp lifter for removal from the mill by way of a radially inward discharge region, and wherein the openings in the grate are distributed such that an area of the grate nearer the trailing edge wall has substantially fewer openings than an area of the grate nearer the leading edge wall, whereby the grate and the trailing edge wall form a pocket for retaining slurry as the mill rotates and the pulp lifter chamber rises from a lower position towards a higher position.
BRIEF DESCRIPTION OF THE DRAWINGS
For a better understanding of the invention, and to show how the same may be carried into effect, reference will now be made, by way of example, to the accompanying drawings, in which:
FIGS. 1A , 1 B, and 1 C (collectively referred to as FIG. 1 ) illustrate carryover of pebbles in a conventional pulp lifter,
FIGS. 2A-2D illustrate operation of a first pulp lifter embodying subject matter disclosed in this application,
FIG. 3 illustrates schematically a second pulp lifter embodying subject matter disclosed in this application,
FIG. 4 illustrates schematically a third pulp lifter embodying subject matter disclosed in this application,
FIG. 5 illustrates schematically a fourth pulp lifter embodying subject matter disclosed in this application, and
FIG. 6 illustrates schematically a fifth pulp lifter embodying subject matter disclosed in this application.
DETAILED DESCRIPTION
Referring to FIG. 2A , a pulp lifter chamber 1 is defined between a trailing edge wall 2 and a leading edge wall 4 (relative to the counterclockwise direction of rotation of the mill). Each pulp lifter chamber 1 is provided with a pebble gate 6 that is mounted for pivotal movement about an axis adjacent the trailing edge wall of the pulp lifter chamber. The gate 6 is able to turn through an angle of about 90° between an open position, in which it rests against the trailing edge wall 2 and extends substantially radially inward from its pivot axis, and a closed position, in which it extends substantially circumferentially towards the leading edge wall 4 of the pulp lifter chamber. When the gate 6 is closed, it divides the pulp lifter chamber radially between an outer collecting region and an inner discharge region. The outer region of the chamber is divided by an intermediate wall 5 into a trailing compartment and a leading compartment. Alternatively the pebble gate may be hinged between the leading edge wall and the intermediate wall or between the intermediate wall and the trailing edge wall between the collecting region and the discharge region. Pivotal movement of the gate between its open and closed positions takes place automatically due to the force of gravity on the gate and the load on the gate. Movement of the gate may be assisted and/or damped by an actuator operated by external force, e.g. pneumatically or electro-mechanically. As shown in FIGS. 2A-2D , the gate starts to open when the pulp lifter chamber is at about the 3:00 o'clock position and is fully open from about 2:00 o'clock to 11:30. The gate closes during rotation from about 11:30 to 9:00 o'clock and remains fully closed until about 3:00o'clock.
When a pulp lifter chamber is at the 6:00 o'clock position, slurry and pebbles pass through the grate into the collecting region 10 of the pulp lifter chamber. The pulp lifter rotates and when the chamber reaches about the 2:00 o'clock position, the pebbles start to slide down the intermediate wall and the trailing edge wall of the pulp lifter chamber. As the pulp lifter continues to rotate, some of the pebbles are discharged from the pulp lifter chamber and some pass the gate 6 but are not discharged. A small proportion of the pebble fraction may remain radially outward of the gate in the collecting region of the chamber, as shown in FIG. 2B . At about the 9:00 o'clock position, the gate is fully closed and the pebbles that passed the gate but were not discharged are blocked from returning to the collecting region by the closed gate, as shown in FIG. 2C . Thus, as the pulp lifter continues to rotate (and the chamber picks up another charge of slurry and pebbles in the collecting region) the pebbles in the radially inner discharge region of the pulp lifter chamber are blocked from returning to the collecting region. When the pulp lifter chamber reaches the 2:00 o'clock position, and the gate is fully open, the pebbles that are in the discharge region of the pulp lifter chamber slide down the trailing edge wall towards the discharge cone. Because these pebbles are located in the radially inner discharge region, the distance that they must travel in order to be discharged from the chamber onto the discharge cone is short and a large proportion of the pebbles will be discharged.
It will be understood that gravity supplies a centripetal force that brings about radially inward movement of the pebbles, and that for a given rotational speed of the pulp lifter, the centripetal force that is required to move the pebbles inward is directly proportional to the radius of the path followed by the pebbles. Because of the smaller radius of the path of travel of the pebbles in the discharge region, the force required to bring about inward movement is smaller for a pebble in the inner discharge region than for a pebble of the same mass in the collecting region and accordingly inward movement of the pebbles in the discharge region starts earlier in the rotation cycle.
In the case of the pulp lifter shown in FIG. 2 , the grate (not shown in FIG. 2 ) may be separate from the pulp lifter or, in the event that the pulp lifter is modular, may be integrated into the pulp lifter. When the pulp lifter shown in FIG. 2 is in use, slurry and pebbles pass through the holes in the grate and enter the collecting region of a pulp lifter chamber when the collecting region is at least partly immersed in the material on the upstream side of the grate. The material in the collecting region of the pulp lifter chamber collects against the trailing edge wall as the mill rotates, and the pulp lifter chamber rises. As soon as the pulp lifter chamber is no longer immersed in the material on the upstream side of the grate, there is a tendency for the slurry and pebbles in the collecting region to pass back through the grate to the upstream side of the grate, thereby reducing the efficiency of the pulp lifter.
FIG. 3 shows the holes in the grate through which slurry and pebbles pass from the upstream side of the grate to the pulp lifter chamber when the collecting region is immersed in the material on the upstream side of the grate. It will be seen from FIG. 3 that a substantial proportion of the area of the grate is not formed with holes. This imperforate region of the grate is closer to the trailing edge wall of the pulp chamber than to the leading edge wall. The location of the imperforate region of the grate is chosen so that when the pulp lifter chamber rises, and slurry and pebbles collect in the outer trailing region of the chamber, they are prevented from passing back through the gate to the upstream side of the grate.
In the embodiments shown in FIGS. 2 and 3 , the trailing edge walls of the adjacent pulp lifter chambers are radial, with the result that there is no significant radially inward movement of the pebbles in a pulp lifter chamber before the trailing edge wall of the pulp lifter chamber reaches about the 1:30 position, and is inclined at 45° to horizontal (although, as shown in FIG. 2A , the mass of slurry may slump before that point is reached). U.S. Pat. No. 7,566,017 discloses use of a modular pulp lifter with a curved guide to cause radially inward movement of the material before the pulp lifter reaches the 3:00 o'clock position, but such a pulp lifter is more expensive to produce than a pulp lifter in which the pulp lifter chamber is defined only between straight leading and trailing edge walls. In the case of the embodiment shown in FIG. 4 , the walls that separate the pulp lifter chambers are straight but are not radial. Each trailing edge wall is inclined to the radius such that the inner end of the wall is rotationally behind the outer end. As shown in FIG. 4 , this results in the trailing edge wall of each pulp lifter chamber attaining an inclination of about 45° to horizontal before the inner end of the trailing edge wall reaches the 3:00 o'clock position, with the result that the material in the pulp lifter chamber begins moving radially inwards toward the discharge cone earlier during the rotation of the pulp lifter than in the case of the conventional pulp lifter with radial walls.
FIG. 5 illustrates another configuration of the walls that separate the pulp lifter chambers. As shown in FIG. 5 , each wall (which is the leading edge wall of one pulp lifter chamber and the trailing edge wall of another pulp lifter chamber) has an S-shaped curvature such that the radial position at which the tangent to the wall is vertical depends on the angular position of the wall. As shown in FIG. 5 , the curvature is such that the outer segment of the wall is already inclined at a relatively steep angle when the radially inner end of the wall is at about the 5:00 o'clock position, so that the slurry and pebbles start moving radially inward well before the wall reaches the 1:00 o'clock position. By moving the material inward, the centripetal force that must be supplied by gravity in order to bring about radial inward movement of the pebbles is reduced. As the pebbles move inward, the slope of the trailing edge wall is reduced, but since the centripetal force is reduced, the pebbles continue to move inward. When the inner end of the wall is between about 2:30 and 1:00 o'clock, the inner segment of the wall is steep and the pebbles move readily toward the discharge cone and are diverted to the outlet of the mill.
FIG. 6 illustrates a further modification in which each wall separating two adjacent pulp lifter chambers is provided on one side with a projection that performs a similar function to the gate described with reference to FIG. 2 . The projection forms a pocket on the leading edge wall of the pulp chamber. The outer part of the wall is inclined to the radius, as described with reference to FIG. 4 , in order to initiate inward movement of the slurry and pebbles early in the rotation cycle, and the inner part of each wall is radial. Thus, as the pulp lifter chamber rises, the slurry and pebbles move radially inward, but some material remains in the chamber, resting on the leading edge wall of the chamber, when the inner segment of the wall reaches the 9:00 o'clock position. On further rotation of the pulp lifter, the material will move outward, away from the cone. As the material moves down the leading edge wall, it encounters the projection, which is configured as a pocket. The material enters the pocket and is retained by the pocket and prevented from returning to the collecting region of the chamber. The material in the pocket will start to fall from the pocket when the inner segment of the wall reaches about the 3:00 o'clock position, but at this point the slumping of the material in the collecting region prevents the material from the pocket from passing outward, away from the cone.
It will be appreciated that the invention is not restricted to the particular embodiment that has been described, and that variations may be made therein without departing from the scope of the invention as defined in the appended claims, as interpreted in accordance with principles of prevailing law, including the doctrine of equivalents or any other principle that enlarges the enforceable scope of a claim beyond its literal scope. Unless the context indicates otherwise, a reference in a claim to the number of instances of an element, be it a reference to one instance or more than one instance, requires at least the stated number of instances of the element but is not intended to exclude from the scope of the claim a structure or method having more instances of that element than stated. The word “comprise” or a derivative thereof, when used in a claim, is used in a nonexclusive sense that is not intended to exclude the presence of other elements or steps in a claimed structure or method. | A pulp lifter for installation in a rotary grinding mill has a leading edge wall and a trailing edge wall with respect to rotation of the mill. The leading edge wall and the trailing edge wall define a pulp lifter chamber, and a grate allows slurry to pass to a radially outward collecting region of the pulp lifter chamber for removal from the mill by way of a radially inward discharge region of the pulp lifter chamber. In one embodiment, a gate is positioned between the collecting region and the discharge region, the gate being movable between an open position, in which the gate permits solid material to pass from the collecting region to the discharge region, and a closed position, in which the gate prevents return movement of solid material from the discharge region to the collecting region. | 1 |
REFERENCE TO RELATED APPLICATIONS
This application is a continuation of U.S. patent application Ser. No. 12/845,439, filed Jul. 28, 2010 and now U.S. Pat. No. 8,046,851, which is a continuation of U.S. patent application Ser. No. 12/330,982, filed Dec. 9, 2008 and now U.S. Pat. No. 7,784,121, which is a continuation of U.S. patent application Ser. No. 11/566,040, filed Dec. 1, 2006 and now U.S. Pat. No. 7,490,377, which claims the benefit under 35 U.S.C. §119(e) of Provisional Application No. 60/742,222, filed on Dec. 5, 2005, and entitled “Patient Single Surface System”, the contents of each of which are herein incorporated by reference in their entirety.
FIELD OF THE INVENTION
This invention generally relates to a single surface system for patient accommodation, diagnosis, treatment and transfer. The invention particularly relates to a contoured thin single surface platform or bed surface and a unique single surface platform to cantilever frame interface which functions in concert with unique, auxiliary components and systems designed to interface with the single surface platform patient accommodation, diagnosis, treatment and transfer systems, for enabling the patient to remain on a single surface from the trauma site through, diagnosis, treatment and convalescence, while simultaneously adapting and accommodating auxiliary features and modules.
BACKGROUND OF THE INVENTION
Patients in a medical care facility often require movement from one location to another within the facility. This frequent movement is often necessitated by the layout or configuration of the facility. A typical medical care facility is organized into several specialty centers. These centers may include, for example, an emergency room, the patient's room, a radiology center, operating rooms and a recovery center. Each of these centers typically has a bed (single surface platform) or procedure area onto which the patient must be transferred upon their arrival into the center. For example, if a patient is brought into the emergency room they usually arrive in an ambulance. Upon arrival the patient must be transferred from the ambulance gurney to a bed in the emergency room. If the physician in the emergency room requires an x-ray for his diagnosis, the patient must be transferred from the bed in the emergency room onto a transport gurney. The gurney is then transported to the radiology center and the patient is placed onto the x-ray table. After the x-ray procedure is complete, the patient is transferred onto another gurney and transported back to the emergency room where the patient is then transferred back into a bed. Thus, prior to being admitted into the medical care facility, the patient has already required five transfer events (from the ambulance gurney to the emergency room bed, from the bed onto a gurney, from the gurney to the x-ray table, from the x-ray table back to a gurney, and from the gurney back to bed) and three transport events (from the ambulance to the emergency room bed, from the bed to the radiology center and from the radiology center back to the emergency room bed). If the patient is then admitted into the medical care facility there are two more transfer events and another transport event.
Patient transfer is typically performed when transferring the patient from a bed to a transport device such as a gurney. Often times the patient is not conscious or cannot physically assist in the transfer and so the hospital personnel must perform the transfer. The current patient transfer method with a bed sheet or thin plastic sheet requires between four and six personnel for incapacitated patients depending on patient size and personnel available. Current transfer methods are entirely a manual process, which requires significant lifting, pushing and pulling onto a transferring device (e.g. a roller-board or a back board), lifting the patient from the bed and placing the patient on a gurney. Patient handling is the leading cause of hospital staff injury. While it is not clear if patient surface transfer is the leading cause, it does appear to cause approximately 4000 reported incidents of injury/year according to US Bureau of Labor Statistics data, ranging in a direct cost of between $28 and $112 Million/year—depending on injury severity. Furthermore, this process can lead to injury to the patient caused by either improper manipulation or dropping. Since studies show that the average weight of the population is increasing, this transfer process will continue to become more difficult and injury-prone in the future. The disclosed PS3 single surface design allows a single person to easily transfer a patient, along with the auxiliary equipment for the patient, such as intravenous fluids and medications, which remain connected throughout the transfer of the patient.
There is additionally a need to improve patient movement through a medical care facility and reduce the time prior to starting of the treatment. This is exemplified by the need for reduction in the time required to provide treatment for stroke victims once they have arrived in the hospital. Data has demonstrated that the current manual, multi-person transfer of patients to imaging equipment were a key bottleneck in the diagnosis and treatment of stroke patients. Analysis of the data indicated that 20 to 40 minutes alone could be lost prior to the start of treatment for a stroke victim due to the standard transfer procedures from bed to radiologic device tables. Furthermore, a need exists to minimize disturbance/movement of patients, especially spinal injury victims, where the possibility of harming the patient during transfer is a very real possibility.
With regard to hospital staff injuries during patient transfers, it is well documented that immobilized acute care patients currently require multiple, injury-prone, manual, multi-person transfers from one surface to another throughout the care process from the incoming ambulance gurney to a hospital gurney and within the hospital for triage, imaging, surgery and various testing. This care process can vary from a short period (hours) to a couple of days.
In recognition of these needs to provide improvements in the areas of efficiency, cost and continuity of patient care, the instant inventor has provided herein a Patient Single Surface System (PS3) which provides a stable, cantilever frame design to support a resting and supporting surface (e.g. a bed) which provides a single surface platform on which the patient remains at all times, even during transfer from one surface to another (i.e. transfer to triage beds, imaging tables, diagnostic tables, gurneys, etc.). The PS3 cantilever design and contoured single support surface for transfer requires only a single person, regardless of patient weight, to position the unit above the surface for transfer, and subsequently lower them mechanically with the cantilever frame. Lifting, pulling, and or pushing of the patient is not required. Further, additional personnel are not required to move the patient, even for completely incapacitated patients.
PRIOR ART
Numerous prior art references exist which disclose a variety of disparate features generally related to transport mechanisms per se, and/or transport mechanisms compatible with medical equipment such as imaging devices. These references include: (A1) US Patent Pub. 2005/0246833, published Nov. 10, 2005 to Barth et al.; (A2) US Patent Pub. 2004/0111800, published Jun. 17, 2004 to Bartels et al.; (A3) US Patent Pub. 2003/0101513, published Jun. 5, 2003 to Wong; (A4) US Patent Pub. 2002/0042952, published Apr. 18, 2002 to Smeed; (A5) EP Patent 1 449 506 A1, published on Aug. 25, 2004 to Medical Iberica, S.A.; (A6) U.S. Pat. No. 6,782,571, issued Aug. 31, 2004 to Josephson et al.; (A7) U.S. Pat. No. 6,640,364, issued Nov. 4, 2003 to Josephson et al.; (A8) U.S. Pat. No. 6,374,438, issued Apr. 23, 2002 to Fox et al.; (A9) U.S. Pat. No. 6,178,575, issued Jan. 30, 2001 to Harada; (A10) U.S. Pat. No. 6,098,216, issued Aug. 8, 2000 to Williamson et al.; (A11) U.S. Pat. No. 5,475,884, issued Dec. 19, 1995 to Kirmse et al.; (A12) U.S. Pat. No. 5,319,817, issued Jun. 14, 1994 to Hay et al.; (A13) U.S. Pat. No. 5,285,539, issued Feb. 15, 1994 to Anderson et al.; (A14) U.S. Pat. No. 4,939,801, issued Jul. 10, 1990 to Schaal et al.; (A15) U.S. Pat. No. 4,658,450, issued Apr. 21, 1987 to Thompson; (A16) U.S. Pat. No. 4,019,772, issued Apr. 26, 1977 to Lee; (A17) U.S. Pat. No. 3,815,164, issued Jun. 11, 1974 to Smith; (A18) U.S. Pat. No. 3,304,116, issued Feb. 14, 1967 to Stryker; and (A19) U.S. Pat. No. 2,905,952, issued Sep. 29, 1959 to Reichert et al.
Reference A1 to Barth et al. discloses various embodiments of a patient removal system for evacuating a patient during an emergency. The patient removal systems may be used to transport the patient while the patient is on a mattress, or the patient removal systems may be used to transport the patient without the mattress. The patient removal systems permit caregivers to transport patients out of danger or harm without requiring patient support devices to be transported along with the patients.
Reference A2 to Bartels et al. discloses a gurney for transporting a patient. The gurney has a chassis with a support component for a supporting board for a patient. The board is fastened to prevent lateral motion and can be removed to provide medical treatment or to provide an examination device. The support component allows at least two different boards to be alternately supported and fastened with a positive fit at their head ends. The boards are different from one another at their head ends on the underside in shape and/or in width.
Reference A3 to Wong discloses a hospital bed adapted for use with an open geometry imaging system, such as a C-arm imager. The hospital bed includes a mobile base, a frame, a bed top, and a patient support. At least one portion of the bed top and patient support are substantially radiotransparent. The radiotransparent portions are capable of axial displacement along the lengthwise axis of the bed, thereby allowing the use of an imager on a patient in the bed without interference from the base. The axial displacement is preferably indexed to at least one predetermined stop position. One or more independent lateral sections can be selectively moved away from the radiotransparent portion, allowing for a reduction in the overall width of the bed. A patient transport system is also provided, in which the bed top and attached patient support can be used as a portable support, such as a stretcher, and may be secured to the base for subsequent transport and/or imaging when appropriate.
Reference A4 to Smeed discloses an invention formed from a platform ( 100 ) having a support surface ( 110 ), a pair of legs ( 150 , 150 ) connected to the support surface ( 110 ), and footings ( 152 ) and securing mechanism ( 160 or 180 ) on the legs ( 150 , 150 ) for attaching the invention to a litter that preferably satisfies NATO requirements. Preferably, the invention attaches to the poles used to carry a patient on a litter such that the invention provides space for the patient's legs to pass under if necessary. A further embodiment of the invention adds at least one accessory clip, which preferably includes at least one attachment for a piece of medical equipment such as medical monitors, ventilators, and infusion pumps.
Reference A5 to Medical Iberica, S.A. discloses a gurney which has a base platform with two levels joined by an oblique central transition segment. The lower segment housing includes a power source and a means for raising the mattress, while another articulated means for raising the gurney includes on each side a pair of tubes that rise from the two levels of base platform. The base platform is jointed to curved tubes which are joined to the frame of the mattress. The frame also incorporates a control for turning the mattress towards its drainage area.
Reference A6 to Josephson et al. discloses a patient transport system for transporting a patient from a magnetic resonance imaging system to a second imaging system and includes an elongated member and first and second coupling mechanisms. The elongated member has an upper surface configured to support a patient. The first coupling mechanism is coupled to the elongated member and is configured to removably couple the elongated member to the magnetic resonance imaging system. The second coupling mechanism is coupled to the elongated member and is configured to removably couple the elongated member to a second imaging system.
Reference A7 to Josephson et al. discloses a pedestal for use with a patient transport system for multiple imaging systems can include a support member configured to support a patient or object of interest, an elongated planar member coupled to the support member and configured to removably couple and slidably engage an elongated cradle member, and a docking assembly coupled to the elongated planar member configured to engage the receipt of and the removal of the elongated cradle member supportable by the elongated planar member.
Reference A8 to Fox et al. discloses a mobile patient stretcher particularly adapted for additional use as a pain clinic treatment table designed to accommodate a C-arm of a fluoroscopic or like imaging apparatus. The stretcher litter top or patient support surface is radiolucent and includes selectively removable lateral side rail sections so that the litter top can be selectively converted into an hourglass shape without side rails as required for treatment procedures and/or C-arm access and imaging. Alternatively, with the lateral side rail sections in place, the stretcher includes a full-width patient support surface, and also includes a radiolucent fowler back rest, selectively deployable side rails, and a hydraulically or otherwise controlled conventional wheeled stretcher base that is adapted to place the patient support surface in a raised, lowered, Trendelenburg, or reverse Trendelenburg orientation. The stretcher can be used as a fully functional stretcher to transport a patient to and from a procedure area and a recovery area, provides a comfortable resting place with a fowler back rest for a patient, and is also usable as a treatment table during fluoroscopic or other imaging procedures.
Reference A9 to Harada discloses a stretch mounting unit which includes a unit body detachably mounted on a stretcher. A drive device is attached to the unit body for providing an output with a center shaft for receiving the output of the drive device. A coupling that couples the drive device and the center shaft for transmitting the output of the drive device to the center shaft includes a roller pressed on the center shaft to produce torque. A carrier swingably disposed on the center shaft, a pair of wheels rotatably mounted on the carrier and rotated by the torque of the roller, and a friction clutch provided rotatably on the center shaft and associated with the carrier for swinging the carrier until one of the pair of wheels touches the ground.
Reference A10 to Williamson et al. discloses a convertible patient transport apparatus including a frame assembly adapted for supporting a patient. A plurality of bent pivot legs are attached to the frame assembly and mounted on respective wheels for rolling movement of the transport apparatus over a supporting surface. Each of the pivot legs includes a vertical upper portion, an intermediate portion formed at an angle to the upper portion, and a vertical lower portion formed with the intermediate portion. An actuator pivots the legs between an open position, wherein the distance between the lower portions of laterally adjacent legs is increased, and a closed position, wherein the distance between the lower portions of laterally adjacent legs is reduced. In the open position, the width of the transport apparatus is expanded to move the frame assembly over a bed of the patient. In the closed position, the width of the transport apparatus is narrowed.
Reference A11 to Kirmse et al. discloses a patient support apparatus that comprises a first support plate which can be transferred from an undercarriage onto a table frame of a medical apparatus. The table frame is provided with a second support plate which receives the first support plate directly, but enables an examination subject to be directly received on the second support plate without requiring the assembly of the first support plate.
Reference A12 to Hay et al. discloses a patient lift apparatus with a U-shaped base that folds to enable convenient reduced width storage of the unit when not in use. Accordingly, the U-shaped base of the unit has a hinge with a vertical axis in each leg of the “U”. These hinges are located midway of each of the vertical legs. Typically, these hinges provide for a pivotal movement of the casters at the ends of each leg of the “U” from a caster extended position for patient lifting and transport to a caster folded position parallel to and spaced apart from the base of the “U”. A releasable lock mechanism is provided to each leg for locking the hinge in either the caster extended position or the caster folded position. The lock includes an outer moving sleeve with a spring biased inner key connected to the spring biased sleeve. The key moves with the sleeve and fits into and out of paired apertures in the hinge. One aperture of the hinge is for maintaining the hinge in the caster folded position; the other aperture of the hinge is for maintaining the hinge in the caster extended position. In operation, an attendant moves the sleeve to unlock the hinge. Thereafter, and while the rest of the lift apparatus is supported at its respective casters, the outer leg member of the “U” is moved between the caster folded position and the caster extended position for patient transport.
Reference A13 to Anderson et al. discloses a flexible bathing fluid permeable mesh sheet attached to a rectangular frame. A flexible and collapsible bathing fluid impermeable sheet is attached to the frame below the mesh sheet and spaced apart therefrom for forming an open fluid receptacle. The mesh sheet is attached to the frame with straps which may be adjusted for allowing the patient to be placed substantially coplanar with the frame and away from the fluid collected in the impermeable sheet or lowered toward the impermeable sheet to provide an immersion bath.
Reference A14 to Schaal et al. discloses an improved patient transporting and turning gurney for receiving and lifting a patient from a hospital bed, for transporting and depositing the patient on a hospital operating table, and for lifting and turning a patient for surgery. Preferably, the gurney has a U-shaped base, this base of sufficiently small dimension to fit under a hospital bed and of sufficiently large dimension to straddle the sides of a conventional operating table pedestal. The gurney further includes an overlying stretcher support, preferably U-shaped, for supporting a rotatable stretcher frame. A longitudinally extending rotating stretcher frame is mounted for rotation about its longitudinal axis on the stretcher support. Extending from the U-shaped base to the overlying stretcher support, there is provided a lifting device for moving the stretcher support upwardly and downwardly relative to the base. A system of patient attachment to the stretcher frame is disclosed in which two tensile supported sheet members can be detachably supported from the frame.
Reference A15 to Thompson discloses a multi-position bed such as is used in hospitals and for persons who by reason of physical disability of age are unable to turn or move themselves in bed. As shown in FIG. 4 the bed comprises a base frame 1 supported on casters and having a pair of pivoted angled lifting arms 2 . One of the pair of lifting arms is pivoted in turn to an interlink pivoted to a pivot bracket 4 . The other lifting arm 2 is pivoted directly to a second pivot. The pivot brackets 4 and 5 act as the pivot supports for the center section 6 of a mattress platform which also comprises two side sections 7 . The side sections 7 are not hinged directly to the center section but simply have interengaging features in the form of side frame registers 11 . When the bed is used as a turning bed the interengaging features 11 disengage. The side sections 7 are carried by pairs of links 8 and 9 which join the pivot brackets 4 to the side sections 7 at points underneath the side sections. These side sections are also connected by side frame pivot arms 13 to an end pivot frame 12 , at each end of the bed, the pivot frame 12 being rigidly connected to the center bed section 6 . The movement of the bottom links 8 is restricted, in a downward direction, by bottom link stops 10 . The links 8 , 9 may be disconnected and the side sections 7 connected rigidly to the center section 6 so that the mattress platform can be caused to tilt bodily in a lateral sense.
Reference A16 to Lee discloses a hospital patient transfer system by a transfer trolley with a wheeled undercarriage. A lift ram is movable up and down with respect to the undercarriage and can also tilt about a horizontal pivot on the undercarriage. The lift ram supports an upper frame so that it can be raised, lowered or tilted in response to varying positions of the ram. The upper frame has parallel end pieces spaced from each other by a distance such that a hospital bed, operation table or trolley can be received between them. The end pieces of the upper frame are provided with lift members which can be raised or lowered with respect to the end pieces. A flat rectangular patient-supporting element can removably be inserted in opposed tracks in the end pieces so that it may be positioned below a stretcher supported by the lift members when they are in a raised position. The lift members can then be lowered to enable the weight of the patient to be taken by the patient supporting element.
Reference A17 to Smith discloses A patient lifting and transporting vehicle having a U-shaped base frame with four wheels, two telescopic tubes extending upward from the base frame, a rectangular upper frame provided with a removable strong transfer sheet for supporting a patient, said upper frame being fixed on the upper ends of the telescoping tubes, and operating mechanism comprising a lifting arm assembly hinged at its lower end to the base frame and at its upper end to a follower block slidable in one tubular side of the upper frame, said tubular side containing a drive screw engaging the follower block and crank-operated bevel gears for rotating the drive screw. When the upper frame is in its lowest position the lifting arm assembly lies at an angle of about 45° from the horizontal; as the lifting arm is moved, by the drive screw and follower block, toward a vertical position the upper frame is raised correspondingly to a highest position when the arm is vertical. Springs under compression in the telescoping tubes counter-balance part of the weight of the loaded upper frame. The location of the telescoping tubes on one side of the base frame and spaced from its ends enables the upper frame to be moved over a bed or operating table or into the range of an X-ray machine.
Reference A18 to Stryker discloses a wheeled carriage for supporting a patient and, more particularly, to a type of carriage having a vertically adjustable support frame upon which a stretcher can be removably placed for the purpose of safely supporting and transporting a patient disposed thereon in a horizontal or tilted position.
Reference A19 to Reichert et al. discloses new and useful improvements in hospital equipment and, more particularly, to a patient stretcher adapted for transporting patients from the hospital bed to a surgical operating room, X-ray room, or the like.
Additionally, references are known which relate to devices which are height-adjustable and/or capable of multiple positioning. These references include: (B1) U.S. Pat. No. 6,499,163, issued Dec. 31, 2002 to Stensby; (B2) FR Patent 2 789 302, published on Aug. 11, 2000 to Antar; (B3) U.S. Pat. No. 5,934,282, issued Aug. 10, 1999 to Young III et al.; (B4) U.S. Pat. No. 5,461,740, issued Oct. 31, 1995 to Pearson; (B5) PCT Publication No. WO 94/09738, published May 11, 1994 to Blanco GMBH & Co.; (B6) U.S. Pat. No. 5,187,821, issued Feb. 23, 1993 to Nieminen et al; (B7) PCT Publication No. WO 90/03158, published Apr. 5, 1990 to Oy AFOR; (B8) PCT Publication No. WO 89/02260, published Mar. 23, 1989 to Siegener Feinmechanik GMBH; and (B9) GB Patent Application 2 039 731, published Aug. 20, 1980, to Rogers.
Reference B1 to Stensby discloses an apparatus convertible to a chair or table comprises a support structure; first and second pairs of wheels rotatably supporting the support structure; and a platform supported by the support structure. The platform includes a seat support and a back support. The platform is positionable between a chair configuration and a table configuration. The first pair of wheels have inboard and outboard positions. The first pair of wheels are in the inboard position when the platform is in the table configuration. The first pair of wheels are in the outboard position when the platform is in the chair configuration.
Reference B2 to Antar discloses a modular gurney for transporting patients, the gurney has two or more rigid frame members ( 1 , 2 ) each formed of two hollow tube sections connected by a honeycomb panel between a double skin ( 17 , 17 ′). The gurney has a stainless steel plate ( 6 , 6 ′).
Reference B3 to Young III et al. discloses a spine board for use in supporting a patient during emergency medical treatment comprising a pair of board joined together by a hinge. The hinge is provided with a latch which allows the board to be rigidly locked in a flat condition so as to provide rigid support for a patient receiving CPR or other treatment.
Reference B4 to Pearson discloses a multi-positional bed comprised at one end thereof with a pair of pillars. One of the pillars is disposed at or near each side of the bed and at the opposite end a single pillar is disposed substantially on the longitudinal center line of the bed. The bed has a user-supporting frame, and respective mounting devices for mounting the frame to each of the pillars. Each mounting device is arranged to move lengthwise with respect to the respective pillar independently of the movement of the other mounting devices.
Reference B5 to Blanco GMBH & Co. discloses a patient-transport trolley with a chassis ( 12 ) and a support frame ( 16 ) designed for a patient to lie on, the support frame ( 16 ) being held by a height-adjustable arm mounted on the chassis ( 12 ). In order to simplify the design, the invention calls for the trolley to include an arm with an elevating mechanism ( 14 ) with a parallelogram-type action, one end of the elevating mechanism ( 14 ) being held in a lower bearing block ( 28 ) on the chassis ( 12 ) while the other end is held by an upper mounting block ( 42 ) on the support frame ( 16 ).
Reference B6 to Nieminen et al. discloses a hospital bed comprising a body ( 4 ) provided with wheels, a transfer underlay frame ( 24 ) for a patient, a lying or resting frame ( 17 ), which can be lifted and lowered down, lifting means ( 30 ) for the lying frame, and bearer means ( 15 , 20 ) for a transfer underlay frame; the bearer means comprise two U-shaped bearer rods ( 15 ) disposed side by side and turnable in the body, the upper and the lower arms ( 15 b , 15 c ) of which are interconnected through articulated joints ( 18 , 22 ) by a transverse support ( 16 , 21 ) so as to secure a parallel turn of the arms aside. A bearer beam ( 20 ) is secured to the upper transverse support ( 21 ) and wheels ( 19 ) to the lower support ( 16 ). The invention allows a sideways transfer of a patient on a transfer underlay supported by straps ( 26 , 28 ) secured to a bearer beam, without changing the direction. Wheels ( 19 ) provided in the bearer rods ( 15 ) move simultaneously to the same direction which ensures that the bed ( 2 ) is properly supported during all stages of the transfer.
Reference B7 to Oy AFOR discloses a treatment table ( 1 ) manufactured for the needs of physical care and rehabilitation in which the height of the treatment table and the position of the treatment level ( 20 ) are adjusted simultaneously by means of a single power device ( 5 ). The adjusting apparatus of the treatment table ( 1 ) comprises a power device ( 5 ), which is joined in a pivoting manner to the lower frame ( 2 ), lifting arms ( 7 , 8 ), which are joined in a pivoting manner by their lower end to the lower frame ( 2 ) and the power device ( 5 ) and by their upper end to be upper frame ( 6 ) by means of pivoting fastening members ( 13 ), an extension arm ( 9 ), which is locked to be parallel with the lifting arm ( 8 ) when the position of the treatment level ( 20 ) and the height are adjusted simultaneously, and which said extension arm ( 9 ) pivots in relation to the lifting arm ( 8 ) when the treatment level ( 20 ) is moved in the vertical direction without the position of the treatment level ( 20 ) being changed.
Reference B8 to Sie-gener Feinmechanik GMBH discloses a couch with main components ( 1 ) a central part ( 5 ) arranged on a chassis ( 2 ) with running wheels and capable of being vertically lifted and lowered by a driving motor, and a plate for seating ( 6 ) hingedly linked to a head-rest ( 7 ) and to a leg-rest ( 8 ) that can be pivoted by means of a further driving motor up to a seating and to a lying position. In the area of an opening ( 10 ) of the seating plate ( 6 ) of the central part are arranged sanitary devices with a water supply for washing the body. A collection container ( 12 ) can be placed in an overflow tub ( 11 ) arranged underneath the seating plate ( 6 ) for receiving the excrements of a bedridden person and the washing water evacuated through the opening ( 10 ) in the seating plate ( 6 ). A mattress ( 13 ) of elastic material fitted to the form of the body and having an opening ( 14 ) that corresponds to the opening ( 10 ) of the seating plate ( 6 ) is removably secured on the couch ( 1 ).
Reference B9 to Rogers discloses an apparatus 1 , FIG. 1 , e.g. a nursing or orthopaedic bed, for supporting a patient comprises a rigid undercarriage 2 carrying a rigid frame 7 turnable, e.g. pivotable, about a horizontal axis. A further rigid frame 3 is slidably and/or removably supported on the frame 7 and can be releasably locked thereto by first locking means 100 , FIG. 4 . The frame 7 carries patient-supporting frames 4 , 5 which are rotatable about a longitudinal axis of the apparatus through at least 180° and which can be releasably locked in one or more predetermined positions by second locking means 50 .
Additionally, references are known which teach various support systems. These references include: (C1) U.S. Pat. No. 6,546,577, issued Apr. 15, 2003 to Chinn; (C2) U.S. Pat. No. 6,619,599, issued Sep. 16, 2003 to Elliott et al.; (C3) U.S. Pat. No. 6,375,133, issued Apr. 23, 2002 to Morrow; (C4) US Patent Pub. 2002/0162926, published Nov. 7, 2002 to Nguyen; (C5) U.S. Pat. No. 6,073,285, issued Jun. 13, 2000 to Ambach et al.; (C6) U.S. Pat. No. 5,987,670, issued Nov. 23, 1999 to Sims et al.; (C7) U.S. Pat. No. 5,611,638, issued Mar. 18, 1997 to Dörr et al.: (C8) U.S. Pat. No. 5,651,150, issued Jul. 29, 1997 to Kanitzer et al.; (C9) U.S. Pat. No. 5,687,942, issued Nov. 18, 1997 to Johnson; (C10) U.S. Pat. No. 5,699,988, issued Dec. 23, 1997 to Boettger et al.; (C11) U.S. Pat. No. 5,588,166, issued Dec. 31, 1996 to Burnett; (C12) U.S. Pat. No. 5,407,163, issued Apr. 18, 1995 to Kramer et al.; (C13) U.S. Pat. No. 5,117,521, issued Jun. 2, 1992 to Foster et al.; (C14) U.S. Pat. No. 5,016,307, issued May 21, 1991 to Rebar; (C15) U.S. Pat. No. 4,720,881, issued Jan. 26, 1988 to Meyers; (C16) U.S. Pat. No. 4,768,241, issued Sep. 6, 1988 to Beney; (C17) U.S. Pat. No. 4,489,454, issued Dec. 25, 1984 to Thompson; (C18) U.S. Pat. No. 4,262,872, issued Apr. 21, 1981 to Kodet; (C19) U.S. Pat. No. 4,273,374, issued Jun. 16, 1981 to Portman; (C20) U.S. Pat. No. 4,016,612, issued Apr. 12, 1977 to Barile, Sr.; (C21) U.S. Pat. No. 3,709,372, issued Jan. 9, 1973 to Alexander; and (C22) U.S. Pat. No. 2,696,963, issued Dec. 14, 1954 to Shepherd.
Reference C1 to Chinn discloses a mobile medical emergency and surgical table that comprises a frame assembly, a pair of mechanically advantaged undercarriage assemblies having wheels, a plurality of stretcher yoke assemblies, a plurality of preferably uniformly dimensioned and interchangeable storage cassettes, an electrical subsystem, and a plurality of optional mounts for the attachment of medical and surgical equipment.
Reference C2 to Elliott et al. discloses an intravenous (IV) support system including a moveable base and an upright IV pole. The base comprises a lower wheeled plate, an upper plate having a through hole, and an upright elongate tube fastened to the upper and lower plates. The tube is aligned with the through hole of the upper plate to form a passage for the IV pole. A bolt transversely extends through the wall of the tube to form a transverse supporting surface for the IV pole. The IV pole comprises, at a lower end thereof, a pin extending from a flange so that the IV pole may be fitted in a through bore of and supported by a mounting adapter mounted to a patient support frame. The system allows the IV pole to be easily transferable among numerous stand-alone bases and patient support frames, and steadily retained by the bases and mounting adapters mounted to the patient support frames without positive locking mechanisms.
Reference C3 to Morrow discloses an intravenous (IV) support assembly including a mounting adapter and an upright IV pole. The mounting adapter is mountable to a single rail of a patient support frame, and includes an insertion member and a locking mechanism. The IV pole is supported by the mounting adapter, and includes a hollow lower end for receiving the insertion member of the mounting adapter. The IV pole is secured to the insertion member by the locking mechanism of the insertion member. A variety of different mounting adapters each configured for a different rail configuration are available for supporting a common IV pole, so the IV pole is transferable between mounting adapters mounted to different rails.
Reference C4 to Nguyen discloses an apparatus for supporting medical fluids for delivery to a patient during surgery, in particular for fluids for intravenous delivery to the patient. The apparatus comprises a clamp for removably securing the apparatus to an object, such as a surgical table or bed, to allow the object to support the apparatus, the object being immovable relative to the patient to which the fluids are to be delivered. An arm is provided extending from the clamp. A support is connected to the arm remote from the clamp, the support being adapted to retain a receptacle containing medical fluids. In one embodiment, the arm is movable longitudinally with respect to the clamp, thereby allowing the position of the support with respect to the clamp to be adjusted. In a second embodiment, the arm is rotatable about the clamp such that the fluid receptacle support may be moved within a plane containing the longitudinal axis of the arm.
Reference C5 to Ambach et al. discloses a mobile support unit such as an IV stand or the like coupled to a mobile hospital bed, gurney or wheelchair by a latch mechanism which provides hands free operation thereby avoiding the need for a nurse or care provider to manually manipulate the latch to secure the units together for tandem transport. Further, the latch mechanism according to this invention includes a clutch which prevents relative movement of the IV stand or support unit with respect to the hospital bed during transport up to a specific adjustable torque level thereby avoiding the problem of the IV stand or support unit swinging freely relative to the bed during movement. Further, the clutch permits movement of the IV stand or support unit through an arc relative to the bed when a specified force is applied as required by the nurse or care provider to reposition the stand or support unit relative to the bed and provide increased access to the patient or the like. The IV stand includes a relatively heavy base which provides a low center of gravity for the unit and offers a very stabile mobile IV stand which resists tilting or tipping during transport.
Reference C6 to Sims et al. discloses a system for securing a wheeled pole, such as an IV pole, to an adjustable height mobile bed to form a movable assembly. The system includes a linkage element with first and second mounting blocks effective to secure the linkage element to an intermediate frame portion of the bed. An elastomeric member is extendable from the linkage element for engagement with a plurality of engagement members disposed on opposite sides of a channel formed in the linkage element. The elastomeric member effectively secures the IV pole in the channel for transport of the IV pole/bed assembly.
Reference C7 to Dörr et al. discloses a connecting device with at least two connecting elements fastened to the patient support and insertable into pin receivers of the column and carriage. Each connecting element has two latching elements each movable between a latching position and an unlatching position, and during relative movement between the transport carriage and the support column resulting in the transfer of the patient support from the column to the transport carriage, or the reverse, each connecting element becomes received at the same time in a column pin receiver and a carriage pin receiver. Each receiver has a detent recess for receiving one of the latching elements of a received connecting element in its latching position and a control surface associated with the other latch element of the received connecting element which control surface upon the reception of the connecting element transfers this latching element to its unlatched position. Each of the latching elements has associated with it a sensor for detecting the latching position of the latching element.
Reference C8 to Kanitzer et al. discloses a structure providing a patient support surface which is transferable between a stationery support column and a wheeled transport carriage with the transport carriage, the support column and the support surface providing structure having connecting parts which cooperate to securely hold the structure to the transfer carriage or to the support column when the structure is mounted on the transfer carriage or the support column, the connecting parts during transfer of the structure from the transfer carriage to a support column, or vice versa, being automatically moved between latched and unlatched conditions to allow the transfer to occur and having security features preventing the patient support surface providing structure from being inadvertently unfastened from both the support column and the transport carriage during a transfer procedure.
Reference C9 to Johnson discloses a support system for detachably mounting an article to a tubular support structure. The system includes a bracket plate having a key-way with side walls diverging from a front face of the bracket plate to a rear face thereof. The key-way extends entirely through the bracket plate between the front and rear faces and includes an entry mouth opening at an edge of the bracket plate. A support plate is adapted to be attached to the rear face of the bracket plate to close the key-way at the rear face. A mounting device mounts the bracket plate and attached support plate to one of the tubular members, with the key-way facing away from and extending longitudinally of the one tubular member. An elongated supporting key is adapted to be attached to the other of the tubular members lengthwise thereof. The supporting key is positionable into the entry mouth of the key-way and has side walls converging from a front face of the key to a rear face thereof for mating proximity to the diverging side walls of the key-way.
Reference C10 to Boettger et al. discloses a coupler clamping assembly ( 10 ) for releasably connecting a mobile support stand ( 52 ) with a patient transport device such as a gurney ( 54 ), in order to allow patient transfer with the support stand while eliminating the need for extra transport personnel. The clamp ( 10 ) preferably includes a pair of opposed, laterally spaced apart jaws ( 20 , 22 ) interconnected by a central bight section ( 24 ). A connector assembly including a pair of oppositely extending elongated connection elements ( 14 , 16 ) is supported on the body for relative pivotal movement, and the connection elements are received for rotation in a tubular section ( 66 ) conventionally provided as a part of the gurney ( 54 ). A clamping screw ( 18 ) is threaded for receipt in a threaded opening through one of the jaws ( 20 ) and cooperates with the opposed jaw ( 22 ) for securely clamping the upright standard ( 60 ) of the pole unit ( 52 ) within the clamping assembly ( 10 ). An arm assembly is also provided for permitting releasable interconnection between a mobile support stand and any type of patient transfer device. The arm may be fixed to the stand or transfer device, and includes an attachment clamp or coupling for releasably interconnecting the stand and transfer device.
Reference C11 to Burnett discloses a medical attachment device that is hung upon and rigidly attached to an upright and horizontally disposed part of a patient transport vehicle and that also grasps an upright pole of a wheeled patient care apparatus for maintaining the vehicle and the apparatus in fixed spatial relationship while both are being moved by a single medical attendant.
Reference C12 to Kramer et al. discloses a pole support for an IV pole mounted adjacent a patient support and having two pole supports separated by a pair of tracks providing guided paths between the two pole supports. The IV pole has a pole locking block at one end with pins that engage the tracks for slidingly moving the IV pole along the track between the two pole supports. The pins on the pole locking blocks further engage first slots and notches in the two pole supports for supporting the IV pole in a generally vertical position; and the pins engage second slots and notches in the two pole supports for supporting the IV pole in a generally horizontal position.
Reference C13 to Foster et al. discloses a care cart and a hospital bed having mating bases to permit the care cart to nest with the hospital bed. The combination of cart and bed can be rolled from place to place to transport the patient and the cart can be removed from the bed while maintaining the life support systems connected to the patient while the patient is transferred to another patient support.
Reference C14 to Rebar discloses a patient transportation apparatus comprising a stretcher and a collapsible pole for use in supporting IV sets and the like. The pole portion of the apparatus is adjustable in height with respect to the plane of the stretcher while being capable of being collapsed to a position below or equiplanar with the horizontal surface of the stretcher. The pole is located so that in all positions it does not extend beyond the perimeter of the horizontal surface. In another embodiment a lower support means is also provided for supporting gravity dependent drainage bags and the like.
Reference C15 to Meyers discloses an anesthesia accessories unit which is adapted to be placed and supported on an end portion of a patient's bed structure normally a hospital operating room table. The anesthesia accessories unit includes a primary tray assembly having the following items supported thereon or forming a portion thereof (1) a support hole assembly adapted to receive various syringe structures and other items therein in a neat and orderly fashion; (2) a headrest assembly adapted to receive a patient's head thereon in proper relationship to the drugs and medicine needed; (3) an instrument holder compartment adapted to receive instruments therein; (4) a drape frame assembly adapted to be erected over the patient's head and receive a surgical drape or cover member thereon in an elevated position relative to the patient's head; (5) a needle remover assembly allowing the anesthesia provider to remove covers and needle members with the use of only one hand; (6) an intravenous tubing holder assembly adapted to receive and anchor an intravenous tubing assembly; (7) an attachment assembly adapted to receive and hold various items such as tape, scissors, etc.; (8) a tube tree assembly adapted to receive air supply tubes and the like thereon to hold in an elevated condition; and (9) a transducer pole assembly adapted to attach a transducer member thereto which then is automatically moved with raising and lowering of the operating table structure. The intravenous tubing holder assembly includes a first tube holder adapted to receive an intravenous tubing therein and a stop cock holder operable to hold a stop cock therein so as to be readily operable by one hand of the anesthesia provider.
Reference C16 to Beney discloses a self contained, mobile intensive care bed structure adapted to carry a plurality of devices for monitoring and/or providing treatment to a patient in the bed structure and including built in direct current lines and outlets, communication lines and outlets, a pneumatic oxygen air and vacuum lines and outlets, and a direct current source, with the bed structure being operable in a stationary mode from fixed sources of d-c power, a-c power, oxygen, air and/or vacuum.
Reference C17 to Thompson discloses an apparatus for carrying a hemodynamic pressure transducer in a hospital bed so that the transducer is maintained in a constant relationship with the level of the heart of a patient in said bed, which comprises a first, vertical member for mounting said apparatus on said hospital bed, where said first vertical member is adapted to fit into a bracket provided on a hospital bed, and is further adapted to hold an intravenous feeding pole, so that said apparatus may hold an intravenous feeding pole as well as said hemodynamic pressure transducer; hinge means attached to and projecting horizontally from said first vertical member; a second member engaging said hinge means and disposed to project in a direction perpendicular to the axis of said first member; and a third, vertical member to which said transducer is adjustably but securely affixed. The bracket may be an intravenous feeding pole bracket provided on said bed. The first member may be mounted on a portion of said bed which is so selected that the relationship between the height of the transducer and the height of the patient's heart remains constant when the level of the bed is raised or lowered.
Reference C18 to Kodet discloses a pole attached to a hospital stretcher or the like for supporting an intravenous solution container. This pole has an improved collapsible construction attaching it to the stretcher so such pole does not interfere with any stretcher operation.
Reference C19 to Portman discloses a device for anchoring an upright pole or other supporting means used to support an intravenous bottle holder, particularly for use in an emergency vehicle, such as an ambulance. The anchoring device is particularly useful to secure the upper extremity of a pole to the vehicle inside roof surface, and in one embodiment of the device, a locking feature is provided with the anchoring device to prevent accidental disengagement of the pole and holder. The pole is typically mounted upon a platform, such as a cot used in emergency transport of patients, and with use of the invention, inconvenient and undesirable swaying of the pole and rotation of the holder is prevented, thereby minimizing a safety hazard to ambulance attendants and the patient.
Reference C20 to Barile discloses a bed frame especially suitable for a hospital bed construction. The bed rails are provided by one or more extruded metal channel members connected into a familiar rectangular frame. Extruded metal corner brackets are riveted to the corners of the frame. The corner brackets have integral extensions and formations which serve a variety of functions such as for supporting safety side rails and for the bed headboard and footboard members, standards for supporting patient treating equipment, among others. The bracket serves a dual function of strengthening and/or retaining the channel members in the rectangular frame formation and providing means for attaching a variety of different devices to the bed frame.
Reference C21 to Alexander discloses an apparatus for supporting intravenous supply bottles including an upright standard and a cross bar extending substantially horizontally across the top of the standard. An elongated cantilever spring secured to the standard extends to opposite sides of the standard beneath the cross bar. Reaches of the spring are adapted to press into tight frictional contact with upwardly facing ends of supply bottles depending from catches in the cross bar. A mounting for the standard permits vertical adjustment of the standard relative to a bed or other body support.
Reference C22 to Shepherd discloses a portable transfusion apparatus carrier, and more particularly to a carrier construction, which is removably attachable to a hospital bed or stretcher.
Lastly, references are known which disclose various devices for transport and/or transfer having exchangeable parts. These references include: (D1) US Patent Pub. 2005/0102748, published May 19, 2005 to Johnson; (D2) US Patent Pub. 2003/0213064, published Nov. 20, 2003 to Johnson; (D3) US Patent Pub. 2002/0174485, published Nov. 28, 2002 to Bartels; (D4) US Patent Pub. 2001/0044957, published Nov. 29, 2001 to Hodgetts; (D5) U.S. Pat. No. 6,101,644, issued Aug. 15, 2000 to Gagneur et al.; (D6) U.S. Pat. No. 5,487,195, issued Jan. 30, 1996 to Ray; (D7) U.S. Pat. No. 5,111,541, issued May 12, 1992 to Wagner; (D8) U.S. Pat. No. 5,014,968, issued May 14, 1991 to Lammers et al.; (D9) U.S. Pat. No. 3,902,204, issued Sep. 2, 1975 to Lee; (D10) U.S. Pat. No. 3,917,076, issued Nov. 4, 1975 to Campbell; (D11) U.S. Pat. No. 2,610,330, issued Sep. 16, 1952 to Sutton; and (D12) U.S. Pat. No. 2,512,160, issued Jun. 20, 1950 to Koenigkramer.
Reference D1 to Johnson discloses a transfer and transport device and method for moving a patient from a bed to another location within a medical facility. The transport device includes an integral transfer mechanism for transferring a patient from a hospital bed to the device and back.
Reference D2 to Johnson discloses a transfer and transport device and method for moving a patient from a bed to another location within a medical facility. The transport device includes an integral transfer mechanism for transferring a patient from a hospital bed to the device and back.
Reference D3 to Bartels discloses a patient support mechanism having a patient gurney for the delivery and removal of a patient, the patient gurney having a removable bed board, and having a stationary patient bed provided for the acceptance of the bed board or having a stationary supporting part provided therefor at an imaging medical system such as, for example, a CT installation, an angiography device or a NMR installation. The patient gurney has carriages that are transversely displaceable toward both sides for accepting the bed board and for shifting the bed board from the patient gurney onto the patient bed or onto the supporting part and vice versa. A patient gurney having two double T-shaped supports that are centrally connected to one another by a longitudinal support.
Reference D4 to Hodgetts discloses a patient transport system for transporting a patient from a bed to a stretcher or vice versa, using a bed sheet and a conveyor attached to the bed or the stretcher. A first end of the sheet is removably attached to the conveyor and a second end of the sheet is free. The sheet is adapted to be positioned onto the patient supporting member of the bed or stretcher. The conveyor includes a roller received by bearings. The roller can be removably received by the bearings. The roller can also include a telescopic arrangement so that its length can be adjusted. A pawl and ratchet assembly can be provided on the conveyor to prevent unwinding of the conveyor. The sheet is removably attached to the roller by adhesive tape or a clip arrangement. A flexible belt attaches the clip to the conveyor and is removably secured to the roller. The clip includes a body member having a recess with a plug received therein.
Reference D5 to Gagneur et al. discloses a transport cart/patient table system for transferring an exchangeable slab of the patient table, which slab can be moved by means of a lifting arrangement, between the table and the transport cart, whereby the transport cart is moved under the patient table for the transfer of the exchangeable slab, has a first guide arranged on the transport cart and a second guide arranged on the patient table, which can be brought to engage one another as the cart is moved under the table. The guides engage in such a way to allow the transport cart to be pivotable and to be displaced longitudinally, while the engaged guides serve to guide the transport cart.
Reference D6 to Ray discloses an apparatus for lifting and transporting a prone patient comprising a mobile base frame that may extend under the patient's bed, a vertical support structure mounted along one side of the base frame, a pair of cooperating patient supporting plates connected to the support structure, the first supporting plate is horizontally oriented and may be lowered onto the bed and slid partially under a prone patient who has been rolled slightly to the side away from the support structure, after rolling the patient in the opposite direction towards the support structure and upon the first supporting plate, the second supporting plate is pivoted downwardly onto the bed into alignment with the first supporting plate, and the patient is rolled away from the support structure onto the second supporting plate. A sling may assist positioning the patient relative to the supporting plates.
Reference D7 to Wagner discloses a gurney, or hospital cart, that is characterized as being made predominantly of materials that are non-metallic, non magnetic, and of low electrical conductivity. Such a feature is of particular importance in those health care facilities wherein modern non-invasive body scanning equipment is in use, such equipment as provides imaging based on NMR, MRI, and the like, especially wherein large-scale superconducting magnets are in use.
Reference D8 to Lammers et al. discloses a patient table having round surface edges for coupling between a trolley and a patient table for the transfer of a table top from the trolley to the patient table. When the patient table is lifted by a table lifting mechanism, the table top is decoupled from the trolley after which the trolley can be decoupled from the patient table so as to be removed. The lifting construction of the patient table enables a large stroke to be made in a vertical direction without giving rise to longitudinal displacement of the table includes top. The patient table a hydraulic displacement mechanism for a longitudinal displacement of the table top; this mechanism can also be operated by hand in the case of emergencies.
Reference D9 to Lee discloses a hospital transfer trolley comprising a main frame from which two parallel end pieces extend at right angles so that a bed, trolley or the like can be received between the end pieces. A pair of horizontal lift members are carried by the end pieces and can be raised or lowered with respect to the end pieces. A couch including a mattress and a mattress support is movable between a horizontal patient-supporting position in which it is between the end pieces and an upright inoperative position on the main frame. The mattress support is engageable with the lift members when the couch is in its patient supporting position to enable the couch to be raised and lowered.
Reference D10 to Campbell discloses trolleys and in particular a trolley for handling patients on a stretcher where in certain instances it is essential that the patient be moved as little as possible. Accordingly the important features of the trolley are a base frame on wheels, a stretcher support spaced from and above the base frame and means for raising, lowering and tilting the stretcher support relative to the base.
Reference D11 to Sutton discloses improvements in wheeled tables for transferring invalids.
Reference D12 to Koenigkramer discloses a physicians' carriage or litter for professional use in the treatment or diagnosis of human ailments.
While the prior art discloses several individual features ultimately incorporated in the instantly disclosed PS3, the references nevertheless fail to disclose or suggest the combination of features as taught and claimed herein. For example, referring to Reference D10 (U.S. Pat. No. 3,917,076) which discloses a cantilever frame, the reference fails to teach or suggest a bed-to-frame interface construction and function, wherein a fail-safe mechanism is included for prevention of unwanted folding of the bed during transport, which is a critical component of the PS3 design. This anti-folding fail-safe mechanism renders the PS3 unique over the prior art cited. Additionally, auxiliary components such as the wing and frame construction, and the adjustable IV pole holder have not heretofore been disclosed in the prior art.
SUMMARY OF THE INVENTION
The Patient Single Surface System is a system solution which represents the next generation in patient accommodation, diagnosis, treatment, transfer and transport. PS3 provides a single surface for the patient to remain on from the trauma site through diagnosis, treatment and convalescence. PS3 addresses the long-felt needs of providing improved patient treatment through reduction in time to treatment; reduced or eliminated unnecessary patient movement and injury as well as improved comfort throughout treatment and convalescence.
In addition, PS3 addresses significant economic considerations. Economic considerations include elimination of costly hospital staff injuries during patient transfers, up to six to one (6:1) reduction in hospital staff required for patient transfers, increased patient throughput and improved long term patient outcome/reduced healthcare costs for patients benefiting from reduced time to treatment and/or unnecessary disturbance elimination, and improved long-term hospital staff retention.
PS3 is comprised of four major systems: (1) a single surface support (or patient single surface, (2) a single surface to frame interface, (3) auxiliary accommodation features and modules and (4) a cantilever transfer and transport frame. PS3 novelty lies in multiple features within each of the major systems.
The PS3 patient single surface platform, a contoured thin, rigid bed-type surface for transfer requires only a single person, regardless of patient weight, to position the unit above the surface for transfer, and then lower them mechanically with the cantilever frame. No lifting/pulling/pushing of the patient is required. No additional personnel are required, even for completely incapacitated patients. This is quite contrary to the historic and current patient transfer method with a bed sheet or thin plastic sheet, which requires between four and six personnel for incapacitated patients depending on patient size and personnel available. With rare exceptions, current methods are entirely a manual process, which requires significant lifting, pushing and pulling. In addition, PS3 single surface design and unique auxiliary equipment accommodation allows for the patient to remain connected and auxiliaries unmoved throughout a transfer (unless removal is required in an MRI or similar equipment). Numerous design features of the PS3 frame to single surface platform interface, the thin frameless segmented single surface platform and the modular auxiliaries are novel, which add significant usability, minimize complexity and greatly increase its range of application over prior designs. In addition, the PS3 single surface platform is unique in its ability to provide superior comfort/accommodation for patient rest during critical treatment periods.
PS3 provides a single surface for the patient to remain on from the trauma site through all diagnosis, all treatment and convalescence. PS3 accommodates the widest range of application with the least modification to interfacing equipment when compared to existing devices/prior art due to its inherent design and modularity.
Accordingly, it is an objective of the instant invention to provide a frameless single surface system (PS3) for patient accommodation, diagnosis, treatment and transfer, which eliminates the current practice requiring multiple manual patient transfers.
It is a further objective of the instant invention to provide a patient transfer system which incorporates efficient, safe, passive and secure single surface to frame interface, mated to a cantilever frame, which includes self-aligning features and an ability to withdraw horizontally once mated to another surface.
It is an additional objective to provide the PS3 with a segmented support surface (PS3 bed) containing a segment interlock functionality for maintaining rigidity of the frameless PS3 single surface platform, when desired, wherein segment articulation of the frameless single surface is not permitted to occur without proper mating surface support and engagement of the positive mating means, e.g. T-Pin engagement.
It is a further objective of the instant invention to provide means for efficient width adjustment, e.g. in the form of readily attachable segmented components or “wings” which interlock with lateral edges of the PS3 single surface platform thereby enabling scalability in the PS3 single surface platform width, with no loss in PS3 single surface platform functionality, or alternatively, in the form of multiple fixed width options.
It is another objective of the instant invention to provide a cantilever transport/transfer frame which allows greater and more stable range of height adjustment, and provides support arms which enable both Trendelenburg and reverse Trendelenburg tilt.
It is still a further objective of the instant invention to provide a cantilever transport/transfer frame which enables full articulation of the PS3 single surface platform segments while supported thereon.
It is yet an additional objective of the instant invention to provide a cantilever transport/transfer frame which enables reversible cantilever via centrally located support columns, and which provide arms and/or columns with rotatable and translatable functionality.
It is still an additional objective of the instant invention to provide a PS3 single surface platform articulation enabling interface effective for inclusion with standard gurneys.
Yet an additional objective of the instant invention is the provision of a PS3 single surface platform to mating surface interlocking design.
An additional objective of the instant invention is to provide components of the PS3 system with a matable, full length, receiving surface to enable universal and infinitely adjustable engagement of PS3 auxiliaries and wings thereto.
Still a further objective of the instant invention is to provide the PS3 system with quick-locking and single-handedly removable auxiliaries and width adjustment components.
A further objective of the instant invention is to provide a PS3 auxiliary block with a stepped holed design to accommodate multiple pole/interface sizes, and additionally providing a Poke Yoke design to insure proper insertion orientation for locking.
Still another objective of the instant invention is to provide an auxiliary block having a 2 stage release handle to allow for release of auxiliaries, while preventing accidental release from the Single Surface.
Yet another objective of the instant invention is to provide the PS3 system with a separate articulation inter-lock module which is installable/removable while the frameless single surface is suspended in the PS3 frame.
It is an additional objective of the instant invention to provide the PS3 single surface with a multiple layer non-continuous air mattress which is rapidly adaptable to improve patient comfort.
Other objects and advantages of this invention will become apparent from the following description wherein, by way of illustration and example, certain embodiments of this invention are set forth.
BRIEF DESCRIPTION OF THE FIGURES
FIG. 1 is a perspective view of the PS3 system depicting the initial step of alignment of PS3 as the patient is transported to a MRI lab and initially positioned next to a MRI bed;
FIG. 2 is perspective view of the PS3 system depicting the next step of raising the MRI Bed into position then pushing PS3 system into position above the MRI bed;
FIG. 3 is a perspective view of the PS3 system depicting the step of lowering the PS3 single surface platform into position with cantilevered arms to a safe distance just above (˜1 inch) the MRI bed;
FIG. 4 is a perspective view of the PS3 system depicting the next step wherein the quick release guardrails, the quick release auxiliary blocks and poles are removed;
FIG. 5 is an exploded view of PS3 single surface platform, wings and guardrails;
FIG. 6 is a perspective view illustrating the PS3 system with the single surface platform wings removed to accommodate a narrow MRI bed;
FIG. 7 is an end view of FIG. 4 , with the quick release single surface platform wings removed to accommodate a narrow MRI bed, also locking T-pins are shown on the MRI bed;
FIG. 8 is a perspective view of FIG. 7 , illustrating the PS3 single surface platform and patient lowered fully onto a MRI bed and locked into self-guiding T-pins;
FIG. 9 is a perspective view of the system similar to FIG. 7 , illustrating the PS3 cantilevered frame being removed from the PS3 single surface platform and MRI bed;
FIG. 10 is a perspective view of the PS3 single surface platform illustrating its ability to transfer a patient into a MRI device while patient remains on PS3 single surface platform;
FIG. 11 is a partial view of the PS3 system illustrating one example of the PS3 single surface platform to frame interface;
FIG. 12 is a perspective view of another embodiment of the PS3 frame to single surface interface member;
FIG. 13 is a perspective view illustrating a third embodiment of a PS3 frame to single surface interface member with redundant alignment surfaces for the single surface to frame interface members;
FIG. 14 is a partial view of the PS3 single surface platform provided with a “box” receiver, as an additional example of the single surface to frame interface, for insertion of the frame to single surface interface of FIG. 11 ;
FIG. 15 is a perspective view of the PS3 single surface platform with the wings attached and a hinge for the single surface backrest section;
FIG. 16 illustrates the PS3 system and a gurney onto which the PS3 single surface platform is to be placed;
FIG. 17 is a perspective view of the PS3 single surface platform illustrating the single surface backrest section of the PS3 single surface platform tilting, after the PS3 is securely mated to the gurney;
FIG. 18 is a bottom view of the PS3 single surface platform assembly of FIG. 15 ;
FIG. 19 is a bottom view of the PS3 single surface platform assembly without wings and without the single surface backrest section, illustrating the lock plates and 4-bar linkage, which causes the plates to move toward each other when the handle is rotated;
FIG. 20 is a top perspective view of the PS3 lock plate with keyhole and interlock;
FIG. 21 is a bottom perspective view of the PS3 lock plate and a T-pin;
FIG. 22 is a top perspective view of the PS3 lock plate engaging a T-pin;
FIG. 23 is a top perspective view of the PS3 lock plate illustrating positioning of the PS3 interlock lever above the interlock ramp when the bottom of the PS3 single surface platform is resting on a mating surface;
FIG. 24 is a top perspective view of the PS3 lock plate in its final locked position;
FIG. 25 is a bottom view similar to FIG. 19 , illustrates the PS3 single surface without wings and without the single surface backrest section, illustrating the lock plates and 4-Bar linkage;
FIG. 26 is the PS3 single surface platform of FIG. 25 illustrating the PS3 lock/unlock handle rotated 90 degrees counter clockwise causing translation of the two lock modules toward each other (due to the 4-Bar Linkage) to secure the PS3 single surface to the mating surface and retracting the single surface backrest section lock bar;
FIG. 27 is the PS3 single surface platform of FIG. 25 with the PS3 lock/unlock handle rotated 180 degrees counter clockwise causing translation of the two lock modules toward each other to their final locked location, wherein the single surface backrest section lock bar is completely withdrawn;
FIG. 28 is an exploded view of the PS3 single surface with incline wings and main wings separated from the single surface;
FIG. 29A illustrates an alternative PS3 lock for the wings, which is of a quick lock and release design, but is not self-locking into the side of the single surface;
FIG. 29B illustrates the alternative PS3 lock, in its unlocked position, with the wing abutted to the single surface;
FIG. 30 illustrates the alternative PS3 lock, in its locked position, securing a wing to the single surface;
FIG. 31 is a perspective view of a preferred embodiment of a PS3 wing which is self-locking onto the main single surface platform;
FIG. 32 is a partial perspective view of the PS3 wing illustrating the self-locking mechanism;
FIG. 33 is a perspective view of a PS3 push button modular auxiliary block, which self-locks onto the single surface platform or wing;
FIG. 34 is a perspective view of another embodiment of the push button modular auxiliary block illustrated in FIG. 33 ;
FIG. 35 is an end view of the push button modular auxiliary block illustrating the push button mechanism for closing and releasing the catch mechanism of the auxiliary block;
FIG. 36 is a top perspective view of the PS3 push button modular auxiliary block of FIG. 34 , illustrating stepped holes to accommodate multiple pole diameters;
FIG. 37A is a perspective view of another embodiment of the auxiliary block illustrating a self-locking modular auxiliary block and its relationship with the PS3 main single surface platform or wing T-slot;
FIG. 37B is a cross sectional view of the auxiliary block of FIG. 37A , illustrating the internal design of the single lever, dual purpose T-slot and pole locking mechanism;
FIG. 38 is a side view of the PS3 auxiliary block of FIG. 37 A showing the release lever, and the self-locking catch, for mating between the auxiliary block and PS3 wing or main single surface platform, the auxiliary pole spring loaded lock and the stepped hole features for different sized auxiliaries;
FIG. 39 illustrates the auxiliary block in position to engage the T-Slot in the PS3 main single surface platform or wing;
FIG. 40 illustrates the auxiliary block locked into the T-Slot in the PS3 main single surface platform or wing;
FIG. 41 illustrates a modified T-Slot in the PS3 single surface platform or wing, which includes cutouts with vertical surfaces to securely locate the auxiliary blocks along the length of the slot;
FIG. 42 shows the PS3 auxiliary block release lever wherein the release lever translates and engages a conical ramp feature on the self-locking catch for self-lock into PS3 main single surface platform or wings, The catch is formed as a spring or living hinge;
FIG. 43 illustrates another embodiment of the PS3 auxiliary block release lever and auxiliary catch wherein the catch is rotated 90 degrees from the position shown in FIG. 42 ;
FIG. 44 is a perspective view of the PS3 auxiliary block illustrating a slot in the top to mate with the spline feature of an auxiliary lock ring to insure they mate properly. It also shows a patient safety strap attached to the auxiliary block;
FIG. 45 illustrates the PS3 auxiliary lock ring starting to engage the auxiliary pole lock, a standard auxiliary pole is then inserted inside this lock ring allowing accommodation of the belt strap and an auxiliary pole;
FIG. 46 illustrates the PS3 lock ring “opening” the auxiliary pole lock;
FIG. 47 illustrates the auxiliary pole lock in its locked position;
FIG. 48 illustrates the PS3 auxiliary block showing the first phase of the staged release wherein the auxiliary pole lock has completely disengaged the slots in the auxiliary poles or lock ring to allow removal of auxiliary poles or lock ring, while the release lever has just started to engage the self-locking catch;
FIG. 49 further illustrates the PS3 auxiliary block showing the second phase of staged release, wherein the release handle has engaged the self-locking catch enough for the catch tips to completely retract;
FIG. 50 is an exploded view of a PS3 auxiliary tray assembly which includes an auxiliary tray, two auxiliary block assemblies, two lock rings to lock the assembly together and an auxiliary pole;
FIG. 51 is a rear of FIG. 50 illustrating the support pin attached to the rear of the auxiliary tray to support heavier loads;
FIG. 52 is a front perspective view of the assembly shown in FIGS. 50 and 51 ;
FIG. 53 is a side view of the PS3 assembly with the main single surface platform in a horizontal position;
FIG. 54 is a side view of the PS3 assembly with the main single surface platform in a Trendelenburg (tilted) position in which the single surface platform to frame interface arms on the left have rotated about the frame to single surface interface to compensate for the reduction in the horizontal distance between the two frame to single surface interface members;
FIG. 55 is an perspective view of the PS3 single surface platform in a Trendelenburg (tilted) position in which one of the frame to single surface members is lower than the other one;
FIG. 56 is a top perspective view of the PS3 main single surface platform including an upper body section and a knee gatch section;
FIG. 57 is a bottom perspective view of the PS3 main single surface platform without the interlock/interface module and single surface platform to frame transfer arms;
FIG. 58 is a top perspective view of a removable three segment self-contained interlock/interface module which cooperates with the main single surface platform of FIGS. 56 and 57 ;
FIG. 59 is a bottom partial view of a base three segment PS3 single surface platform without the interlock/interface module and module retainer plates. It also shows the tilt/bend lock tubes connecting the upper body section and the main single surface platform section. Also the tilt/bend lock tubes connect the lower leg section to the main single surface platform section;
FIG. 60 is an perspective view of the tilt/bend lock tube;
FIG. 61 is an end view of the PS3 single surface platform without the interlock/interface module, illustrating the tips of the tilt/bend lock tubes that interface the interlock/interface module;
FIG. 62 is a perspective view of the three segment PS3 main single surface platform, without the interlock/interface module, including single surface platform to frame interface hooks which have been provided with a cross bar so they can be used as handles;
FIG. 63 is a top view of a three segment interlock/interface module with the mechanisms in the locked position;
FIG. 64 is a top view of a three segment interlock/interface module with the mechanisms in the unlocked position;
FIG. 65 is a partial view of a three segment interlock/interface module illustrating the alignment between hinge joints on the interlock/interface module and the four bar member, which allows articulation of the single surface backrest portion, mid portion and knee gatch portion;
FIG. 66 is a bottom view of the complete interlock/interface module;
FIG. 67 : is a bottom view in part of the interlock/interface module docking into the PS3 single surface platform and just starting to engage the tilt/bend lock tubes;
FIG. 68 : is a bottom view in part of the interlock/interface module in its final position in the PS3 Single surface platform in which it has fully retracted the tilt/bend lock tubes beyond the hinge joints;
FIG. 69 is a bottom view of the assembled PS3 single surface platform, interlock/interface module and single surface platform to frame interface hooks;
FIG. 70 is a top perspective view of a complete PS3 single surface platform wing assembly;
FIG. 71 is a bottom view of a complete PS3 single surface platform wing assembly;
FIG. 72 is a perspective view of the wing catch/tension/release module removed from the single surface platform wing;
FIG. 73 is a perspective view of the wing catch/tension/release element;
FIG. 74 is a bottom view is part of a PS3 single surface platform wing assembly with the eccentric tension lever of the wing catch/tension/release element in the unlocked position;
FIG. 75 illustrates the PS3 single surface platform wing assembly of FIG. 74 with the eccentric tension lever in the locked position;
FIG. 76 is end view of the self catch/latch of the wing catch/tension/release element of FIGS. 74 and 75 ;
FIG. 77A is an end view of a rectangular or square single surface platform rail and a self catch auxiliary block prior to engagement;
FIG. 77B is an end view of “external” engagement of a rectangular or square single surface platform rail with a self-catch auxiliary block;
FIG. 78 illustrates a standard gurnie which could utilize the “external” engagement self-catch auxiliary block shown above in FIG. 77B ;
FIG. 79 is an perspective view of the “external” self-catch auxiliary block and an alternative single surface platform rail;
FIG. 80 shows an perspective view of an “internal” engagement self-catch auxiliary block aligning to mate to an alternative single surface platform rail design with a slot or appropriately sized through hole;
FIG. 81 is an perspective view of the “internal” engagement self-catch auxiliary block of FIG. 80 mated to an alternative standard rail design with a slot or appropriately sized through hole;
FIG. 82A illustrates a side view of alternative self-catch mechanism design;
FIG. 82B illustrates a side view of another alternative self-catch mechanism design;
FIG. 83 is a perspective view of the auxiliary block assembly and a lateral lock version of the T-Slot;
FIG. 84 is a perspective view of the a PS3 T-Slot with slots at the back wall of the T-Slot for the nose of the auxiliary block or the vertical support pins;
FIG. 85 is an enlarged view of FIG. 84 ;
FIG. 86 is a top perspective view of the auxiliary block illustrating the four flats poke yoke;
FIG. 87 is a bottom perspective view of the auxiliary lock ring with the four flats poke yoke and with corresponding slots for the auxiliary pole lock;
FIG. 88 is an exploded view of the auxiliary block, auxiliary lock ring and the bottom of the auxiliary pole;
FIG. 89 is a perspective view of the PS3 system including guardrails, which mount into the PS3 T-Slot with the same Self-Catch Mechanism as the Auxiliary Blocks and Wings;
FIG. 90 is a perspective view of PS3 system approaching an MRI in which auxiliary T-Slots are placed on the side of the MRI bed platform to attach the PS3 wings and guardrails thereby providing additional patient safety;
FIG. 91 is a perspective view of the PS3 single surface platform to frame interface hooks provided with the same basic self-catch mechanism as the auxiliary block and wings
FIG. 92 is a perspective view of the single surface platform to frame interface hooks installed on the PS3 Single surface platform;
FIG. 93 is a bottom view of the PS3 single surface platform with a recess for the single surface platform to frame interface hooks self-catch mechanism to provide a secure mating of the single surface platform to frame interface hooks to the single surface platform;
FIG. 94 is a bottom view showing the retraction of the single surface platform to frame interface hooks self-catch mechanism to allow removal of the single surface platform to frame interface hooks;
FIG. 95 is a perspective view of the PS3 single surface platform with a deflated air mattress on top covering the entire single surface platform surface;
FIG. 96 is a perspective view of the PS3 Single surface platform with wings attached and without the deflated air mattress;
FIG. 97 is a perspective view of another embodiment of the single surface platform to frame interface hooks wherein the hooks are straight and a crossbar connects the interface hooks;
FIG. 98 is a perspective view of the hooked shaped single surface platform to frame interface hooks provided with a crossbar;
FIG. 99 is an exploded view of a handle assembly and sleeve which are insertable into the crossbar to provide carrying handles;
FIG. 100 is an alternative mechanism for attaching the handle assembly to the sleeve;
FIG. 101 is a side view of the sleeve illustrated in FIG. 100 ;
FIG. 102 is a side view of the handle assembly and sleeve illustrating the relationship of the latch and receiving holes;
FIG. 103 is a side view of the latch assembly of FIG. 102 ;
FIG. 104 is a side view of an alternative embodiment of the auxiliary block provided with a tension lock;
FIG. 105 is a view similar to FIG. 104 with the tension lock in its locked position;
FIG. 106 is a side view of the PS3 assembly provided with push/pull folding handles, which are used to move and position the PS3 assembly, in their inoperative position;
FIG. 107 is a side view of the PS3 system of FIG. 106 with the push/pull handles in their operative position;
FIG. 108 is a partial view of the push/pull handles and PS3 frame illustrating the self-locking latch which holds the handles in their operative position;
FIG. 109 is a partial side view of the ends of the push/pull handles provided with telescoping extensions;
FIG. 110 is a top plane view of the PS3 single surface platform incorporating an upper body section hinged to a mid section which is hinged to a lower leg section. Separate wing sections are illustrated on the top portion of the Fig. and hinged wing sections are illustrated on the lower portion of the Fig.;
FIG. 111 illustrates an internally mounted adaptor plug for an auxiliary pole;
FIG. 112 illustrates an externally mounted adaptor plug for an auxiliary pole;
FIG. 113 illustrates an alternative, triangular shaped T-pin;
FIG. 114 illustrates and alternative frame useful with a single surface platform in an unlocked, articulated state;
FIG. 115 illustrates the single surface platform supported by the alternative frame of FIG. 114 and
FIG. 116 illustrates a rack and pinion mechanism designed to insure coordinated movement of the frame supporting arm and frame cantilever column.
DETAILED DESCRIPTION OF THE INVENTION
The Patient Single Surface System (PS3) provides an all encompassing, systematized approach to patient transport and care, representing a paradigm shift from current systems and methods.
PS3 has been designed to provide a fully modular and scalable system based upon the provision of a single surface upon which a patient may remain beginning at a trauma site and extending throughout the steps of diagnosis, treatment and convalescence.
The origins of the PS3 concept emanated from a study of stroke victim care in which studies indicated that up to 16 patient transfers were required for treatment, which corresponded to a loss of 20-40 minutes required for these manual transfers. The deficiencies of current patient care systems thus necessitate frequent movements which detract from effi115cient care and often tax the abilities of all involved, including the patient, caregivers (such as doctors, nurses, orderlies, attendants and paramedics), and the institutions for whom they serve, including hospitals, emergency medical services and health insurance providers.
Implementation of the PS3 system will provide myriad benefits, such as reduced time to treatment for all immobilized patients (e.g. stroke or acute coronary syndrome patients, where time lost translates into irreversible loss of function); elimination of unnecessary disturbance of acute care victims, such as those suffering spinal injuries; and improved patient comfort during diagnosis, treatment and convalescence.
Implementation of PS3 will also serve to enhance economics related to patient care by eliminating patient transfer associated hospital staff injuries during patient transfer (which is estimated to have a direct cost in the range of $28-$128 million annually), eliminating patient injuries during surface transfers, reducing staff requirements for patient transfers by as much as 6 to 1, improving long-term outcome and reducing healthcare costs for patients benefiting from reduced time to treatment, improving long-term hospital staff retention and improving patient throughput.
The PS3 has been designed to provide a wide range of application across a broad spectrum of patient treatment from trauma through convalescence, in a scalable and modular format. PS3's design requires little modification to existing interfacing equipment, while providing a multiplicity of safety interlocks using simple and readily adapted mechanisms.
The heart of the PS3 system is the frameless single surface platform which may be formed in 2-3 segments to provide articulation of a backrest portion and, optionally, a knee gatch. Although some loss of functionality may occur, it is nevertheless contemplated to provide full or partial framing, as need may dictate, for particular applications. The single surface platform or bed is designed to be lightweight, thin and modular, and may incorporate a wing system to provide for scalability in width, as required. In a preferred embodiment, a self-aligning self-locking quick release wing construction is provided to rapidly adapt the PS3 single surface platform to width requirements dictated by either patient comfort requirements, equipment space requirements or the like. In a particularly preferred embodiment, the wing attachments are additionally provided with a tension lever to insure tight fit to a single surface, while simultaneously acting as a fail-safe mechanism to prevent inadvertent disengagement. When desirable, and in order to reduce the number of loose parts, it is contemplated to fabricate the wings in a multiple segment hinged embodiment.
In an alternative embodiment, as opposed to scalable wings, a multiple width integrated solution may be provided, wherein a particular width PS3 single surface platform is initially chosen based upon anticipated needs. This embodiment serves to eliminate a proliferation of loose parts, e.g. wings, however it may necessitate a transfer of the patient to an alternatively sized PS3 single surface platform, as may be required.
The PS3 single surface platform is designed to facilitate compatibility with MRI and X-ray imagery equipment, as well as providing an easily adaptable platform for usage by emergency medical services personnel.
In a particular embodiment, the PS3 single surface platform can be provided with an inflatable air mattress for enhanced patient comfort. This mattress may be provided with multiple layers including a foam or gel overlying an impervious layer or an alternative self-healing layer analogous to a basketball self-healing membrane overlying a plurality of air chambers. The air mattress provides a means for rapid adaptation to various conditions experienced as the patient progresses from trauma through diagnosis, treatment and convalescence. Inflated on-demand by a small compressor in the frame, separate stand or auxiliary tray on PS3. This multi-layer air mattress is an alternative to continuous air systems which require constant power supply, constant connection to the fan system, are noisy and more maintenance intensive due to the constant run nature.
The second major component of the PS3 system is the single surface to transfer frame interface, which provides rapid transfer, is self-aligning, secure, of passive design and is designed to provide both Trendelenburg and reverse Trendelenburg positioning. In an illustrative, albeit non-limiting embodiment, the frame to single surface platform interface is further provided with one or more tabs which are designed to rotate or translate to a position above the single surface platform-to-frame interface to provide additional security. Contrary to prior art devices, the instant invention permits horizontal withdrawal of the frame to single surface interface, without requiring that the components drop below the mating surface for disengagement.
The third major component of the PS3 system is encompassed in the provision and accommodation of auxiliary components. Auxiliary components such as guard rails, IV pole holders, and the like are attachable to the PS3 support surface anywhere along the periphery of the support surface, utilizing the same self-locking features as the auxiliary blocks and wings, and need not be attached and reattached during patient movement from one area of treatment to another. The auxiliaries are designed so as not to extend below the PS3 or wing surface, thereby ensuring that the auxiliaries can be removed while the PS3 is mated to another surface.
In a preferred, albeit non-limiting embodiment, provision of a unique auxiliary block having a self-locking and quick release design enables enhanced ability for attachment of auxiliary devices. The system's modular design permits quick self-aligning attachment of all auxiliary components to a variety of modular components such as the PS3 surface support platform and/or the wings. By use of the scalable wings, along with an auxiliary block which incorporates a unique two-step locking mechanism, secure assemblage of specifically needed surface structure and auxiliary implementation can be readily achieved.
Application Example
In an illustrative example, a patient will initially be assessed by EMS personnel and placed upon a PS3 patient surface platform or “PS3 bed”. Auxiliary components such as an IV bag carrying fluids to the patient may be attached thereto. Self-lock, quick release transfer hooks may also be applied to the PS3 single surface platform along with the adjustable width self-storing handles and the single surface platform may be affixed to a wheeled carrier for transfer to the hospital emergency room. Once within the ER, a backrest and mid-section self-locking wing might be installed to enhance patient comfort. Additionally, guard rails may be secured along the peripheries of the PS3 single surface platform to provide enhanced patient security, while still enabling articulation for patient treatment and comfort.
Once within the hospital, the transfer frame can be positioned for engagement with the PS3 single surface platform. Utilizing the self-aligning features inherent in the single surface platform-to-frame interface, safe and secure transfer may be easily accomplished, thereby enabling removal of the wheeled carrier. Upon positioning of the PS3 single surface platform upon the transfer frame, the patient may be easily moved throughout the hospital for necessary tests and the like. This transport may be carried out in a horizontal mode or, by vertically orienting the support structure of the transfer frame, in the Trendelenburg or reverse Trendelenburg position, as desired.
In an illustrative embodiment, as will be further described below, the patient, while resting on the PS3 single support surface which is interfaced with the transfer frame, is first transported to the vicinity of an MRI device. The patient is then transferred directly to the MRI device, while always remaining on the PS3 single support surface.
The only modification required of the MRI device is the installation of an appropriate number of “T-pins” (usually two) to couple to the PS3 single surface platform. The entire patient support surface is positioned above the MRI scan bed, and once nominally positioned, any guard-rails or auxiliaries may be dismounted and stored on a separate rack or mounted to T-slots, or the like matable receiving surface, built into the MRI transfer frame. The quick-release Mid/Lower leg wings and guard-rails can then be removed, as well as the quick-release backrest wings and associated guard-rails. At this point the PS3 single surface support is lowered onto the MRI bed and self-positioning openings guide the T-pins into place as the patient support surface is lowered thereon. When fully supported upon the MRI bed, the PS3 transfer frame may be removed. Subsequently, the PS3 support surface is locked to the MRI bed by activation of the single handle which translates the locking mechanism, simultaneously interlocking about the T-pins, and releasing the locking elements which had prevented articulation of the backrest and knee gatch joints, which had maintained the PS3 support surface rigid. If necessary, auxiliaries may remain fixedly engaged to the MRI bed, while still enabling insertion of the patient within the MRI device.
Alternatively, when space within the MRI or CT scanner becomes problematic, the PS3 single surface platform may fully replace the imaging bed of the scanning device. In such an embodiment, the MRI or CT scanner will engage the PS3 in a side-drive configuration, wherein the matable receiving surface, e.g. the T-slot, is directly engaged by mating means made integral with the MRI/CT scanner. This allows elimination of the extra thickness caused by stacking of the PS3 and MRI/CT scan bed, and allows for removal of the articulation inter-lock module (which allows for improved imaging) and does away with the need for the T-pins.
With reference to the PS3 single surface support platform or “PS3 bed”, the design is configured to initially provide a rigid backboard facility. Means are provided to maintain the segmented surface in a rigid configuration, e.g. by the use of spring loaded locking tubes, which are biased to a home position which insures positive engagement of adjacent segments, thereby precluding relative articulation therebetween, e.g. about the back rest or knee gatch articulation points.
An articulation inter-lock module is provided which is positionable within the confines of the PS3 single surface platform, in a manner such that translation of the articulation interlock module securement means can only be accomplished subsequent to insertion of the T-pins within the T-pin reception means, at which point the articulation inter-lock blocks securely grasp the T-pins and simultaneously disengage the means providing rigidity of the segments to a second position, whereby articulation of the segments is enabled. Thus, when mounted to an underlying surface which permits of articulation, the knee gatch and backrest may be adjusted for most efficient treatment and patient comfort.
An additional feature of the PS3 system is illustrated in the PS3 auxiliary block mounting mechanism. This mechanism is designed to securely mount within a matable receiving surface, which is ubiquitous to various members of the PS3 system. In a preferred, albeit non-limiting embodiment, the matable receiving surface is depicted as a T-slot. The T-slot may be provided in the sides of the PS3 single support surface, the transfer frame, the scalable wing system, and the various manifestations of guide-rails. By utilizing a combination of male/female coupling configurations, the component mounting system provides a self-locking and self-aligning attachment system which is infinitely adjustable within the mounting surface. Spring biasing means, or the like, provide for easy and quick release of mounted components, while, in a preferred embodiment, providing a supplemental locking element which provides for a secure fit and fail-safe attachment, thereby preventing inadvertent disengagement. Unique to the auxiliary mounting block, is a locking element incorporating a two-stage quick release feature. As illustrated below, this locking element provides for self-locking of the auxiliary block to a mounting surface and also self-locking of an auxiliary feature, e.g. an intravenous support pole (IV pole) within the auxiliary block. Application of force to the release mechanism to a first release point enables release of the IV pole, without any release of the auxiliary block form the mounting surface. Continued application of pressure to a second release point is effective for disengagement of the auxiliary block from the associated matable receiving surface.
In an alternative embodiment, a modification of the PS3 support surface is provided which enables articulation and actuation of both the knee gatch and backrest incline while the PS3 support surface is engaged with the PS3 Frame, in addition to Trendelenburg and Reverse Trendelenburg within the PS3 Frame. This modification, in addition to allowing backrest incline and knee gatch articulation while in the PS3 frame, further permits improved access to both sides of the PS3 single surface platform when in “Bed/Gurney” mode (at rest or transport) and support of PS3 Single Surface when suspended in the PS3 Frame, which allows for easier installation/removal of the Articulation Interlock Module. This support embodiment heavily reduces the chance of binding and force required to install/remove the Articulation Interlock Module.
Two major approaches for this embodiment are contemplated, a first embodiment wherein a full width version with full low profile frame is provided which stays attached to the frame at the main single surface platform to frame interface hooks. This embodiment utilizes conventional gurney backrest incline actuation which is usually pneumatic shocks which stay within the frame height. The knee gatch is also actuated by typical gurney means within the frame height. This embodiment would require one transfer to narrow width version of PS3 if need for MRI/CT scan. It is noted that the T-pins and keyhole lock modules would still be used to lock PS3 into another surface, but the interlock for backrest and knee gatch articulation would not be necessary. In a second embodiment a two column mid cross-bar version is provided, wherein one version has “head” end and leg end “specified” and a more complicated version which is not specific with regard to the head end versus the leg end of the single surface platform with respect to frame. In this embodiment, the frame cross bar may be moved laterally to a middle position, irrespective of the backrest/knee gatch articulation within the frame, thereby improving side access within the frame.
In order to fully explain the various features, of PS3, its auxiliary components and alternative embodiments, reference will now be made, in detail, to the accompanying figures, wherein like elements are uniformly numbered throughout.
With regard to diagnostic interfaces, the MRI is thought to be the most difficult, primarily due to its package constraints and very narrow patient platform. The MRI also adds a challenge through the requirement that any interface equipment is of nonferrous material, which the PS3 design facilitates.
Now with particular reference to FIGS. 1-10 , a stepwise example of use of the PS3 system in conjunction with an MRI is described. PS3 design features that facilitate each step are shown as well in the following MRI example. The heart of the PS3 system is a frameless single surface platform 12 which may be formed in 2-3 segments to provide articulation of a backrest portion 14 and an optional mid portion and knee gatch of sections 20 and 18 respectively ( FIG. 110 ). The single surface platform is designed to be lightweight, thin and modular. A wing system may be incorporated onto the single surface platform for scalability in width. In an embodiment a self-locking, quick release wing system 22 is provided to adapt the single surface platform 12 to width requirements dictated by either patient comfort requirements, equipment space requirements or the like. As illustrated in FIG. 5 wing sections 24 may be attached to one or both sides of the backrest portion 14 of the single surface platform. Also, wing sections 26 may be attached to one or both sides of the lower portion 16 of the single surface platform. As shown in FIG. 110 wing section 28 may be attached to one or both sides of the knee gatch portion 18 of the single surface platform and wing section 30 may be attached to one or both sides of the mid portion 20 of the single surface platform. Wing sections can be attached to each other to further increase the width of the platform. For example, 2 or more wing sections 24 and/or 26 can be attached to one or both sides of the single surface platform in FIG. 5 .
With reference to FIG. 1 , a perspective view is shown depicting the initial alignment of PS3 single surface platform 12 , while supported upon the transfer frame 32 , as the patient is transported to the MRI lab and initially positioned next to the MRI device 194 upon the extended MRI bed 196 . Initially usage of PS3 simply involves the transport of the patient on the PS3 apparatus 10 to the MRI lab, as one would do on a standard gurney. Modes of operation for vertical raising and lowering or Trendelenburg motion are through either electromechanical means, hydraulic or pneumatic means. FIG. 1 illustrates step of raising the PS3 platform into position by either electromechanical means, hydraulic or pneumatic means. Also, the initial alignment of PS3 and patient next to the MRI bed. Note the placement of means for securing the PS3 platform 12 to the MRI bed, herein illustrated as T-pins 86 .
FIG. 1 , illustrates the steps of raising the PS3 Single surface platform into position by either electromechanical means, hydraulic or pneumatic means and then translating the PS3, by pushing it into position above the MRI bed.
As further illustrated in FIG. 2 , the PS3 single surface platform is next lowered into position by vertical translation of the cantilevered arms or single surface to frame interface 40 of the transport and transfer interface frame 32 to a safe distance just above (˜1 inch) the MRI bed. Note that the quick release guard rails 64 and auxiliaries 66 remain in place.
Regarding FIG. 3 , illustrated here is removal of the quick release guardrails 64 and auxiliaries 66 . The guard rails may be placed aside or hung from the frame on hooks (not shown), while the quick release auxiliary blocks and poles, may be likewise removed or shifted to the distal end of the PS3, as necessary, thereby permitting entry into the MRI apparatus.
The embodiment illustrated in FIG. 4 illustrates a frame upper cross member 34 (which may be replaced by an alternative transfer frame which permits reversal of the cantilever frame). Note the frame lower legs 38 are provided with wheels 46 permitting easy transport of the frame. Frame to single surface interface or cantilever arms 40 are mounted on frame cantilever column 36 enabling vertical movement of the cantilever arms.
Now referring to FIG. 5 , an exploded view of PS3 single surface platform, wing sections and guardrails is illustrated. The single surface platform is segmented into two sections, a backrest section or uppermost section 14 and a lower section 16 . In addition backrest section wings 24 (2 shown) and a lower section wings 26 (2 shown) are illustrated. The backrest section and lower section of the platform are provided with single surface to frame interfaces or hooks 50 . The single surface platform is shown as frameless. However, a frame may be associated with the platform. For example, a frame could completely encircle the perimeter of the single surface platform or only extend along both longitudinal edges of the platform.
FIG. 8 shows the PS3 platform and patient lowered fully onto the MRI bed platform and locked into the self-guiding T-pins. The PS3 platform is released from the cantilever frame 32 at this stage. Note gap between the frame to single surface interface or single surface supporting member 40 and the single surface to frame interface or supporting member engagement means 50 , which allows for the removal of the frame. Due to the design of the frame and hook components, the frame to single surface interface 50 enables separation from the transport frame 32 without requiring the frame to single surface interface hooks to drop below the surface of the platform 12 .
FIG. 10 illustrates an ability to complete the MRI test by traversal of the PS3, shown in mechanical engagement with the MRI bed, into the MRI device. Note that the self lock, quick-release hooks or single surface to frame interface 50 can be removed if necessary. It is understood that to retrieve the patient for further transport/transfer, the above steps will be reversed.
It is further noted that the unique design of the single surface to frame interface 50 on the single surface platform provides a secure, self-aligning interface between the PS3 platform 12 and the frame to single surface interface 40 . The single surface to frame interface also allows quick release of the single surface platform 12 from the frame 32 once the single surface platform is fully lowered onto another surface.
FIG. 11 shows an illustrative example of a PS3 single surface to frame interface 50 using a hook style which is self aligning with the alignment and lateral location members 54 on the frame to single surface interface 40 .
FIG. 12 shows an alternative illustrative example of a central, upraised alignment and lateral location member 56 on the frame to single surface interface.
FIG. 13 is yet another illustrative example of a PS3 single surface to frame interface which depicts redundant transverse surfaces on the frame to single surface interface 58 for mating of the single surface to frame interface 50 with the frame to single surface 58 .
FIG. 14 shows an alternative embodiment of the PS3 single surface to frame interface wherein a receiver or “box” 52 is designed to encircle and self-align with a frame to single surface interface as shown in FIG. 11 . Alternatively, this design may be formed with an upper opening for receipt of the central upraised surface of the arm of FIG. 12 , in order to make that coupling self-aligning as well.
FIG. 15 represents a perspective view of the PS3 segmented single surface, inclusive of segmented wing assemblies, removable single surface to frame interfaces or hooks and actuation handles 92 .
FIG. 16 shows an embodiment which illustrates the PS3 single surface platform 12 approaching a gurney 60 . The gurney includes mating T-pins for affixing the PS3 single surface platform to the gurney, which are the only additions/modifications required to the gurney to allow a secure interface with the PS3 single surface, thereby enabling disengagement of the articulation inter-lock system 68 . Engagement of the inter-lock system prevents the hinged portions of the frameless version single surface from bending with respect to each other. Thus permitting the frameless version single surface support platform to be supported only at each of the ends. Details regarding the secure interface and articulation inter-lock follow in FIG. 18 to FIG. 27 .
FIG. 17 illustrates the PS3 single surface platform with the backrest portion 14 elevated, such articulation only being enabled once the PS3 single surface is securely mated to a surface like this wheeled gurney via positive engagement of the T-pins whereby the articulation inter-lock may be disengaged.
FIG. 18 is an underside view of the PS3 single surface platform having the articulation inter-lock system formed integral therewith and illustrates translation of the interlock plates via the four-bar linkage 70 which is enabled upon engagement of interlock plate release lever (not shown) by the T-pins (not shown). Note the eccentric lever 76 or “articulation handle(s)” effective to operate the articulation inter-lock system and lever 92 effective to operate the inter-lock for the wing assemblies.
FIG. 19 is an underside view of the PS3 single surface platform without wings and without the backrest section. This figure shows the inter-lock plates 78 and four-bar linkage 70 . Rotation of the handle 76 in a counterclockwise direction moves the right inter-lock plate 78 toward the left, which pushes bar 70 to the left. This action rotates four-bar center link 72 clockwise, which pulls four-bar link 74 to the right. This moves the left inter-lock plate to the right thereby causes the inter-lock plates to move toward each other when the eccentric lever 76 is rotated. Additionally, a backrest lock bar 88 ( FIGS. 25 & 26 ) keeps the frameless PS3 single surface platform rigid and flat when it is suspended and/or not properly supported by a mating surface underneath such as a gurney. The T-pin inter-lock keyhole 85 is illustrated wherein an internal taper surrounding the keyhole slot 85 provides a self-aligning feature.
FIG. 20 is a detailed isometric view of the inter-lock plate assembly 78 showing the inter-lock plate rails 80 which are affixed to the PS3 single surface platform. The inter-lock plate is in its open position, and the spring-biased inter-lock lever 82 is shown in its lower position, in inter-lock lever recess 84 , which prevents movement of inter-lock plate 78 . Inter-lock plate is connected to four-bar link 70 which moves another inter-lock plate 79 . Inter-lock lever 82 is raised upon insertion of the T-pin 86 or equivalent mating means, thereby enabling translation of the inter-lock plate about the mating device to retract the single surface locking pins (not shown) while simultaneously affixing the single surface platform to the underlying support gurney, MRI/scanner bed, articulating transfer frame, or the like.
FIG. 21 is an isometric view of the underside of the PS3 inter-lock plate module 77 , showing alignment of the T-pin 86 with the keyhole 85 , by virtue of the tapered mating area by which a self-aligning utility is achieved, and also showing the small to large cross-sectional are of each which allows secure mating in all directions. Although the T-pin or inter-lock module securement element 86 is illustrated as being round, triangular, hexagonal, or the like shapes may be used effectively, so long as they generally embody a large cross-section versus small cross section relationship that facilitates their mating together.
FIG. 22 illustrates the PS3 single surface platform inter-lock plate module 77 with the T-pin 86 engaged in large end of keyhole 85 . Note that the inter-lock lever 82 is still below the top surface of the inter-lock ramp 83 . The inter-lock plate 78 still cannot translate motion to inter-lock plate 79 at this stage.
FIG. 23 illustrates further engagement of the T-pin with the inter-lock plate module 77 whereby the PS3 inter-lock lever 82 is now above the inter-lock ramp 83 . At this stage, since the bottom of the PS3 single surface platform is resting on a mating surface such as a gurnie, the inter-lock lock plate can translate motion to the inter-lock plate 79 (in the direction of the arrow shown in FIG. 20 ) as long as the other inter-lock plate block 77 is disengaged in a similar manner.
FIG. 24 shows the PS3 inter-lock block 77 in its final locked position as its opposing inter-lock plate is as well, whereby the PS3 Single surface platform is secure to its mating surface in all directions. Also, the Backrest lock bar 88 is retracted as shown in FIG. 27 .
With reference now to FIGS. 25-27 , as FIG. 25 is equivalent to FIG. 19 , above which shows an underside view of the PS3 single surface platform without wings and without the backrest section. These figures shows the inter-lock plates and four-bar linkage, which causes the plates to move toward each other when the eccentric lever is rotated (note that the eccentric lever could be flipped, the lock plates rotated 180 degrees and a flexure in the lock bar added like the knee gatch lock bar in which the lock plates would move away from each other). Additionally, the backrest tilt lock bar, which keeps the frameless PS3 single surface platform “Rigid” and flat when it is suspended and/or not properly supported by a mating surface underneath like, e.g. a stretcher. The docking/mating means (T-pin) interlock is illustrated wherein an internal taper surrounding the keyhole slot provides a self-aligning feature.
FIG. 26 shows the PS3 eccentric articulation handle 76 (Lock/Unlock Handle) rotated 90 degrees counter clockwise causing translation of the two inter-lock blocks 77 toward each other (due to the four-bar linkage) to secure the PS3 single surface lower section to the mating surface and retraction of the backrest lock bar 88 as shown. (T-pins are not shown for clarity, which would be required in position as shown above to release the Interlock and allow translation.)
FIG. 27 further illustrates the PS3 eccentric articulation handle 76 rotated 180 degrees counter clockwise causing translation of the two inter-lock blocks 77 toward each other to their final locked location and the backrest lock bar 88 completely withdrawn. (T-Pins not shown for clarity, which would be required in position as shown above to release the Interlock and allow translation of the Lock Plates.)
FIG. 28 illustrates the PS3 single surface platform provided with a backrest portion 14 , a lower portion 16 and a wing system 22 .
FIG. 29A is illustrative of one embodiment of a PS3 wing lock assembly 90 , illustrating a quick lock and release actuation handle 92 . The actuation handle 92 is eccentrically mounted such that counterclockwise rotation moves lock actuation pin 94 in an upward direction. The actuation pin 94 moves lateral lock bars 96 in an outwardly horizontal direction engaging wing lock pins 98 (the inner pins are no longer lock pins, but alignment and vertical load support pins). The lateral lock bars and the lock pins have tapered profiles (not shown) to assist their engagement. The engagement of the lock pins 98 by the lateral lock bars secures the wings to the single surface platform. The lateral lock bars are spring loaded to return them to their unlocked position when the lock actuation pin 94 disengaged them and retracts.
FIG. 29B is illustrative of the wing abutting the single surface prior to the lock being engaged.
FIG. 30 illustrates engagement of the PS3 lock. Actuation handle 92 has been rotated clockwise to its locked position. The eccentricity of the actuation handle moves the lock actuation pin 94 upwardly which actuates a set of lateral lock bars 96 . The short wing lock pins provide additional support of the wing with respect to the single support platform thereby locking the wings securely onto the single support surface platform.
FIG. 31 shows an embodiment of the PS3 wing which is self-locking into the PS3 single surface platform. The figure shows hand access cutouts for release levers to retract self-locking catches 104 . Alignment pins 105 provide vertical load support and alignment to the single surface. The number of alignment pins 105 may vary as required, for example one or more may be added in the middle of the wing.
FIG. 32 illustrates a transparent view of a PS3 wing including hand access apertures 100 for release levers 102 to retract self-locking catches 104 . Alignment pins 105 provide vertical load support and alignment with the single surface platform 12 . A detailed depiction of the two-stage release lever and self-locking catch mechanism and the T-Slot for mounting auxiliaries is set forth below.
FIG. 33 illustrates a modular auxiliary block 108 having a push-button release mechanism coupled to a self-lock catch, having a pair of locking tabs which are spring biased to a locked position, but can be deflected to enable insertion into the T-slot 62 of the PS3 single surface platform or wing to enable self-locking therewith. It is noted that a passive part could also be utilized for appending to the T-slot, for example a T-pin (analogous to the T-nuts used in the machining industry for fixturing/clamping items to a T-slot surface) having a threaded nut which could be tightened to form a secure connection, or tightening of the tension lock lever style cam.
FIGS. 34 and 35 illustrate one embodiment of an auxiliary block design showing an external isometric view ( FIG. 34 ) and transparent orthogonal view ( FIG. 35 ) respectively. FIG. 34 illustrates shows push buttons 110 which interact with an internal spring biasing means (not shown) having tapered surfaces which act upon the catch tips 112 to close and release the catch when the push buttons are pressed inward. An auxiliary pole is inserted into the auxiliary block 108 through aperture 114 . The auxiliary pole is then supported adjacent the single surface platform. FIG. 35 illustrates stepped holes 116 , 118 and 120 which are designed to accept various auxiliary pole diameters and sizes.
FIG. 36 is an perspective view of the auxiliary block of FIG. 35 which illustrates the inclusion of stepped holes to accommodate multiple pole diameters
FIG. 37A is a perspective view of an alternative embodiment of the auxiliary block illustrating a self-locking modular auxiliary block 122 . The auxiliary block is adapted to engage a T-slot 62 on the side of a wing or single surface platform. Release lever 124 activates both catch tips 112 and auxiliary pole lock 126 as further illustrated in FIG. 37B .
FIG. 37B is a cross sectional view of the auxiliary block of FIG. 37A , illustrating the internal design of the single lever, dual purpose release lever 124 and self-locking auxiliary pole lock 126 . The release lever 124 may be moved to a first position, to the left in FIG. 48 , which permits auxiliary pole lock 126 to disengage and auxiliary pole and provide for removal of the auxiliary pole. Subsequently the release lever 124 is moved to a second position which disengages the self-locking catch tips 112 from the T-slot 62 of the PS3 single surface platform or wing.
FIG. 38 is a view of a preferred embodiment of PS3 auxiliary block 128 showing a release lever 130 . A self-locking catch 134 is engagable with the PS3 T-Slot design in the wing or PS3 single surface for mating the auxiliary block 128 and PS3 wing or PS3 single surface. The front surface of the auxiliary block nose 134 is tapered to permit self alignment with a mating surface such as a T-slot. The release lever 130 also operates a auxiliary pole lock 136 which secures and auxiliary pole to the auxiliary block.
FIG. 39 illustrates the auxiliary block 128 of FIG. 38 in position to engage the T-Slot 62 in the PS3 single surface platform or wing.
FIG. 40 illustrates the auxiliary block 128 of FIG. 38 locked into the T-Slot 62 in the PS3 single surface platform or wing. The tapered self-locking catches 112 are biased in the outward “locked” position but self-retract upon engagement with the T-slot (due to the tapers) and then “spring” back into locked position once fully engaged into the T-slot as depicted in this figure.
FIG. 41 illustrates a modified T-slot 62 in the PS3 single surface or wing, which includes cutouts 138 with vertical surfaces to securely locate the auxiliary blocks laterally or along the length of the slot, and further depicts tapers for self-alignment laterally and vertically.
FIG. 42 illustrates the PS3 auxiliary block release lever which can rotate to engage a conical ramp 106 on the self-locking catch 104 for self-lock into PS3 single surface or wings. The aperture 107 in the release handle engages the conical ramp thereby causing the self-locking catch ends to move toward each other and release from the T-Slot on the edge of a single surface or wing. The conical ramp feature 106 on the self-locking catch 104 allows any orientation of the self-locking catch along its horizontal axis, as illustrated further in FIG. 43 . The self-locking catch is formed as a spring or living hinge.
FIG. 43 additionally illustrates the functioning of the PS3 auxiliary block release lever and auxiliary catch. Note the self-locking catch 104 is rotated 90 degrees from the prior figure. This orientation is the one used for the single surface wing self-locking catch mechanism. This orientation could also be used for a “horizontal” version of the auxiliary block, for example.
FIG. 44 shows a PS3 auxiliary lock ring 140 with a spline on the side to mate with the auxiliary block 128 and insure they go together properly for the self-locking auxiliary pole lock 136 . It also shows a patient safety strap 142 in position to mate to the auxiliary block.
Now with reference to FIG. 45 , an embodiment of the PS3 auxiliary lock ring 140 is illustrated as it begins to engage the “locked” position biased auxiliary pole lock 136 . The lock ring is provided with a slot or aperture 144 into which auxiliary pole lock 136 can move to secure the lock ring to the auxiliary pole. Note, a standard auxiliary pole can fit inside the lock ring to allow accommodation of both the patient safety strap and an auxiliary pole.
FIG. 46 is the next step wherein the PS3 lock ring is shown starting to engage the auxiliary pole lock 136 to force it to “unlock” prior to self-returning into the slot 144 in the lock ring. Although not herein depicted, it is understood that the engaging leading edges of the auxiliary poles, lock ring and receiving holes' top edges in the auxiliary block may be tapered to aid self-alignment as used throughout the PS3 design.
FIG. 47 illustrates the final step wherein the auxiliary pole lock has self-returned and is fully engaged with the auxiliary block. The auxiliary pole lock 136 is shown in aperture 144 thus securing the lock ring to the auxiliary block.
FIG. 48 is illustrative of positioning of the release lever 130 of the PS3 auxiliary block showing a first phase of staged release. In this figure, the auxiliary pole lock 136 has completely disengaged the slot 144 in the lock ring to allow removal of auxiliary poles and lock ring. In addition, the release lever 130 has just started to engage the self-locking catch ramps 106 of the self-locking catch 134 . Note, kinematics are key to allow staged process and proper engagement between the release handle and catch. In addition, the kinematics of the release lever rotation must be correct to properly engage both the top and bottom of the catch.
With reference to FIG. 49 , the PS3 auxiliary block is illustrated showing the second phase of staged release. The release handle 130 has engaged the self-locking catch ramps 106 enough for the catch tips 112 to completely retract. (Note catches are not shown retracted).
FIG. 50 is a front isometric exploded view of a PS3 auxiliary tray assembly 146 which includes: an auxiliary tray, two auxiliary blocks (self-locking assemblies) 128 , two lock rings 140 to lock the assembly together and an auxiliary pole, which fits inside the lock ring and is secure in the auxiliary block.
Referring to FIG. 51 , a rear isometric exploded view of the PS3 auxiliary tray assembly 146 is provided, which shows the same elements as those in FIG. 50 as well as a support pin 148 to support heavier vertical loading in the auxiliary tray.
FIG. 52 is a front isometric view of the auxiliary tray assembly in an assembled condition shown in FIG. 50 and FIG. 51 .
FIG. 53 is a side view of the PS3 single surface platform 12 (in a horizontal position), frame to single surface interface arms 50 and a new pivot center 40 for one frame to single surface interface arm. The pivot center allows rotation of the frame to single surface interface arms to compensate for the reduction in the horizontal distance (X-Direction) between the two frame to single surface interface arm pairs when the PS3 single surface platform is placed in a Trendelenburg (tilted) position.
FIG. 54 is a side view of the PS3 single surface platform in a Trendelenburg (tilted) position in which the frame to single surface interface arm, on the left has rotated about its pivot center accordingly to compensate for the reduction in the horizontal distance between the two single surface to frame interface centers.
FIG. 55 is an isometric view of the PS3 single surface platform in a Trendelenburg (tilted) position in which the frame to single surface interface arm 40 , on the left has rotated about its pivot center accordingly to compensate for the reduction in the horizontal distance between the two single surface to frame interface centers. Note a round interface between the frame to single surface arms and the single surface to frame interface hooks is still required for Trendelenburg (full bed tilt) as shown.
FIG. 56 is a top isometric view of a three segment base PS3 single surface platform without the articulation inter-lock system 152 and single surface to frame interface hooks. Labeled specifically are the single surface backrest or uppermost section 14 , the single surface mid or middle section 20 and the single surface knee gatch or lowermost section 18 with hinged interface/joints therebetween. The construction of this single surface platform would likely be of a composite exterior shell utilizing, for example structural foam, honeycomb, balsa wood, etc. for core for stiffness to weight, X-Ray translucency and non-magnetic (MRI) compatibility. The T-Slots would likely be extruded or machined in plastic and sandwiched in the composite shell. All aspects of the PS3 single surface platform design facilitate the use of non-ferrous materials. This rigid backboard mode is intended for just that, a backboard, to facilitate usage by the EMS.
FIG. 57 is a bottom isometric view of the base three segment PS3 single surface platform without the articulation inter-lock system and single surface to frame interface hooks. Labeled specifically are the recesses 150 for the articulation inter-lock system.
FIG. 58 illustrates a top isometric view of the three segment self-contained articulation inter-lock module system. This figure and FIG. 63 through FIG. 66 show the same basic inter-lock mechanisms and include therein the self-contained articulation system itself and the addition of lock and unlock for the knee gatch section.
FIG. 59 illustrates a bottom view of the base three segment PS3 single surface platform without the articulation inter-lock system 152 and module retainer plates. It shows a portion of the single surface backrest portion and the single surface knee gatch and all of the single surface mid portion. It also again highlights the pivot centers hinged interface/joint between the single surface backrest portion and single surface mid portion and the hinged interface/joint between the single surface mid portion and single surface knee gatch section. FIG. 59 further illustrates the spring loaded tilt/bend lock tubes 154 . The tilt/bend lock tubes that translate longitudinally are shown normally spring loaded in position to “lock out” or prevent any tilting or bending of the three segments maintaining a single flat surface. Spring 158 provides the bias to hold the tilt/bend lock tubes in this position. The spring could be a non-ferrous coil design or a composite or non-ferrous leaf spring as is the case for anything of the “spring-loaded” mechanisms in PS3. Also shown are tips 156 on the tilt/bend lock tubes which contact specific points on the articulation inter-lock system to retract the lock tubes. When the self-contained articulation system 152 is inserted into the apertures 150 in the single surface platform ( FIG. 57 ) the top edge and the stepped edge of the articulation system engage the tips 156 of the tilt/bend lock tubes 154 and push the tubes upwardly ( FIG. 59 ) disengaging the connection between the backrest portion and mid portion and also between the mid portion and the knee gatch. The self-contained installed articulation interlock module takes “control” of locking out the articulation of the backrest and knee gatch joints prior to the complete retraction of the lock tubes. The articulation inter-lock module self-locks into place via the same self-lock catch and release mechanisms described throughout PS3.
FIG. 60 is an isometric view of the tilt/bend lock tube 154 including tip 156 .
FIG. 61 represents an end view of the PS3 single surface platform without the articulation inter-lock system and single surface to frame interface hooks. Shown are the horizontally staggered tips 156 of the tilt/bend lock tubes that interface the articulation inter-lock system. Note, tips of the tilt/bend lock tubes could be alternatively staggered vertically. This figure also illustrates the apertures 202 for attachment of the extension on the single surface to frame interface.
FIG. 62 is a top isometric view of the base three segment PS3 single surface platform without the articulation inter-lock system, but with the single surface to frame interface hooks. Cross bars 160 are provided between the hooks and can be used as a handle or receiver for the interface hooks.
FIG. 63 is a top view of the three segment separable self-contained articulation inter-lock system 152 shown in FIG. 58 with the mechanisms in the locked position. Backrest lock bar 88 locks the mid portion to the backrest portion. Knee gatch lock bar 162 locks the mid portion to the knee gatch such that the three single surface platform segments are not allowed to bend at the hinge joints.
FIG. 63 through FIG. 66 show the same basic inter-lock mechanisms as described in the document in FIGS. 18 through 27 of the detailed description overview with the following additions involving the inter-lock system itself and the addition of lock and unlock for the knee gatch segment. The first addition is comprised of the knee gatch lock bar 162 for the knee gatch segment and a corresponding hinge lock bar. Note, these figures initially show the four bar member and lock bar in position such that the segments cannot articulate. In addition, these figures show surfaces which contact the tips on the tilt/bend lock tube in FIG. 59 and FIG. 60 . This interface and significance is described in further detail below in FIG. 67 and FIG. 68 .
FIG. 64 is a top view of the three segment articulation inter-lock system with the mechanisms in the unlocked position. The three segments and corresponding single surface platform portions are allowed to bend at the hinges. This figure now shows the elements positioned such that the portions can articulate. The hinge joint of the single surface platform is aligned with the hinge joint of the articulation inter-lock system to allow this articulation along with full retraction of the knee gatch lock bar 162 . A simple revolute hinge can be used at the hinge joint, however, a spherical joint could be used as well to allow for some misalignment of the hinge axis or a flexible coupling/joint. Use of this same design provides an ability to add segments and add hinge joints to the corresponding four bar mechanism such that the additional joints align with the new segment joint when the entire mechanism is in the unlock position. T-pins, although required to unlock the interlock plate module, are not shown in these figures.
FIG. 65 is directed toward a zoomed in top view of the alignment between hinge joints on the articulation inter-lock system and the single surface platform, which ultimately allows articulation of the single surface knee gatch portion with respect to the mid portion.
FIG. 66 is a bottom view of the complete self-contained articulation inter-lock system 152 .
FIG. 67 is a bottom view of the articulation inter-lock system 152 sliding/docking into the PS3 single surface platform and just beginning to engage the tips of the tilt/bend lock tubes. The stagger of the lower interface is required to properly engage the tilt/bend lock tubes. As illustrated, the tilt/bend lock tubes are in their baseline position which is maintained by the four springs 158 , thereby locking the three segment PS3 single surface platform into one flat surface at this point.
FIG. 68 is a bottom view of the articulation inter-lock system 152 in its final position in the PS3 single surface platform in which it has fully retracted the tilt/bend lock tubes beyond the hinge joints. At this point the articulation inter-lock system 152 controls articulation of the PS3 single surface platform joints. As described earlier, the inter-lock plate modules cannot be released without the two required T-Pins (mated to a separate surface like a gurney) engaged into the inter-lock plate module. Therefore, the articulation inter-lock system will always be in the locked configuration (no articulation of PS3 Single Surface joints allowed) while docking or removing the articulation inter-lock system. In addition, the four springs automatically force the four tilt/bend lock tubes back into a position, which securely locks out articulation of the hinge joints. Therefore, this design combination allows rapid installation and removal of the articulation inter-lock system without the chance of accidentally allowing articulation of the PS3 single surface platform hinge joints.
FIG. 69 is a bottom view of the assembled PS3 single surface platform ( 14 , 18 , 20 ), articulation inter-lock system and single surface to frame interface hooks 50 .
FIG. 70 illustrates a top isometric view of a complete PS3 single surface wing assembly. The wing is provides with three support pins 174 which provide additional support between the wing and the platform. Also an eccentric tension lever 168 is shown which will be described later.
FIG. 71 is a bottom view of the complete PS3 single surface wing assembly highlighting the inclusion of the wing catch/tension/release module 166 ( FIG. 72 ), which comprises a pair of self-locking catch mechanisms and release levers joined by a bar 172 . There could also be a single mechanism at the center of the wing for a wing of a shorter length.
FIG. 72 is an enlarged top view of the wing catch/tension/release module 166 highlighting the parts thereof which include the eccentric tension lever 168 , and the tension bar 170 . The eccentric tension lever is shown in the “locked” position. Tension bar 170 is eccentrically mounted to the eccentric tension lever and connected to bar 172 connecting the catch mechanisms. Movement of the tension bar 170 by actuation of the tension lever 168 causes translation of the wing catch/tension/release module relative to the wing body itself due to the offset or eccentric nature of the pivot center versus the outer radius or cam profile of the tension lever 168 . The tension bar 170 is threaded into the wing catch/tension/release bar 172 , which allows for adjustment of the tension of the wing to the single surface platform side.
FIG. 73 is a top isometric view of one of the wing catch/tension/release module elements. A release handle 102 engages the ramped portion 106 of the self-locking catch 104 thereby retracting catch the self-locking tips 112 from engaging the T-slots in the in single surface platform or wings.
FIG. 74 is a bottom view of the complete PS3 single surface wing assembly with the eccentric tension lever 168 in the unlocked position. Note the gap between the wing catch/tension/release module and the wing itself and compare it to the gap in FIG. 75 .
FIG. 75 is a bottom view similar to FIG. 74 of the complete PS3 single surface wing assembly with the eccentric tension lever 168 in the locked position. Note that the gap between the wing catch/tension/release module and the wing itself has closed as the catch/tension/release module is moved upward. This relative movement upward causes the self-locking catches to pull the wing tight into the single surface platform side. Note this same tension and release system could be used on the prior described auxiliary block assemblies if desired.
FIG. 76 represents an end view of the self-locking catch. The back side edge of the tips 112 are angled rearward from vertical, which contacts the vertical mating surface on the T-Slot on the single surface platform (the prior design showed this surface to be purely vertical). The rearward angle means the tip 112 of the self-locking catch will contact the T-slot before its base does and will provide a more secure lock into the T-Slot. This back angle will cause the self-locking catch tips to lock/bite into the T-Slot when the eccentric tension lever 168 is locked, which will not allow one to release the wing with the release levers until the eccentric tension lever is unlocked.
FIGS. 77A and 77B illustrates a side view of an “External” engagement of a standard rectangular or square bed/stretcher/gurnie rail 178 by inwardly projecting self-locking catch tips 176 of auxiliary block 122 .
FIG. 78 is a standard gurnie which could utilize the “External” engagement self-locking catch auxiliary design shown above in FIGS. 77A and 77B .
FIG. 79 is an isometric view of another alternative single surface platform rail 180 which provides for “External” engagement of the tips of auxiliary block.
FIG. 80 is an isometric view of the preferred “Internal” engagement of a self-locking catch auxiliary block 122 aligning to mate to an alternative standard rail design 180 with a slot or appropriately sized through hole.
FIG. 81 is an isometric view of the preferred “Internal” engagement of a self-locking catch auxiliary block 122 mated to an alternative standard rail design 180 with a slot or appropriately sized through hole.
FIGS. 82A and 82B illustrate a side view of alternative types of mounts 182 , 184 for self-locking catch designs. FIG. 82A depicts a “rigid” mount for the self-locking catches 182 in which the catch itself must flex/act as a living hinge. FIG. 82B depicts a pivot mount for the self-locking catches 182 in which the catch is spring-loaded.
FIG. 83 illustrates an isometric view of an auxiliary block assembly 122 mating to a lateral lock version of the T-Slot 162 . This figure shows an auxiliary block with a longer “Nose” that fits into the apertures 186 (5 shown) at the back wall of the T-Slot. This mate improves the vertical load carrying ability of the auxiliary block and lateral lock.
FIG. 84 is an isometric view of the standard PS3 T-Slot with slots 188 at the back wall of the T-slot for then nose of the auxiliary block. Note this is a separate piece of the standard PS3 T-Slot that can be placed anywhere (MRI, PS3 Frame, separate rack, a wall, etc. to accommodate PS3 wings, guardrails and auxiliaries when not assembled to the PS3 single surface platform. The same holds true for the lateral lock PS3 T-slot of FIG. 83 .
FIG. 85 is an enlarged view of FIG. 84 illustrating a taper on the leading edge of the T-slots. This taper assists with the self-alignment of an auxiliary block or another wing section.
FIG. 86 is a top isometric view of the auxiliary block 122 showing in detail the four flats-90 degrees apart configuration of the PokeYoke 190 . This configuration allows four orientations of the pole and is easier from a manufacturing standpoint. Note, this also shows the auxiliary pole lock 136 .
FIG. 87 is a bottom isometric view of the auxiliary lock ring 140 with the four flats-90 degrees apart PokeYoke with corresponding slots 144 for the auxiliary pole lock. The Poke Yoke insures 140 mates to 122 properly always resulting in a self-lock mate with pole lock 136 .
FIG. 88 is an isometric exploded view illustrating the relationship of the auxiliary block 122 , the auxiliary lock ring 140 and the bottom of the auxiliary pole 66 .
FIG. 89 is an isometric view of the PS3 single surface platform including the addition of guardrails 192 , which mount into the PS3 T-slot with the same self-locking catch mechanism as the auxiliary blocks and wings. The guardrails further include a PS3 auxiliary T-slot mounted thereon, and further illustrate the use inclusion of auxiliary T-slots 198 mounted to the frame 32 .
FIG. 90 represents an isometric view of the above illustrated PS3 single surface platform approaching an MRI device in which auxiliary T-slots 198 are placed on the side of the MRI bed platform to attach the PS3 wings and guardrails. The guardrails would be placed in the upper T-slots on the MRI platform to provide additional patient safety. These auxiliary T-slots could be mounted horizontally as shown or vertically.
FIG. 91 is an isometric view of the PS3 single surface to frame interface hooks 50 adapted for inclusion of the same basic self-lock catch mechanism as the auxiliary block and wings (see FIGS. 92 and 93 ) by the addition of extensions 200 . They are released from the PS3 single surface platform with a push button as shown attached to the extension. The push buttons are preferably positioned on the inside of the single surface to frame interface extensions to help prevent accidental release. They could also be placed on both inside and outside or just outside.
FIG. 92 is a zoomed isometric view of the single surface to frame interface hooks provided with the self-catch mechanism release pushbutton 204 and inserted into the PS3 single surface platform.
FIG. 93 is a bottom view of the PS3 single surface platform with a recess for the single surface to frame interface hook self-catch mechanism 204 to provide a secure mate of the single surface to frame interface hooks to the single surface platform.
FIG. 94 is a bottom view similar to FIG. 93 showing the retraction of the single surface to frame interface hooks self-catch mechanism 204 to allow removal of the single surface to frame interface hooks when the buttons are pushed in this manner.
FIG. 95 is an isometric view of the PS3 single surface platform illustrating an air mattress 206 in a deflated condition on top, and covering the entire surface.
FIG. 96 illustrates an isometric view of the PS3 single surface platform with wings and without the deflated air mattress on top. Hinge 208 is provides between the backrest portion and the mid portion of the PS3 single surface. Hinges 212 are provided between the corresponding wings attached to these surfaces. Hinge 210 is provided between the mid portion and the knee gatch of the single surface. Hinges 212 are provided between the corresponding wings attached to these surfaces. Note, there could be an innumerable number of wing width options depending on the specific application.
FIG. 97 is a perspective view of another embodiment of the single surface platform to frame interface wherein the interface members 214 are straight and project outwardly from the single surface platform. A crossbar 216 connects these interface members (these could not be used to interface with the frame, but would function strictly as handles) and permits the interface member to be utilized as a handle or attachment member to the frame.
FIG. 98 is a perspective view of the hook shaped single surface platform to frame interface hooks 50 provided with a crossbar 216 .
FIG. 99 is an exploded view of a handle assembly 218 and sleeve 220 which are insertable into the crossbar 216 to provide carrying handles. The sleeve 220 is provided with a longitudinal slot 224 and vertical slots 226 for the reception of pins 222 of handle assembly 218 . This permits the distance that the handle assembly protrudes from the crossbar 216 to be adjusted. The hinge joint in the handle allows for angular orientation adjustment for the user's comfort as well as the ability to straighten and store away in the crossbar 216 . Note optional detent features (not shown herein) may be positioned near the top of the slots 226 to “snap/lock” the pin 222 into when rotated into position.
FIG. 100 is an alternative mechanism for attaching the handle assembly to the sleeve. Self catch mechanism 228 is mounted in the handle assembly. Apertures 230 and 232 are provided in sleeve 220 . The tabs of the self catch mechanism 228 are engagable with the apertures 230 and 232 thereby enabling the distance that the handle assembly extends from the sleeve to be adjusted.
FIG. 101 is a side view of the sleeve 220 illustrated in FIG. 100 .
FIG. 102 is a side view of the handle assembly 218 and sleeve 220 illustrating the relationship of the self catch mechanism 28 and apertures 230 in the sleeve.
FIG. 103 is a side view of the self catch mechanism of FIG. 102 either rigidly fixed and required to flex or a pivot and spring-loaded.
FIG. 104 is a side view of an alternative embodiment of an auxiliary block provided with a tension lock 234 in the unlocked position.
FIG. 105 is a view similar to FIG. 104 with the eccentric tension lock in its locked position. The tension lock lever is moved upwardly to its vertical position. This action moves the tension lock to the left whereby the self-locking catch is also moved to the left. This provides an additional force to secure the auxiliary block to the T-slot of the wing or single surface platform and does not allow one to release the auxiliary block from the wing or single surface via the release handle when tension lock lever 236 is locked.
FIG. 106 is a side view of the PS3 assembly provided with push/pull folding handles 238 , which are used to move and position the PS3 assembly, in their inoperative position.
FIG. 107 is a side view of the PS3 system of FIG. 106 with the push/pull handles 238 in their operative position.
FIG. 108 is a partial view of the push/pull handles and PS3 frame illustrating the hinge pin 242 about which the handles pivot. Also shown is the self-locking latch 240 which holds the handles in their operative or inoperative positions.
FIG. 109 is a partial side view of the ends of the push/pull handles provided with telescoping extensions 244 .
FIG. 110 is a top plane view of the PS3 single surface platform incorporating an upper body portion hinged to a mid portion which is hinged to a knee gatch portion. Separate wing sections 24 , 30 and 28 are attached to the respective portions of the single surface platform. Hinges are illustrated on the single surface platform and the lower wing sections.
FIG. 111 illustrates an internally mounted adaptor plug 246 for an auxiliary pole.
FIG. 112 illustrates an externally mounted adaptor plug 248 for an auxiliary pole.
FIG. 113 illustrates an alternative, triangular shaped T-pin.
FIG. 114 illustrates transfer/transport frame 252 which is an alternative embodiment of transfer/transport frame 32 . The new additional frame elements shown in FIG. 114 , which are described in the following, enable the following additional functions: in PS3 frame articulation of the frameless single surface backrest and kneegatch joints, complete reversal of the cantilever with or without the PS3 single surface in place, equal access to either transverse side of the frame during all situations except surface transfer and additional single surface support to minimize binding/friction during docking of the articulation inter-lock module 152 while the frameless single surface is supported in the PS3 frame. Articulation of the backrest incline and knee gatch within the PS3 frame as well as the ability to provide equal access to both sides of the single surface while in the PS3 frame, except during surface transfer, eliminates the need for a separate supporting surface and elimination of the need for storage of the PS3 frame during patient convalescence or otherwise. Frame 252 includes frame lower legs 256 positioned at each end of frame 252 . A collapsible/extendable lower cross member 260 , extends between and connects the frame lower legs 256 . Cross member 260 is collapsible/extendable to compensate for large horizontal distance changes required between support columns 254 during in frame articulation of the backrest and knee gatch joints as shown in FIG. 115 , while maintaining interface between arms 258 and single surface to frame interface member 50 . Maintaining the arm 258 to single surface to frame interface member 50 during articulation of these joints adds support/stability and reduces the function required from the inner support assemblies 262 and 264 . For example, member 266 in FIG. 115 would not require engagement/actuation of the backrest section for backrest articulation and/or Trendelenburg if the main single surface to frame interface members 258 are engaged as described. One of the frame interface members 258 still utilize the pivot 40 to accommodate small horizontal distance changes for pure Trendelenburg and reverse Trendelenburg. The lower cross member 260 is in telescoping engagement with said legs 256 , as well as traversing said legs in a lateral direction, wherein said cross member 260 is movable from one side of said frame 256 to another in which the wheels' 46 rotation are locked to facilitate this traverse of the cross member 260 . Simply the lateral movement of the cross member 260 to a mid position lengthwise of legs 256 allows equal access to either side of the single surface while in the PS3 frame in all situations other than those transfers requiring the cantilever function. The cantilever columns 254 are each telescopingly engaged with said legs 256 , as well as being rotatable and translatable in a manner effective to rotate the support members 258 180° in response to translation of said columns from a first side of said frame 252 to the other side thereof. Rotation of said support members 258 permits the single surface platform to remain aligned with the lower legs 256 , thereby preventing the frame from becoming unstable and reversing the cantilever in concert with the traverse of cross member 260 . This allows correct orientation of the patient to transfer surface within the PS3 frame dependent on which side of a surface for transfer has clear access without having to disengage and engage the single surface and patient on another surface to re-orient. The bottom large square column 254 which interfaces 256 remain fixed in orientation about its vertical axis and cylinder 278 allows a rotational degree of freedom and is mated to pinion 279 which repeatability automates rotation during translation and proper final orientation of arms 258 depending on the end positioned on the leg 256 . Reversing the cantilever with the single surface and patient in place requires the usage of the inner support column assemblies 262 and 264 in which the single surface platform is raised to a position above the tops of assemblies 262 and 264 . Further included are telescoping, rotatable and longitudinally adjustable supports 262 , 264 which are engageable with, and support said single surface support platform. Each of said adjustable supports 262 , 264 are provided with a mating means assembly for selectively enabling reversible engagement with and adjustment of the single surface support platform, the mating means assembly being comprised of pivoting support member 266 , adjustable extension 268 and mating means 270 . A pivoting support member 266 is mounted above each adjustable support 262 , 264 , each said supporting member 266 being vertically adjustable and rotatable. Each said supporting member 266 further including adjustable extensions 268 which are provided with mating means, e.g. T-pins, 270 for enabling reversible engagement with the single surface support platform, in a variety of configurations. For example, when rotated 90 degrees, the T-pins 270 will provide mating engagement with coupling elements 285 , 286 , as illustrated in FIG. 69 . Support columns 274 enable vertical adjustment and rotation of said support members 266 with respect to support columns 272 . Columns 272 slidably engage lower cross member 260 via column mounting elements 276 . The next step in cantilever reversal involves the cross member 260 and assemblies 262 and 264 which are positioned in a mid leg 256 position so the assemblies 262 and 264 are positioned below the lateral center of the single surface. Subsequently, the inner support assemblies 262 and 264 , which are slidably engaged on cross member 260 , are positioned longitudinally below the self-aligning keyhole recesses 285 and 286 in FIG. 69 . In the process of this longitudinal positioning of inner support assemblies 262 and 264 , they automatically rotate 90 degrees via the same basic method as described for translation and rotation of arms 258 except modified for 90 degree rotation instead of 180 degrees. Next, the arms 268 are retracted or extended to allow T-pins 270 to align with the large end of the keyholes 285 and 286 . Then, the single surface is lowered onto the current vertically oriented and locked T-Pins 270 , via the frame top single surface interface arms 258 , which mate in the large end of the keyholes 285 and 286 . Next, the arms 268 retract to securely mount and support the single surface by the assemblies 262 and 264 . At this point, the articulation interlock module 152 could be easily removed or installed in the frameless single surface as described earlier. Finally, the assemblies 262 and 264 raise the single surface off of the single surface to frame interface arms 258 and allow the cantilever reversal of arms 258 . Then the arm 258 and assemblies 262 and 264 engagement is reversed to return the single surface loading to arms 258 and allow the cantilever reversal completion via movement of the cross member 260 and its corresponding assemblies 262 and 264 to the end of the legs 256 in which the columns 254 now reside. Description of the PS3 frame 252 backrest and knee gatch articulation of the frameless single surface follows. Like the cantilever reversal process the first step for backrest and knee gatch articulation involves the single surface platform positioning above the tops of assemblies 262 and 264 via the arms 258 . Once again cross member 260 and assemblies 262 and 264 are moved to a mid leg 256 position so the assemblies 262 and 264 are positioned below the lateral center of the single surface as well as the proper longitudinal position to mate one of the T-pins 270 sets on assembly 262 or 264 to the articulation interlock module keyholes 85 large end. The resultant assembly 262 or 264 to be engaged to the single surface is raised above the non-engaging assembly 262 or 264 . The single surface is lowered onto the intended T-pins 270 via the frame to single surface arms 258 and the single surface articulation handle 76 is rotated accordingly to lock into T-pins 270 as described earlier and release the backrest and knee gatch joint articulation. This locking into the T-pins releases a separate inter-lock to allow the rotation of the crossbar 266 about its pivot on 274 as well as the T-Pins about their pivot on the telescoping arms 268 . The telescoping arms 268 can now retract to cause knee gatch articulation as shown in FIG. 115 in which T-Pins 270 only can rotate about the pictured pivot away from their telescopic arms 268 to force proper articulation of the knee gatch due to a mechanical stop between the T-pin 270 mount and the telescopic arms 268 . The frame to single surface arms 258 can remain engaged in the single surface to frame interface hooks 50 via proper automated and actuated vertical adjustment of the arms 258 and horizontal retraction of the telescopic cross member 260 . Backrest incline and combinations of Trendelenburg and Reverse Trendelenburg are also feasible through coordinated vertical movement of arms 258 and engaged assembly 262 or 264 .
FIG. 115 illustrates articulation of the single surface platform about the articulating joints, permitting movement of the backrest incline and knee gatch with respect to the mid-section. Single surface to frame interface hooks remain attached to either end of said single surface platform whereby engagement with said frame supporting arm may be effected.
FIG. 116 is illustrative of a rack and pinion mechanism 282 designed to insure coordinated movement of the frame supporting arm 258 and frame cantilever column 254 . As illustrated, upon initiation of lateral movement of the frame cantilever column 254 , follower cam 281 begins to traverse across the width of frame lower leg 256 , wherein gear 280 engages rack 284 , providing rotation of frame supporting arm 258 in a coordinated fashion so as to effect a rotation of 180° upon completion of the traversal of said frame lower leg 256 by said frame cantilever column 254 . Follower cam 281 engagement with cam profile 283 post rotation insures and maintains proper orientation of pinion 279 and resultant orientation of frame supporting arms 258 . Pinion 279 is attached directly on the rotational center of the cylinder 278 or offset and connected via gears, belts and pulleys, etc. In an alternative embodiment pinion 279 could be connected to column 254 and eliminate the separate cylinder 278 . This cooperation of elements provides reversibility of the orientation of the frame and cantilever arms while in place.
All patents and publications mentioned in this specification are indicative of the levels of those skilled in the art to which the invention pertains. All patents and publications are herein incorporated by reference to the same extent as if each individual publication was specifically and individually indicated to be incorporated by reference.
It is to be understood that while a certain form of the invention is illustrated, it is not to be limited to the specific form or arrangement of parts herein described and shown. It will be apparent to those skilled in the art that various changes may be made without departing from the scope of the invention and the invention is not to be considered limited to what is shown and described in the specification. One skilled in the art will readily appreciate that the present invention is well adapted to carry out the objects and obtain the ends and advantages mentioned, as well as those inherent therein. Any devices, methods, procedures and techniques described herein are presently representative of the preferred embodiments, are intended to be exemplary and are not intended as limitations on the scope. Changes therein and other uses will occur to those skilled in the art which are encompassed within the spirit of the invention and are defined by the scope of the appended claims. Although the invention has been described in connection with specific preferred embodiments, it should be understood that the invention as claimed should not be unduly limited to such specific embodiments. Indeed, various modifications of the described modes for carrying out the invention which are obvious to those skilled in the art are intended to be within the scope of the following claims. | This invention is directed towards a patient single surface system, PS3, which is a next generation system solution for patient accommodation, diagnosis, treatment, transfer and transport. PS3 provides a single surface for the patient to remain on from the trauma site through diagnosis, treatment and convalescence. Needs addressed by the PS3 system include improved patient treatment through reduction in time to treatment, reduced or eliminated unnecessary patient movement and injury, as well as improved comfort throughout treatment and convalescence. In addition, the PS3 system solves significant economic considerations. | 0 |
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0001] This project has been funded by the Maryland Procurement Office under Contract Number MDA904-99-G-0703/005.
CROSS-REFERENCE TO RELATED APPLICATIONS
[0002] Not applicable.
BACKGROUND OF THE INVENTION
[0003] 1. Field of the Invention
[0004] The present invention generally relates to a debugger for a multiprocessor system. More particularly, the invention relates to a debugger that uses a “tree” communication structure comprising communication nodes that aggregate messages from debugging a plurality of processes and provide aggregated, as well as unaggregated, messages, to a debugger user interface.
[0005] 2. Background of the Invention
[0006] A computer program comprises a set of instructions which are executed by a processor. A software designer writes the program to perform one or more functions. An error in the program (referred to as a “bug”) may cause the program to operate in an unpredictable and undesirable manner. Accordingly, a computer programmer must debug the program to help ensure that it is error free.
[0007] The process of debugging a computer program generally requires the ability to stop the execution of the program at desired points and then check the state of memory, processor registers, variables, and the like. Then, the program can continue to execute. To facilitate the debug process, debug tools (i.e., software) are available which permit a programmer to debug the software. Debug programs have numerous features such as the ability to set break points in program flow, single stepping through a program (i.e., executing one instruction at a time and then stopping), viewing the contents of memory and registers, and many other features useful to the debugging process.
[0008] The computer field has seen numerous advancements over the years. One significant advancement has been the development of multiprocessor computer systems (i.e., computer systems having more than one processor). Multiprocessor systems permit more than one instruction to be processed and executed at time. This is generally called “parallel processing.” The instructions being concurrently executed may be instructions from the same program or different programs.
[0009] Although debugging a computer program that runs on a single processor computer can, at times, be difficult enough, debugging a computer program that runs on multiprocessors concurrently adds considerable complexity. For example, the debugging process may require checking on and keeping track of the status of registers and memory associated with a multitude of processors in the system. Additional complications occur when debugging a multiprocessor system and those complications can best be understood with reference to FIG. 1.
[0010] [0010]FIG. 1 shows a conventional multiprocessor system comprising a plurality of application processes 10 (labeled as “Process 0,” “Process 1,” and so on). Each application process 10 comprises at least one processor and may include more than one processor. The debugging of application software that runs on the various processes 10 can be controlled and monitored via a debugger user interface 18 which has a separate communication channel 16 to/from a debug server 12 associated with each process. Through interface 18 a person can, for example, set break points, examine register contents, etc. As shown, each process 10 is associated with a debug server 12 which may be a computer program that actually causes the actions desired by the computer programmer to occur. The debug server 12 may be embedded in the associated process or be separate from the process. In general, the debug servers 12 cause the debugging actions to occur that the programmer feels are necessary to debug the application and provides status information and memory/register data back to the debugger user interface 18 .
[0011] The architecture shown in FIG. 1 works generally satisfactory for systems having relatively few processes. This is true for several reasons. First, many operating systems limit the number of communication channels 16 that can be open concurrently for a given process. Thus, the number of communication channels that can be open at a time pertaining to the debugger user interface 18 (which itself is a process) may be limited to a number that is less than the number of processes 10 in the system.
[0012] Timing can also become a problem for debuggers in the multiprocessor architecture shown in FIG. 1. It takes a finite amount of time to process a message from a debug server 12 . This amount of time is accumulated when considering processing responses from all of the debug servers 12 . For example, if it takes 1 millisecond for the interface 18 to process a message from one debug server 12 and the system includes 2000 processes, then it would take as much as 2 seconds (2000 milliseconds) to finish processing a message in response to a single command to the interface 18 . This delay can detrimentally interfere with the debugging process.
[0013] The problems described above become more severe as the number of processes increases. Accordingly, a solution to these problems is needed. Such a solution would permit a more efficient debug operation for multiprocessor systems.
BRIEF SUMMARY OF THE PREFERRED EMBODIMENTS OF THE INVENTION
[0014] The problems noted above are solved in large part by providing a computer system with an aggregator network that fans out commands and aggregates messages. A preferred embodiment of the computer system includes a plurality of processes on which an application executes, the aggregator network and a debugger user interface. Using the debugger user interface, commands can be created and sent through the aggregator network to debug servers associated with the processes. Further, messages from the debug servers are routed through the aggregator network to the debugger user interface. The aggregator network preferably, whenever possible, combines the debug servers' messages into fewer messages and provides a reduced number of messages to the debugger user interface.
[0015] The aggregated messages generally contain the same information as the messages they aggregate and identify the debug servers from which the messages originated. The aggregator network examines the debugger server messages for messages that have identical or similar data payloads. Messages with identical data payloads can be easily combined into a single message that indicates which debug servers generated the identical messages. Messages with non-identical payloads having some common data values can also be aggregated. A message that aggregates messages with similar, but not identical, payloads preferably identifies the identical portions of the payload and the non-identical portions along with an identification of the debug servers associate with the non-identical portions. Not all messages can necessarily be aggregated and such unaggregated messages are also routed from the processes through the aggregator network to the debugger user interface.
[0016] The debugger user interface can store and process the messages in their aggregated form or convert the aggregated messages to their unaggregated form. This feature is selectable via the debugger user interface.
[0017] This aggregation of processor message alleviates the burden on the debugger user interface which otherwise would have to be capable of receiving and processing many more messages. Further, the aggregator network is one preferred form of a multi-layer communication network that comprises a plurality of communication nodes that permit a plurality of processes to send messages to a single debugger user interface, and commands to be routed to the processes. Such a multi-layer communication network provides an architecture in which all processes have open and active communication channels despite reasonable limitations imposed by the operating system on the number of communication channels to/from an individual process. These and other advantages will become apparent upon reviewing the following disclosures.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] For a detailed description of the preferred embodiments of the invention, reference will now be made to the accompanying drawings in which:
[0019] [0019]FIG. 1 shows a conventional debug architecture in which a debugger user interface includes a separate communication channel to each process debug server in the system;
[0020] [0020]FIG. 2 shows a preferred embodiment of the invention in which a balanced aggregator network is used to couple debug servers associated with processes to a debugger interface;
[0021] [0021]FIG. 3 shows a method of aggregating messages having identical data payloads;
[0022] [0022]FIG. 4 shows a method of aggregating messages having non-identical data payloads;
[0023] [0023]FIGS. 5 a and 5 b show an alternative method of aggregating messages having non-identical data payloads;
[0024] [0024]FIG. 6 shows a method of aggregating messages provided from separate aggregators;
[0025] [0025]FIGS. 7 a - 7 c include tables of routing information associated with the aggregator network; and
[0026] [0026]FIG. 8 illustrates one embodiment of an unbalanced aggregator network.
NOTATION AND NOMENCLATURE
[0027] Certain terms are used throughout the following description and claims to refer to particular system components. As one skilled in the art will appreciate, computer companies may refer to a component and sub-components by different names. This document does not intend to distinguish between components that differ in name but not function. In the following discussion and in the claims, the terms “including” and “comprising” are used in an open-ended fashion, and thus should be interpreted to mean “including, but not limited to . . . ”. Also, the term “couple” or “couples” is intended to mean either a direct or indirect electrical connection. Thus, if a first device couples to a second device, that connection may be through a direct electrical connection, or through an indirect electrical connection via other devices and connections. In addition, no distinction is made between a “processor,” “microprocessor,” “microcontroller,” or “central processing unit” (“CPU”) for purposes of this disclosure. To the extent that any term is not specially defined in this specification, the intent is that the term is to be given its plain and ordinary meaning.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0028] Referring now to FIG. 2, system 100 is shown constructed in accordance with a preferred embodiment of the invention. As shown, system 100 includes one or more application processes 102 coupled to a debugger user interface 114 via an aggregator network 110 . Although nine processes 102 (P 0 -P 8 ) are shown in FIG. 2, any number of processes can be debugged using the preferred embodiment. Each application process 102 to be debugged preferably includes, or is associated with, a debug server 104 which preferably is a commonly available piece of debug software, such as Ladebug provided by Compaq Computer Corporation, gdb provided from the Free Software Foundation, or dbx from Sun Microsystems, which can be used to set break points, check memory and registers, and other types of debugging tasks initiated via the debugger user interface 114 .
[0029] Using the debugger user interface 114 , a user (e.g., a computer programmer) can send debug commands to one or more of the debug servers and receive messages from the debug servers. The commands may be any commands useful to debugging an application that runs on one or more of the processes 102 . Examples of such commands may include commands that set break points in program flow, single stepping through a program, requests for the contents of memory and/or processor registers, and the like. The messages from the debug servers 102 to the user interface 114 may include the content of memory, the content of registers, status information, and other information that may be useful in the debugging process. The user interface 114 itself preferably runs on a process and includes at least one processor, an input device (e.g., a keyboard and mouse) and an output display device.
[0030] The aggregator network 110 preferably includes two features which help solve the problems noted above. One feature is that the aggregator network 110 preferably includes a hierarchy structure comprising one or more layers 116 and 118 and one or more aggregators 120 , 124 , 126 and 128 in each layer. The use of the aggregators to aggregate messages will be described below. For now, it should be understood that the salient feature of the aggregators is that they are one type of communication “node.” Each communication node (i.e., aggregator) receives and transmits messages and commands. Using the communication infrastructure shown in FIG. 2, no one process need have more communication channels than is permitted by any reasonable limitations on the system, such as the quantity of open communication channels which may be imposed by the operating system as explained above. As shown in FIG. 2, although there are nine processes 102 , each aggregator 120 - 128 only has four communication channels, one channel for each of four processes/aggregators. In the example of FIG. 2, aggregator 120 communicates with processes P 0 , P 1 and P 2 via communication channels 130 . Aggregator 124 communicates with processes P 3 -P 5 using communication channels 132 while aggregator 126 has communication channels 134 to processes P 6 -P 8 . Each aggregator in layer 116 also has a communication channel 136 to aggregator 128 in layer 118 .
[0031] Accordingly, aggregators 120 - 126 have three communication channels 130 , 132 , 134 to each of three processes and a fourth communication channel 136 to aggregator 128 . Aggregator 128 in layer 118 includes the three communication channels 136 to aggregators 120 , 124 and 126 and a fourth communication channel 138 to the debugger user interface 114 . Rather than having nine communication channels from the processes 102 directly to the debugger user interface, which would be the case with the conventional communication architecture of FIG. 1, the aggregator network 110 of FIG. 2 requires no more than four channels to any one process. The aggregator network 110 of FIG. 2 can be scaled for any number of processes. For example, additional aggregators could be added to layer 116 in the network 110 to communicate with hundreds or thousands of processes. Additionally, the number of communication layers in the aggregator network 110 could be increased beyond just the two shown in FIG. 2. Further still, aggregator 128 (layer 118 ) is not necessary to the implementation of a communication network which permits a plurality of processes to communicate with a debugger user interface 114 with the number of active communication channels that the operating system permits. Accordingly, aggregators 120 - 126 in layer 116 could simply communicate with the debugger user interface 114 without communicating through layer 118 . Broadly, the preferred embodiment of the invention includes at least one layer of communication nodes, each node communicates with one or more processes and to one or more other communication nodes or to a debugger user interface.
[0032] In addition to simply being communication nodes, the aggregators in FIG. 2 also perform another function. Accordingly, the second advantageous feature of the embodiment shown in FIG. 2 is that messages from debug servers 104 to the debugger user interface 114 are analyzed and, when appropriate, combined or otherwise aggregated together. For example, if each debug server 104 transmits the same message (e.g., the current date) ultimately destined for the debugger user interface 114 , rather than transmitting nine separate, yet identical, messages to the user interface 114 , the aggregator network 110 aggregates those messages preferably into a single message. The single message might include a single instance of the date and an indication that all nine processes 102 transmitted the date. There are numerous possible techniques to analyze and aggregate messages together and several such techniques will be discussed below. The message aggregation preferably occurs without regard to messages being sent from the debug servers 104 to the debugger user interface 114 . Messages communicated in the opposite direction (i.e., commands from the debugger user interface 114 to the debug servers) generally are not aggregated.
[0033] As shown in FIG. 2, each aggregator 120 - 128 in the aggregator network 110 analyzes and aggregates its input messages and forwards on an aggregated message to the entity to which it communicates. The aggregators in layer 116 aggregates messages from the debug servers 104 and the aggregator(s) in layer 118 aggregates messages from the layer 116 aggregators. Accordingly, aggregator 120 aggregates messages from the debug servers associated with processes P 0 -P 2 . Aggregator 124 aggregates messages from the debug servers associated with processes P 3 -P 5 while aggregator 126 aggregates messages from the debug servers associated with processes P 6 -P 8 . Aggregator 128 in layer 118 aggregates messages from aggregators 120 - 126 .
[0034] Whenever possible, each aggregator tries to aggregate its input messages together to forward on to the next entity in the communication chain. A plurality of messages may be aggregated into a single message or more than one message. In general, n messages are aggregated into m messages, where m is less than n. The value n is greater than 1 and, by way of example and without limitation, may be greater than 100 or greater than 1000.
[0035] Not all messages can be aggregated. Some input messages to an aggregator may be too dissimilar to be aggregated. Non-aggregated messages are simply forwarded on.
[0036] A message preferably includes header information containing routing specifics such as a destination address and a data payload. In accordance with a preferred embodiment, with regard to message aggregation, messages generally fall into one of the following three categories:
[0037] identical payloads
[0038] similar payloads
[0039] completely dissimilar payloads
[0040] Thus, two or more messages may have identical payloads, similar payloads or payloads too different to benefit from message aggregation. Message aggregation may occur for two or more messages that have identical or similar payloads. If the input message payloads into an aggregator are identical, the aggregator can use those input messages to generate a single output message with a single payload also identifying the processes 102 to which the aggregate message pertains. An example of aggregating messages with identical payloads is shown in FIG. 3. As shown, an aggregator receives two input messages 150 and 152 which have identical payloads 156 and 158 , respectively. The difference between messages 150 and 152 is that each originated from a different debug server. Message 150 originated from the debug server associated with process P 0 as indicated by numeral 0 in field 160 and message 152 originated from the debug server associated with process P 1 as indicated by field 162 . The aggregated message 154 preferably includes the same payload ( 156 , 158 ) as messages 150 and 152 . Field 164 includes a process identifier range which identifies the processes to which the aggregated message payload 156 , 158 pertains. In the example of FIG. 3, the value in field 164 comprises “0:1” indicating that the payload originated from the debug serves associated with processes P 0 and P 1 .
[0041] [0041]FIG. 4 illustrates the use of one suitable message aggregation technique for similar, but not identical, messages. As shown in FIG. 4, messages 170 and 172 are aggregated together by an aggregator to form aggregated message 174 . Message 170 originates from process P 0 as indicated by field 180 and message 172 originates from process P 1 as indicated by field 182 . Messages 170 , 172 have similar, but not identical, payloads 176 and 178 , respectively. Payload 176 in message 170 includes the date data value “Feb.11, 2002” and payload 178 in message 172 includes the date data value “Feb. 13, 2002”. The two date data values are identical except for the dates—11, 13. That is, portions 184 , 190 (“FEBRUARY”) are identical and portions 188 , 194 (“, 2002”) also are identical. That is, the initial portions 184 and 190 “FEBRUARY” (including the blank space immediately after the word FEBRUARY) in each payload and the ending portions 188 and 194 “, 2002” (including the blank space after the comma) are common to both message payloads. Portions 186 and 192 (values of 11 and 13, respectively) are different.
[0042] Aggregated message 174 can be formed as shown without repeating the common portions 184 , 188 , 190 , and 194 . Only the dissimilar portions 186 , 192 of the data payloads need to be individually identified. In the aggregated message 174 , field 196 identifies the processes (P 0 and P 1 in the example) from which the aggregated message originated. Data payload 198 includes three fields of data values which generally correspond to the three fields of each of the input messages 170 , 172 . Fields 200 and 204 relate the data values that are common to both input messages. These values are indicated as being common by not including any indication that those values are different in any way. Field 202 includes the data values from the input messages that are different between the messages. These values—11 and 13—are identified as a list of dissimilar data values by the use of predetermined syntax. Although any special syntax can be used, in the example of FIG. 4, the syntax includes brackets around the values and a semicolon indicating a range or a comma individually separating the values. Whether the aggregated messages use a semicolon to indicate a range or a comma to list the differences is a user-selectable feature. Thus, special syntax is used to encode or otherwise identify those data values of the input message payloads 176 , 178 that are unique; all other fields of the data payload 198 are assumed to contain data values that are identical to the aggregated messages.
[0043] [0043]FIG. 4, as shown, retains only the low and high values of the dissimilar fields, and does not retain the origins of the field values. This in itself can be useful to reduce processing and bookkeeping and to enhance speed. Alternate possibilities include retaining all the values and their origins, preferably in a compact form. This would allow a first presentation using a range as shown in FIG. 4, as well as being able to show more detail in expanded presentations. Aggregators could be in modes, e.g., based on time and space versus utility tradeoffs, to discard or retain various degrees of information. This disclosure covers all such cases.
[0044] In this way, messages that contain some identical and some non-identical elements of their data payloads can be aggregated into fewer messages, preferably a single message, that effectively provide the same information. FIGS. 3 and 4 illustrate one possible technique for aggregating messages, but numerous other techniques exist and are within the scope of this disclosure. For example, FIGS. 5 a and 5 b illustrate another technique. In FIG. 5 a , message 210 originated from process 0 and has a data payload comprising the value “ABCDEF”. Message 220 originated from process 1 and has a data payload comprising the value “BCDEFG”. In comparing the two payloads side by side there are no common elements to payloads. However, as shown in FIG. 5 b , if the data payload of message 220 is shifted by one character, or at least viewed in a shifted format, with respect to the payload of message 210 , then it can be seen that the two payloads include common data values. As shown, the values “BCDEF” 224 are common to both payloads, while the values A ( 226 ) and G ( 228 ) are unique to each message (A being unique to message 210 and G being unique to message 220 ). The aggregators preferably analyze the data payloads of their input messages to determine if identical alphanumeric strings, albeit in different portions with the payloads, exist in the input messages.
[0045] These messages can be aggregated together as shown by message 230 in FIG. 5 b . The payload comprising the aggregated message 230 indicates that the first value A ( 234 ) was an element of only the message from process P 0 (message 210 ). This fact is indicated by including the value A in brackets along with the process number to which that value pertains. Similarly, the ending value G ( 236 ) is encoded as being an element of a message from process P 1 only. The field 236 in aggregated message 230 contains the common data values, “BCDEF”. Again, as noted above, there are numerous ways to encode this type of information besides that shown in FIG. 5 b.
[0046] The example of FIG. 5 b assumes the values of the aggregated payloads are maintained in the same order. If, however, order is not necessary then the concept of FIG. 5 b can be extended to reorder payloads to permit aggregation.
[0047] The aggregation techniques described above generally pertain to messages being sent from processes 102 to the debugger user interface 114 (FIG. 2). Messages from the processes 102 are aggregated, if possible, by aggregators 120 - 126 in layer 116 . The aggregator 128 in layer 118 preferably aggregates the aggregated and non-aggregated messages from aggregators 120 - 126 on channels 136 . Aggregator 128 compares the messages it receives from the three aggregators 120 - 126 to determine if any of the messages received from different aggregators can further be aggregated. Also, aggregator 128 determines whether any non-aggregated input messages can be aggregated with either aggregated or non-aggregated messages from other aggregators. The aggregation techniques shown in FIGS. 3 and 4 can be used by aggregator 128 to aggregate messages received from different aggregators 120 - 126 in layer 116 .
[0048] [0048]FIG. 6 illustrates how a non-aggregated message received from one aggregator 120 - 126 can be compared to and aggregated with an aggregated message received from a different aggregator. In the example of FIG. 6, aggregator 128 receives two messages 240 and 154 . Message 240 originated from process P 6 and, according to FIG. 2, passed through aggregator 126 . Message 154 is an aggregated message that originated from processes P 0 and P 1 and was previously described in FIG. 3. Aggregator 128 compares the payloads of the two messages, determines that they are identical and aggregates the two messages together to form aggregated message 246 . Message 246 includes a process identifier field 238 which identifies all of the processes that provided messages that became aggregated together in message 246 . As such, identifier field 238 includes the values 0:1,6 to indicate that messages from processes P 0 , P 1 and P 6 are aggregated together by message 246 . The data payload 248 of message 246 is simply the payload from the messages generated by processes P 0 , P 1 and P 6 .
[0049] Further, it is conceivable to have aggregators operate on objects rather than text. Imagine a query of “statistics of age keyed by name.” The object would be a set. Each entry is a name and information about age statistics (e.g. n, sum(age), sum(age{circumflex over ( )}2) will allow count, average and standard deviation). “Aggregating” two objects would create a new object that represents the union of the names, but with the statistics entries combined, which in this case is a straightforward summation. This kind of partial aggregation can be done in the aggregator network/tree.
[0050] In fact, if the internal representation sorts the set by name, then aggregation can be done in a pipelined/flow-through fashion without having each aggregator read each full object from its inputs before doing the combination, and sending the large result out. Instead, knowing they are sorted allows an aggregator that sees, for example, “Robert” to know it will never see a “David”, so that if there are “David” s pending from other channels, it can safely combine and forward.
[0051] As described above, aggregators layer 116 aggregate messages from the processes 102 , while aggregator(s) in layer 118 aggregate messages from layer 116 aggregators. The message aggregation described herein pertains to messages being transmitted from the processes 102 to the debugger user interface. By aggregating messages whenever possible, fewer messages are provided to the user and the effort of debugging the application program is made considerably easier and more efficient.
[0052] Thus far, a balanced aggregator network has been shown. FIG. 8 shows one embodiment of an unbalanced network. As shown, aggregators 320 may receive inputs from debug servers, while aggregators 330 aggregate messages from other aggregators. The scope of this disclosure includes balanced and unbalanced networks. Further, there is no limit on the depth of the network (i.e., the number of levels in the network).
[0053] As noted above, commands or other information transmitted by the debugger user interface 114 to the processes 102 generally are not aggregated. Instead, each command is routed by the aggregators 120 - 128 to the appropriate destination location(s). Each command preferably is encoded with a process number (e.g., 0, 1, 2, etc.) or a process set corresponding to a group of processes as is commonly understood by those skilled in the art. Preferably, each aggregator has access to routing information which is used to determine how to forward commands on to other aggregators/processes. The routing information may take the form, for example, of a table which is loaded into memory. FIG. 7 a shows one exemplary embodiment of a routing table 300 which is useful for aggregator 128 . As shown, table 300 in FIG. 7 a lists the various processes, P 0 -P 8 , in the system along with an indication for each process of the layer 116 aggregator through which that process communicates. Accordingly, the routing information preferably states that aggregator 120 includes communication channels to processes P 0 -P 2 . Similarly, the routing information may state that aggregator 124 includes communication channels for processes P 3 -P 5 , while the routing information indicates that aggregator 126 includes communication channels for processes P 6 -P 8 . Aggregator 128 uses the routing information table 300 to determine to which aggregator 120 - 126 in layer 116 to transmit a command from the debugger user interface. It many cases, a command may need to be routed to processes corresponding to more than one aggregator 120 - 126 . In these cases aggregator 128 preferably broadcasts the command to all of the aggregators that are to receive the command.
[0054] The debugger user interface 114 similarly may have access to a table of routing information which informs the interface to which aggregator to route commands. FIG. 7 b shows one suitable embodiment of such a table 350 . Each entry in the table 350 includes a process set and a routing disposition. Because the exemplary embodiment of FIG. 2 shows the interface 114 only coupled to one aggregator (aggregator 128 ), table 350 includes only a single entry. Other entries could be included if the interface 114 coupled to other aggregators. Further, each of aggregators 120 , 124 , 126 also have access to a routing table. An exemplary table 370 is shown in FIG. 7 c for aggregator 124 .
[0055] The debugger user interface 114 will generally receive both aggregated and unaggregated messages from the processes 102 via the aggregator network. The messages can be dealt with in any desirable manner. For example, the messages can simply be logged to a file. Further, the messages can be viewed on a display (not shown) that is part of the debugger user interface 114 . If desired, and if sufficient information is available, aggregated messages can be converted back to their unaggregated form. This conversion process will essentially be the reciprocal process from that used to generate the aggregated messages in the first place. In general, the individual unaggregated messages can readily be recreated because each aggregated message identifies the processes from which the messages originated. Further, in the case of aggregated messages based on similar, but not identical, messages, such aggregated messages can be converted back to the original unaggregated messages if the aggregated messages retain the origins of the dissimilar payloads. Using this information, aggregated messages can be converted to their original unaggregated form.
[0056] The use of an aggregator network, such as the network described herein, advantageously solves or alleviates the problems discussed previously. First, the detrimental effects caused by the limitation as to the number of active communication channels that can be open at a time for any one process is avoided through the use of multiple, hierarchically-arranged aggregator processes in the aggregator network. Second, messages from the various processes can be aggregated within the tree, often concurrently with other aggregators, into preferably fewer messages to permit more efficient operation. The benefit of message aggregation increases as the number of processes in the system increases. The architecture is readily scalable to any number of processes (e.g., 100 or more or 1000 or more processes), and may provide significant advantages over conventional architectures (e.g., FIG. 1) when used in conjunction with 64 or more processes/debug servers.
[0057] The above discussion is meant to be illustrative of the principles and various embodiments of the present invention. Numerous variations and modifications will become apparent to those skilled in the art once the above disclosure is fully appreciated. For example, the preferred aggregation technique described herein can be applied to messages that contain text, reply objects, or any other type of payload. It is intended that the following claims be interpreted to embrace all such variations and modifications. | A computer system includes an aggregator network that couples a plurality of processes on which an application executes to a debugger user interface. Using the debugger user interface, commands are created and sent through the aggregator network to the processes and messages from the processes are routed through the aggregator network to the debugger user interface. Whenever possible, the aggregator network combines the processors' messages into fewer messages and provides a reduced number of messages to the debugger user interface. The aggregated messages generally contain the same information as the messages they aggregate and identify the processes from which the messages originated. The aggregator network examines the processor messages for messages that have identical or similar data payloads and aggregates messages that have identical or similar payloads. | 6 |
GOVERNMENTAL INTEREST
The U.S. Government has rights in this invention pursuant to Contract No. DAAK-10-80-C-0323 awarded by the Department of the Army, including without limitation, a royalty-free license to make or have made, and to use products made with this invention, according to the conditions thereto.
This application is a continuation-in-part of application Ser. No. 07/421,429, filed Oct. 12, 1989, now abandoned.
FIELD AND BACKGROUND OF THE INVENTION
The invention relates, in general, to gun launched grenades, and, in particular, to a new and useful movable and tiltable fuse arrangement which can be used for a number of different projectile sizes and projectile velocities. The invention provides a fuse with a clock-type mechanism to move a detonator from a safe to an armed position which requires the occurrence of two different physical phenomena.
Clock-type mechanisms to move critical elements of the initiation train, i.e. the detonator, from a safe to an armed position are known. Also known are designs which require the occurrence of a minimum of two different physical phenomenon in order to move the clock-type mechanism so that an explosive warhead must move a minimum specified distance away from the gunner to prevent completion of the initiation train prior to the projectile having travelled the minimum specified distance.
The fused design of the M550 is composed of two separate mechanical assemblies which joined together in the nose of the projectile, provide a means whereby a projectile will travel a safe distance before the detonator is moved to an armed position whereby the warhead can be exploded. The first mechanical assembly is an escapement assembly with an eccentrically rotatably mounted rotor having an eccentric center of mass. The center of mass moves from a factory-positioned first location near a rotational axis of the projectile to a second location being spaced from the rotational axis of the projectile. The rotational movement moves a detonator to a detonating position adjacent a firing pin. The rotor is part of an escapement configuration in which the rotational energy of the rotor is absorbed by a pinion and verge arrangement thereby effecting a timed relationship for the movement of the detonator from the unarmed to the armed position. The timed relationship is dependent upon the number of rotations of the projectile.
The second mechanical assembly includes an actuator assembly in which a number of hammers are pivotally arranged on the forward end of the projectile which, upon sudden deceleration of the projectile, pivot about a pivot point and impact on and force a firing pin rearward into the detonator, provided the detonator is in the armed position.
When the high velocity version of basically the same warhead was begun, it was realized that, theoretically, the same fuse system would work in the high velocity warhead. The high velocity barrel twist rate was not changed, therefore the relationship of the spin rate to the projectile travel remained constant. Theoretically, the same fuse arrangement could be used for the higher velocity warhead. However, the increased set-back force from the increased acceleration, caused the heavy actuator to practically crush the escapement. Further, the greatly increased spin rate would tear the hammers off the actuator by centrifugal force.
Thus, it was desired to use the same escapement system, but another means of initiating the detonator had to be found. The warhead was re-designed to eliminate the actuator assembly and a firing pin was arranged fixed at the forward end of the warhead pointing rearwardly. The detonator-rotor component of the escapement was allowed to slide forward thereby driving the detonator into the fixed firing pin.
Unfortunately, it was found that the detonator-rotor component of the escapement would have to be increased in weight. The increased rotor weight necessitated changes in other components of the escapement as well. Today, there are no common items of any significance between the low velocity warhead and the high velocity warhead fuses, except that they operate with the same off-center center of mass rotor concept.
The heavier escapement mechanism for the high velocity projectile utilizes a journal for the rotor having a first end affixed to a forward end of the projectile body. An opposite second end of the rotor journal is fixed to a rearward end of the projectile body. Similarly, the energy-absorbing pinion gear rotates about a journal which is fixed at a first end to the forward end of the projectile body, and is fixed at an opposite end to the rearward end of the projectile body. Upon impact, the rotor and the detonator are allowed to slide along the length of the rotor journal and the pinion journal to engage the detonator with the firing pin.
Also disadvantageous is that the high velocity fuse configuration proved to be too bulky and inoperative when used in the low velocity warhead.
SUMMARY OF THE INVENTION
The invention provides a fuse configuration which can be used in both high velocity and the low velocity warheads. The firing pin is held fixed at a forward end of the fuse configuration and projects rearward toward the escapement assembly. Upon impact, the entire mass of the escapement configuration is allowed to slide forward, or to tilt forward, or a combination of both bringing the detonator into contact with the firing pin, thereby exploding the warhead.
The invention provides a rotatable missile comprising a missile body having a space therein. A firing pin is arranged at a forward end of the space projecting rearwardly. A detonator is arranged at a rearward end of the space and is movable along a path from a first position out of alignment with the firing pin to a second position into alignment with the firing pin. The movement of the detonator along the path is effected by the rotation of the missile body. The detonator is then movable toward the firing pin upon a rapid deceleration of the missile body.
The detonator is assembled in a brass body arranged around a pivot axis which is off center with respect to the projectile rotational axis. The center of mass of the body is off axial center with respect to the rotor rotational axis, and is located in-board in an unarmed position, or factory assembled position. The outer portion, or periphery, of the brass body has gear teeth which are engageable with a pinion such that the pinion must rotate whenever the brass body rotates. A weight called a verge is engaged with the pinion such that it must oscillate as the pinion rotates. Rotational energy applied to the brass body, therefore, is absorbed by the oscillation of the verge. All three parts are held in place by individual axles secured between a rearward plastic housing and a forward aluminum top plate of the escapement assembly.
In the safe, or unarmed position, the brass body is advantageously secured by two separate components: a detent and a set-back pin. The set-back pin physically blocks rotation of the rotor by extending into the escapement. A set-back pin is advantageously biased by, for example, a one-way leaf spring requiring a minimum of force to allow the pin to move rearward. Thus, unless the projectile is accelerated in a manner provided only by proper gun firing, the set-back pin maintains its position and the rotor is unable to rotate.
The rotor is also advantageously locked by a detent which is, for example, engaged with the gear teeth of the rotor. The detent is advantageously biased radially inward toward the gear teeth. The mass of the detent is such that the projectile must rotate at least a minimum r.p.m. before centrifugal force on the detent is sufficient to overcome the biasing force.
Thus, two separate locks must be subjected to different forces that will occur only when the projectile is properly launched, thereby providing two different physical phenomena to arm the fuse.
Centrifugal force on the center of mass of the rotor produces a torque on the rotor in direct proportion to the projectile spin rate. Restricted to rotation about the rotor pivot axis, the movement of the center of mass from inboard to outboard position rotates the rotor and consequently the pinion gear. The total path of rotation can advantageously be substantially equal to 100°.
In the unarmed position, the detonator is in an outboard location which, upon rotation of the rotor, moves to an inboard location into alignment with the firing pin. The rotor is held with the center of mass in the outboard position by the continued rotation of the projectile.
The rotation of the rotor and the engaged pinion gear produces an expenditure of energy through oscillation of the verge. Thus, time is expended while the rotor rotates. This expenditure of time allows the projectile to travel a specified distance from the launcher, thereby providing a required safe separation distance before the warhead can be initiated.
As indicated, the entire escapement configuration or fuse housing moves forward or tilts forward upon impact of the projectile. Sufficient force is provided by the movable fuse housing which is configured to include substantially all the supportive mechanisms of the escapement thereby providing enough mass "behind" the fuse to force the detonator into the firing pin.
Impact with various targets by the tilting body fuse causes different reactions as follows:
1. If the projectile impacts on oblique armor, the ogive presenting its most rigid side to the target, crushes inward driving the firing pin into the detonator. Simultaneously, the escapement is free to slide forward, thereby reducing overall fuse time. This effectively speeds up initiation of the warhead creating greater stand-off for improved shape charge penetration.
2. If the target is a hard vertical armor, the escapement is thrown forward to cause penetration of the detonator by the firing pin. In the case of higher velocity impact, it is most likely that the ogive crush-up will occur first. This will simply reduce fuse reaction time still further since the firing pin is driven rearward while the detonator moves forward.
3. If the warhead experiences low graze impact (no ogive distortion), a rapid deceleration of the projectile will cause the escapement to move forward. If graze impact is sufficient to actually turn the projectile in a ricochet, then gyroscopic action of the escapement occurs simultaneously with its forward motion, again reducing fuse reaction time.
4. If the projectile impacts against a soft target, such as snow, the rapid deceleration will cause detonation.
Accordingly, it is an object of the invention to provide a fuse housing which is movable and tiltable inside a cavity of a projectile which can be used for low velocity-high explosive, low-velocity-improved visibility training, low velocity-special purpose, high velocity-high explosive, high velocity-dual-purpose, and high velocity-improved visibility training projectiles.
The various features of novelty which characterize the invention are pointed out with particularity in the claims annexed to and forming a part of this disclosure. For a better understanding of the invention, its operating advantages and specific objects obtained by its uses, reference is made to the accompanying drawings and descriptive matter in which preferred embodiments of the invention are illustrated.
BRIEF DESCRIPTION OF THE DRAWINGS
In the drawings:
FIG. 1 is a longitudinal cross-sectional view of the fuse arrangement according to the invention;
FIG. 2 is a cross-sectional view showing the escapement arrangement taken along the line II--II of FIG. 1;
FIG. 3 is a longitudinal cross-sectional view of a second embodiment according to the invention;
FIG. 4 is a cross-sectional longitudinal view of a third embodiment according to the invention;
FIG. 5 is a longitudinal cross-sectional view of a fourth embodiment according to the invention;
FIG. 6 shows a projectile impacting on the vertical target with the entire escapement arrangement according to FIGS. 1, 2, 3, 4, and 5 sliding forward to engage a detonator with a fixed firing pin with means biasing the escapement away from the pin omitted for clarity; and
FIG. 7 shows the projectile impacting on an oblique target according to FIGS. 1, 2, 3, 4, and 5 with the entire escapement arrangement tilting and sliding forward with means biasing the escapement away from the pin omitted for clarity.
FIG. 8 shows a sectional view of the fuse body at rest.
FIG. 9 shows a sectional view of the fuse body tilted at an angle α to the resting axis.
FIG. 10 shows the relationship of the tilt angles.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring now to the drawings, in particular, the invention embodied therein, FIG. 1 shows a projectile generally designated 10, having a forward shell or ogive 12 encasing a fuse space 14. Located inside the fuse space is an actuator cup 16 fixed to a bottom plate 18 by a crimping 20 of the actuator cup 16. The ogive 12 has an annular shoulder 22 which the actuator cup 16 conforms to. An end wall 24 sits securely against the actuator cup 16 and the annular shoulder 22. Attached near the center of the end wall 24 is a firing pin 26 extending rearwardly toward an escapement mechanism generally designated 28.
The escapement mechanism 28 shown in FIGS. 1 and 2 includes a rotor 30 rotatably eccentrically mounted on a pivot axle 32. Embedded into the rotor is a detonator 34 radially spaced from the pivot axle 32. Also radially spaced from the pivot point is the rotor center of mass 36, shown in FIG. 2 as an x in an inboard position. As the projectile rotates, the centrifugal force causes the center of mass 36 to move from the inboard position to an outboard position (not shown), and consequently causes the detonator 34 to rotate about the pivot point 32 to an armed position adjacent the firing pin 26.
The rotor has exterior teeth 38 arranged at a circumferential edge. Engaged with the gear teeth 38 is a pinion 40. The pinion is rotatably mounted on a pinion journal 42.
A verge 44 is arranged adjacent the pinion 40 and is allowed to oscillate back and forth about a verge pivot point 46 as the projectile rotates and the center mass 36 of the rotor 30 moves to an outboard position, the pinion gear 40 is caused to rotate and the rotational energy is absorbed by the oscillating movement of the verge 44, thereby slowing the rotational movement of the rotor 30.
A set-back pin lock means 48 prevents the rotor from rotating by engaging a rearward side of the rotor. Also shown is a detent lock means 50 engaged with the gear teeth 38 of the rotor 30.
The set-back pin 48 becomes disengaged with the rotor upon an axial acceleration of the projectile.
The detent lock is arranged in a detent sleeve 52 to slide radially outward away from the rotor teeth 38. The detent being of sufficient mass to be forced radially outward by the rotation of the projectile 10.
The escapement includes a plastic housing 54 with a rear wall 56 and an aluminum top plate 58 attached to the housing 54. The rotor pivoting axle 32, and the pinion journal 42 project from the housing rear wall to the top plate.
The set-back pin 48 includes a set-back pin housing 60 arranged on the rear wall 56. The bottom plate 18 includes a bottom plate recess 62 which receives the set-back pin housing 60, thereby securing the escapement housing 54 from rotating relative to the projectile 10.
In the embodiment according to FIG. 1, an anti-creep spring 64 is arranged to keep the escapement mechanism in a rearward position and away from the firing pin 26.
FIG. 3 shows a second embodiment of the invention in which a top plate 58' is attached to a positioning sleeve 64 having a securing flange 66. The positioning sleeve 64 and the top plate 58' each define co-axial recesses 68 and 68' therein. The co-axial recesses 68 and 68' receive a firing pin 26' having an engagement cap 70 attached to a forward end.
Arranged co-axial with the firing pin 26' is a coil spring 72. One end of the coil spring 72 engages with a forward surface of the securing flange 66. A second opposite end of the coil spring 72 engages on a rearward surface 76 of the engagement cap 70. The engagement cap 70 rests on an annular seat 77 which projects from the ogive 20 into the fuse space 14'.
A third embodiment is shown in FIG. 4, in which the firing pin 26" is held in place by a cup 80 which is concave at a forward side, and which rests on an annular shoulder 22' of the ogive 12". Arranged between the convex side of the cup 80 and the escapement is a leaf spring 82 which holds the escapement mechanism rearward while holding the firing pin 26" forward.
FIG. 5 shows a further arrangement for holding the firing pin 26'". Attached to the inside surface of the ogive 12'" and projecting inwardly into the fuse space 14'" is a seat member 84. Resting on the seat 84 and on the annular shoulder 22" is an end wall 24'. The firing pin 26'" is attached to the end wall 24' and projects rearwardly toward the escapement. Biasing the escapement toward a rearward position are leaf springs 86.
All the embodiments shown and described function similarly. When the projectile is launched from the gun barrel, the set-back pin 48 moves rearward from its rotor locking position at the base of the escapement. Rotational acceleration of the projectile is transferred to the escapement through the set-back pin housing of the escapement. Upon exit from the launch tube, the spring means provided between the escapement and the firing pin hold the escapement rearward and hold the firing pin forward insuring that the firing pin does not engage with the rotor. The spring means in each embodiment provides a spring force that is larger than the set forward force on the escapement produced by aerodynamic drag on the projectile.
Provided a minimum r.p.m. of the projectile has been attained during barrel acceleration, the detent within the escapement moves radially outward and the rotor is then free to align the detonator with the firing pin.
FIG. 6 shows a projectile 10 impacting upon a vertical target 88 from a direction which is normal to the target surface. The entire escapement configuration 58 is shifted forward toward firing pin 26 against a biasing means (omitted in FIGS. 6 and 7 for clarity). The entire mass of the escapement configuration providing force to impact the detonator 34 onto firing pin 26.
FIG. 7 shows a projectile 10 impacting on a target 88' from a direction which is askew to the target surface. The entire configuration 58 tilts and moves forward, impacting the detonator 34 on the firing pin 26.
FIG. 8 shows an exaggerated view of the fuze body, hypothetically flat at rest within the projectile. The fuze body diameter (its height here in this crossectional side view), is given by D. This diameter is slightly smaller than the inside diameter of the projectile (ID), shown greatly exaggerated here, to allow the fuze body to slide. Whenever the detonator in central region 34 contacts pin 26, there can be a detonation. Ideally, the pin should contact within the central 1/3 face area of the said region 34. Striking at an angle, when the body is tilted as it slides towards the pin (such as in FIG. 9), will still cause a detonation in the same way, if the same face area is contacted, notwithstanding the angular striking. The center line for the fuze body lies below the projectile's center line, it is noted here, by a small distance (where the center lines hit the face), when the system is at rest in the manner shown in FIG. 9. Obviously X must be less than or equal to the radius, R, of central detonation region 34, or else there will be no detonation; i.e., the pin will not be able to contact within the face area of 34 at all. Further, it should best contact within the inner 1/3 face area of region 34. The radius of such inner 1/3 area, would be R/√3. Thus X must be within the range of R-(R/√3), or 0.423 R. For the pin to contact the inner 1/3 area then, one has that, the fuze body diameter must be such that D≧ID-0.423 R (Equation 1).
FIG. 9 shows (another) exaggerated view of the fuze body when tilted to an angle, α, off the perpendicular resting position of FIG. 8. Even if pin 26 contacts central region 34 at an angle (here, α), there can still be a detonation. The contact is (basically) all that is needed. It is noted that α cannot be greater than 45° or else the fuze body can rotate past its corners as it tilts, and tip over. The fuze then could not operate. Therefore one upper limit is given for α, that is -45°<α<45°. Ideally, one would expect the tilt angle to be: -5°<α<5°. (Equation 2) By reference to FIG. 10, (as explained below), one can determine a general trignometric relationship between W, D and α, for a given ID, being: W sin α+D cos α=ID (Equation 3). By using the design constraints of Equation 1 and (whatever angle selected) of Equation 2, substituted into Equation 3, one can help define the necessary fuze body dimensioning for a particular projectile.
In FIG. 10 one can see that: in triangle (I), the dashed side is equal to W Tan α. In triangle (II), the hypotenuse is equal to (W Tan α+D). It can also be seen that cos α=ID/(WTan α+D). When reduced, this becomes W sin α+D cos α=ID (Equation 3), when the fuze body is tilted at rest in the manner and in the simplified rectangular shape shown in FIGS. 9 and 10.
While specific embodiments of the invention have been shown and described in detail to illustrate application of the principles of this invention, it will be understood that the invention may be embodied otherwise without departing from such principles. | In a fuse arrangement, which can be used in both low velocity and in high velocity gun-launched grenades, which has a rotationally responsive fuse timing mechanism arranged in a fuse casing, The fuse casing being tiltable and axially movable upon impact of the grenade thereby forcing the entire fuse housing toward a fixed firing pin and detonating the grenade. | 5 |
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] The present patent application claims priority from the commonly assigned U.S. provisional patent application S/No. 60/364,954 entitled “Chiral Fiber Structure with Broadband Tuning Capability” filed Mar. 14, 2002.
FIELD OF THE INVENTION
[0002] The present invention relates generally to fiber gratings and functionally equivalent structures, and more particularly to fiber gratings having an expanded adjustable reflection band that are implemented in a chiral structure to provide broadband tunability.
BACKGROUND OF THE INVENTION
[0003] Semiconductor lasers have found many industrial and commercial applications in recent years. For example, lasers are used in telecommunications, in pickups for optically readable media used in CD players, CD ROM drives and DVD players, in medical imaging, and in video displays. However, previously known semiconductor lasers have a number of disadvantages. For example, traditional semiconductor lasers, such as ones used in CD players, emit light from the edge of a chip, making it necessary to cleave a wafer into chips and to package the chip before determining whether the laser functions properly. Other types of light sources, such as LEDs do not provide the performance needed for certain applications.
[0004] Vertical Cavity Surface Emitted Lasers (hereinafter “VCSELs”) have been developed to address the need for a more advanced, higher quality laser that can function well in a variety of applications. VCSELs combine the performance advantages of LEDs and of edge-emitting lasers at costs comparable to LEDs. VCSELs emit light vertically from the wafer surface, like LEDs, allowing for fabrication and testing, which is fully compatible with standard I.C. procedures and equipment. VCSELs have the additional advantage that they can be formed into arrays. In addition, VCSELs are much faster, more efficient, and produce a beam with a smaller divergence than do LEDs.
[0005] The VCSEL structure leads to a host of performance advantages over conventional semiconductor lasers.
[0006] 1) small size
[0007] 2) low power consumption
[0008] 3) two-dimensional array capabilities
[0009] In contrast to conventional edge-emitting semiconductor lasers, the surface-emitting VCSEL has a symmetric Gaussian near-field, greatly simplifying coupling to optical elements or fibers. In addition, VCSEL technology allows the fabrication of two-dimensional laser arrays.
[0010] However, VCSELs suffer from a number of disadvantages. Their manufacture requires sophisticated and expensive microfabrication. Since single-pass gain in thin layer semiconductor lasers is low, VCSELs incorporate highly reflective dielectric stacks which are integrated into the laser as Bragg reflectors. These consist of alternating layers of dielectric material, which are grown using methods of molecular beam epitaxy (MBE). This ensures a close match of the atomic lattice structures of adjacent layers. Alternating atomically ordered layers of materials with different electronic characteristics are thereby produced. The interfaces between the layers must be digitally graded and doped to reduce the electrical resistance.
[0011] Much work has been done to improve the performance of VCSELs by increasing the number of layers and/or the dielectric difference between alternating layers. However, this approach makes the fabrication more expensive and difficult. There is also a limit to the number of layers determined by the absorption in these layers. While VCSELs can be manufactured in two-dimensional arrays, there has been great difficulty in achieving uniform structure over large areas. The materials used for VCSELs generally do not have the desired low absorption and high index contrast over a broad frequency range. In particular, it is difficult to achieve high reflectivity in the communication band around 1.5 microns. In addition, VCSELs cannot be tuned in frequency since their periods cannot be changed. In addition, an external device must be used to control the polarization of the light.
[0012] In recent years, chiral materials, such as cholesteric liquid crystals have been demonstrated and proposed in a variety of lasing and filtering applications to address common drawbacks of standard semiconductor devices such as VCSELs. For example, a commonly assigned U.S. Pat. No. 6,404,789 entitled “Chiral Laser Apparatus and Method,” discloses a chiral laser with a defect formed by a light-emitting material layer. While this approach is advantageous with respect to previously known techniques, it may be difficult to construct a layered structure having a precise light emitting material thickness required to produce a defect (the required thickness must be approximately equal to the wavelength of light in the medium divided by 4). More importantly, the position of the localized state caused by the defect cannot be easily controlled because the thickness of the light-emitting material cannot be changed once the device is manufactured.
[0013] One approach that addressed this problem was disclosed in the commonly assigned U.S. Pat. No. 6,396,859 entitled “Chiral Twist Laser and Filter Apparatus and Method” which is hereby incorporated by reference herein in its entirety. The novel approach of this patent involved creating a localized state by inducing a defect in a chiral structure composed of multiple chiral elements, by twisting one element of the chiral structure with respect to the other elements along a common longitudinal axis such that directors of the element's molecular layers that are in contact with one another are disposed at a particular “twist” angle therebetween. The resulting “chiral twist structure” enabled control of the position of the localized defect state within the photonic band gap by varying the twist angle.
[0014] This novel chiral twist structure is advantageous for a variety of applications including, but not limited to, EM filters, detectors, and lasers that are readily tunable by varying the twist angle. The only limitation of a chiral twist structure is the width of the photonic band gap within which the defect state may be moved. Essentially, the width of the photonic band gap determines the tunability bandwidth of the device. In certain telecommunication applications, it may be useful to have two or more defect states in the expanded band gap.
[0015] It would thus be desirable to provide a chiral structure and method of provision thereof that has a greater tunability bandwidth (i.e. an expanded reflection band) than a standard chiral twist structure. It would further be desirable to provide a chiral structure and method of construction thereof that comprises two or more independently controllable defects within the expanded reflection band.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] In the drawings, wherein like reference characters denote elements throughout the several views:
[0017] [0017]FIG. 1 is a graph diagram of a photonic band gap in a typical chiral twist structure;
[0018] [0018]FIG. 2A is a schematic diagram of a first embodiment of the broadband tunable chiral structure of the present invention implemented with chiral fibers;
[0019] [0019]FIG. 2B is a schematic diagram of a second embodiment of the broadband tunable chiral structure of the present invention implemented with thin film chiral elements;
[0020] [0020]FIG. 3 is a graph diagram of an expanded photonic band gap of the chiral structures of FIGS. 2A and 2B; and
[0021] [0021]FIG. 4 is a schematic diagram of a third embodiment of the broadband tunable chiral structure of the present invention.
SUMMARY OF THE INVENTION
[0022] The present invention is directed to a novel chiral broadband tuning structure, having an expanded adjustable photonic band gap to provide broadband tunability, that may be based on a thin film chiral structure, for example composed of multiple sequential cholesteric liquid crystal (CLC) layers, or, preferably, based on a specially configured optical chiral fiber structure, for example, having advantageous optical properties similar to a CLC structure.
[0023] The chiral fiber structure preferably used in the inventive chiral broadband tuning structure achieves optical properties similar to a CLC structure because it satisfies the requirement that in a CLC structure the pitch of the structure is twice its period. This is accomplished by using a chiral fiber structure having geometric birefringence with 180 degree symmetry. Such properties may be obtained by imposing two identical coaxial helices along a fiber structure, where the second helix is shifted by half of the structure's pitch forward from the first helix. Such structures are described in greater detail in the co-pending commonly assigned U.S. Patent applications entitled “Apparatus and Method for Manufacturing Fiber Gratings”, “Apparatus and Method of Manufacturing Helical Fiber Bragg Gratings”, “Apparatus and Method for Fabricating Helical Fiber Bragg Gratings”, “Helical Fiber Bragg Grating”, and “Long Period Chiral Fiber Grating and Apparatus and Method of Fabrication Thereof” which are hereby incorporated by reference herein in their entirety. Several embodiments of the inventive chiral broadband tuning structure are discussed below.
[0024] In the preferred embodiment, the chiral structure is implemented as a chiral fiber structure and comprises two or more sequential chiral fiber elements with different pitches, each incorporating a tunable chiral defect generator (for example, a chiral twist that can be rotated) for generating and controlling the defect state(s) in the structure's spectral response. Essentially, each tunable chiral defect generator can be adjusted to generate and move a defect state within a photonic band gap (PBG) of the element. The pitch of each chiral fiber element is selected such that the individual reflection bands associated with the respective PBGs of the elements are formed into a single expanded reflection band, such that at least one defect state can be formed and moved within the expanded reflection band by selectively adjusting one or more of the chiral defect generators. Each tunable defect generator may comprise a chiral twist having an adjustable angle, a spacing having an adjustable length or a combination of the two. The chiral twist angle and the length of the spacing are both proportional to the position of the defect state within the PBG of the structure.
[0025] In another embodiment of the present invention, thin film chiral structures, for example composed of multiple sequential CLC layers, are utilized similarly as described above—two or more thin film chiral elements, each having a tunable chiral defect generator, are arranged sequentially and each has a pitch selected such that the individual PBGs of the elements do not fully overlap so that a single expanded reflection band is formed.
[0026] In both of the above-described embodiments, a single defect state can be maintained in the inventive broadband chiral structure by activating the tunable chiral defect generator in only one chiral element at one time while keeping the tunable chiral defect generators inactive in all other elements. However, in some industrial applications, for example in filtering, it may be useful to switch between two or more frequencies without sweeping through intervening frequencies. This may be accomplished by providing a chiral broadband tuning structure with an expanded reflection band having two or more independently controllable defect states therein. Each chiral element having an active tunable chiral defect generator (e.g., having a chiral twist angle other than zero, and/or having a spacing length greater than zero) will generate a defect state in the corresponding element falling within the expanded reflection band. Thus, by selectively activating and controlling the tunable chiral defect generators in multiple chiral elements of the inventive structure, an expanded reflection band having multiple controllable defect states disposed therein.
[0027] Other objects and features of the present invention will become apparent from the following detailed description considered in conjunction with the accompanying drawings. It is to be understood, however, that the drawings are designed solely for purposes of illustration and not as a definition of the limits of the invention, for which reference should be made to the appended claims.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0028] The present invention is directed to an advantageous broadband tunable chiral structure that provides broadband tunability through an expanded photonic band gap. The novel chiral structure can be implemented in a thin film chiral medium, or preferably, in a chiral optical fiber. The novel broadband thin film or fiber chiral structure can be readily tuned, utilizing a tunable chiral defect generator, by moving a defect state within the expanded photonic band gap (hereinafter “PBG”).
[0029] Before describing the present invention in greater detail, it would be helpful to provide definitions of common terms utilized in the dielectric component. “Chiral” materials are not symmetrical on a molecular level—that is molecules of chiral materials are not identical to their mirror images. Cholesteric materials, such as cholesteric liquid crystals (hereinafter “CLCs”), have multiple molecular layers in which molecules in the different layers are oriented on average at a slight angle relative to molecules in other layers. Molecules in consecutive layers are rotated slightly relative to those in the preceding layer. Thus, the average direction of the molecules, known as a “director”, rotates helically throughout the cholesteric material. A pitch of a cholesteric material is defined as a thickness of the material in which the director rotates a full 360 degrees.
[0030] CLCs, and other chiral structures having similar properties, have a particular reflection band (associated with the PBG) which is a result of its periodic structure—a range of wavelengths in which the transmission of light through the structure is small as a result of multiple coherent reflection within the structure. At the edge of the photonic stop band gap there are a series of narrow photonic states (or modes) at the peak of which transmission of light reaches unity. The spectral width of these states is proportional to the inverse of the dwell time for the photons within the CLC medium.
[0031] When a defect is introduced into a CLC structure by modifying the periodic structure by adding a spacing, an additional layer of a different material, or an angular twist between consecutive layers, then an additional localized photonic state or number of photonic states may be introduced into the photonic stop band. An example of a spectrum with a feature associated with such a localized state in the center of the photonic stop band is shown in a graph of FIG. 1.
[0032] A thin film chiral structure, such as may be used in conjunction with the present invention, is described in greater detail in the above-described U.S. Pat. Nos. 6,404,789 and 6,396,859. An exemplary thin film chiral structure may comprise several sequential layers within a CLC film.
[0033] A chiral fiber is a novel structure that mimics CLC properties—the cholesteric periodic photonic band gap structure—in a fiber form. A commonly assigned co-pending U.S. Patent Application entitled “Chiral Fiber Grating” (hereinafter “CFB”)) which is hereby incorporated by reference in its entirety, disclosed the advantageous implementation of the essence of a cholesteric periodic PBG structure in an optical fiber. This novel approach captured the superior optical properties of CLCs while facilitating the manufacture of the structure as a continuous (and thus easier to implement) process. The chiral fiber structure is preferable for implementing broadband tuning because of the relative ease of implementing multiple chiral twists in the structure as described below.
[0034] Referring now to FIG. 1, a graph of the spectrum of a standard PBG of a chiral defect structure (such as a chiral fiber grating with a chiral twist defect) is shown. A 90 degree twist angle between two portions of the element creates a defect state in the center of the PBG. Varying the twist angle causes the defect state to move within the PBG.
[0035] Referring now to FIG. 2A, an exemplary preferred embodiment of a broadband chiral fiber structure 10 is shown. The fiber structure 10 includes a first chiral fiber element 12 of a first pitch P 1 having a tunable chiral defect generator 14 , and a sequential second chiral fiber element 16 of a second pitch P 2 , having a tunable chiral defect generator 18 . The tunable chiral defect generators 14 , 18 may be chiral twists of twist angles T 1 , and T 2 , respectively, spacings of lengths L 1 , and L 2 , respectively, or a combination of both chiral twists and spacings. The chiral twist angles T 1 , and T 2 and the lengths of the spacings L 1 , and L 2 , are both proportional to the position of the defect state within the PBG of the structure and may thus be selectively varied to generate and move the defect state within the reflection band. It should be noted that while the tunable chiral defect generators 14 , 18 are described with reference to chiral twists and spacings, they may be implemented with any other form of chiral defects, such as for example introduction of a different material into a spacing between two portions of a chiral element, as a matter of design choice without departing from the spirit of the invention.
[0036] The essence of the invention is that the relationship between the values of P 1 and P 2 is such, that the structure 10 will have an expanded reflection band having a width approximately equal to the sum of both reflection bands of the elements 12 , 16 . This relationship may be expressed as ΔP/P<Δn/n, where ΔP=P 2 −P 1 , P=(P 1+ P 2 )/2, and Δn/n is the birefringence divided by the average index of refraction of the elements 12 and 16 and is thus representative of the relative width of the reflection band of each element 12 , 16 . For example, Δn/n may be 0.015 for a standard optical fiber, in which case P 2 <(1.015)*P 1 .
[0037] It should be noted that for optimal results, ΔP/P should only be slightly less that Δn/n—this will ensure that the reflection bands of elements 12 , 16 will not substantially overlap, thus maximizing the bandwidth of the expanded reflection band. The expanded reflection band is described in greater detail below in connection with FIG. 3.
[0038] Referring now to FIG. 2B, an alternate embodiment of the inventive chiral broadband tuning structure is shown as a broadband chiral structure 20 . The fiber structure 20 includes a first chiral element 22 of a first pitch P 1 having a tunable chiral defect generator 14 , and a sequential second chiral twist element 24 of a second pitch P 2 having a tunable chiral defect generator 18 . The chiral elements 22 , 24 may be any thin film periodic structures capable of having a tunable chiral defect (such as a chiral twist and/or spacing) implemented therein. For example, they may be composed of thin CLC films.
[0039] As in the chiral structure 10 of FIG. 2A, the relationship between the values of P 1 and P 2 is such, that the structure 20 will have an expanded reflection band having a width approximately equal to the sum of the two reflection bands of elements 22 , 24 .
[0040] Referring now to FIG. 3, a graph of the expanded reflection band of chiral structures 10 and 20 is shown. The expanded reflection band consists of two overlapping reflection bands—a region 26 (corresponding to the chiral fiber element 12 of FIG. 2A, or the chiral thin film element 22 of FIG. 2B) and a region 28 (corresponding to the chiral fiber element 16 of FIG. 2A, or the chiral layered element 24 of FIG. 2B). By selectively activating and controlling one of the tunable chiral defect generators 14 , 18 , a defect state 30 can be generated and moved through the entire expanded reflection band, thus providing broadband tunability. When the chiral defect generators 14 , 18 are chiral twists, this may be accomplished by keeping one of the twist angles (T 1 or T 2 ) at zero and changing the other twist angle. For example, if the twist angle T 2 is kept at zero and the twist angle T 1 is changed, the defect state 30 will appear and move through the region 26 . When the chiral defect generators 14 , 18 are spacings, this may be accomplished by keeping one of the spacing lengths (L 1 or L 2 ) at zero and increasing the other spacing length. For example, if the spacing length L 2 is kept at zero and the spacing length L 1 is changed, the defect state 30 will appear and move through the region 26 . When the tunable chiral defect generators 14 , 18 include both chiral twists and spacings, either or both twist angle and spacing length of one of tunable chiral defect generators 14 , 18 may be changed to generate and control the defect 30 in a corresponding region of the reflection band.
[0041] In some industrial applications, for example in filtering, it may be useful to switch between two or more frequencies without sweeping through intervening frequencies. This may be accomplished by providing a chiral broadband tuning structure with an expanded reflection band having two or more independently controllable defect states therein. While only one defect state 30 is shown in FIG. 3, in an alternate embodiment of the present invention, the tunable chiral defect generators 14 , 18 can be activated and selectively controlled to produce two independent defect states, one in region 26 , controlled by the tunable defect generator 14 , and one in region 28 , controlled by the tunable defect generator 18 .
[0042] The inventive broadband chiral fiber structures 10 , 20 are not limited to two chiral elements—three or more sequential chiral fiber or thin film elements may be used to generate a broader expanded reflection band. An exemplary embodiment of a broadband chiral structure 32 with three elements 34 , 36 , 38 , of respective pitches P 1 , P 2 , P 3 , having respective tunable chiral defect generators 40 , 42 , 44 (each comprising one or both of respective chiral twist angles T 1 , T 2 , and T 3 , and spacing lengths L 1 , L 2 , and L 3 ) are shown in FIG. 3. The relationships between the pitches are defined as above: P 2 =P 1 *(1+Δn/n), while P 3 =P 2 (1+Δn/n). As for the expanded reflection band shown in FIG. 3, each chiral element in a broadband chiral structure having three or more chiral elements contributes to the expanded reflection band.
[0043] Thus, while there have been shown and described and pointed out fundamental novel features of the invention as applied to preferred embodiments thereof, it will be understood that various omissions and substitutions and changes in the form and details of the devices and methods illustrated, and in their operation, may be made by those skilled in the art without departing from the spirit of the invention. For example, it is expressly intended that all combinations of those elements and/or method steps which perform substantially the same function in substantially the same way to achieve the same results are within the scope of the invention. It is the intention, therefore, to be limited only as indicated by the scope of the claims appended hereto. | A chiral structure having an expanded adjustable reflection band to provide broadband tunability is provided. In the preferred embodiment, the chiral structure is implemented as a chiral fiber structure and comprises two or more sequential chiral fiber elements of different pitches, each having a tunable chiral defect generator. The pitches are selected such that the individual photonic band gaps of the elements are formed into one expanded reflection band such that at least one defect state can be formed and moved within the expanded reflection band by selectively activating and adjusting one or more of the tunable chiral defect generator. The tunable chiral defect generators may generate and control defect state(s) in the structure's spectral response by introducing chiral twists and/or spacing between the chiral elements, with the length of the spacings and angles of chiral twists being proportional to the position of the defect state(s) within the reflection band of the structure. | 1 |
BACKGROUND OF THE INVENTION
The present invention relates to athletic shoes, and in particular, to an athletic shoe comprising a `glow in the dark` sole. Phosphorescence enables the wearers of shoes made from, or having soles made from, the compositions of the present invention to be easily identified at night. Such shoes find particular use by pedestrians and bicyclists. In addition, children are intrigued by the glow in the dark feature of the sole and are inclined to wear these types of shoes more than plain shoes and tend to learn how to put them on faster. Further, glow in the dark soles enable a person to locate their shoes quickly and easily at night.
Phosphorescent materials have been used in a variety of commercial applications because they have the property of continuing to emit light for an extended period of time after excitation. Phosphorescent pigments have, therefore, been used in warning signs; marking of vital machinery; dial illumination; directional signs on walls of underground stations, garages, hallways; and applied to helmets as used in fire departments, accident prevention, etc. Phosphorescent pigments have also found application for use on protective clothing, sports equipment and a variety of toys where the effect of glowing in the dark provides amusement, ornamental and/or safety features. Phosphorescent materials include a phosphor which has been artificially prepared and has the property of luminescence when activated by appropriate wavelengths of light. A variety of phosphors are available for use in providing luminescence when activated by an appropriate source of light. Commercially available phosphors include zinc sulfide, zinc cadmium sulfide, alkaline earth sulfides with or without a trace of activators, such as silver, copper or manganese to provide the desired rapid activation of the phosphorescent material in providing the luminescent image. The phosphorescent pigments may be incorporated into a variety of carriers so that the phosphorescent material may be used in many ways such as forming heat transfers to fabric surfaces for purposes of ornamentation.
The phosphors, which are used as phosphorescent pigments in a carrier to form the phosphorescent material sheet, can be incorporated with a variety of carriers. Commercially available sheets of phosphorescent material include the admixture of phosphorescent pigment with clear polyvinylchloride which is extruded in sheet form. The concentration of the phosphorescent pigment is essentially uniform across at least the upper surface of the sheet. This ensures an even degree of illumination across the surface of the activated phosphorescent material.
"Graying" can occur should the phosphorescent pigments of the material be exposed to direct ultraviolet light and high humidity conditions for a long period of time. This is particularly applicable with zinc sulfides and zinc cadmium sulfides.
In some situations, an intense luminescent image is desired which may require high concentrations of phosphor in the phosphorescent material in the range of 20 to 30%. This can result in the luminescent image remaining for a considerable length of time before the image decays to a level of luminescence which is imperceptible to the human eye in normal dark environments. It has been found that exposing the phosphorescent material to electromagnetic radiation having a wavelength in the range of infrared to red light causes a very rapid deactivation of the phosphorescent material to return substantially to a deactivated state and permit immediate reuse of the device.
Phosphorescence is provided by the addition of a small percentage of a particulate metal sulfide, preferably zinc sulfide containing a minor portion of copper sulfide. Other sulfides such as cadmium are used to vary the color of the phosphorescence.
The phosphorescent pigments used in this invention are metal sulfides which have the ability to quickly absorb light and then emit the light in a colored glow over a period of time. Zinc sulfide is typically used in a proportion with 20 to 50 parts per million of copper sulfide. Zinc sulfide glows a green color after exposure to white light. A mixture of 50% zinc sulfide and 50% cadmium sulfide with the copper activator glows an orange-red color, but is not quite as brilliant as the zinc sulfide glow.
Phosphorescent particles from 20 to 100 microns have been tested and compared as to their efficiency. No noticeable difference was observed in the glow using the same weight percentage over this size range. One advantage in using the small particle sizes is that they remain in suspension better during manufacture. The density of the phosphorescent particles is very high and care must be taken to maintain a homogeneous distribution of them during mixing and packaging.
The phosphorescent particles are not soluble in the water-based compositions and lack any significant coloring in daylight. Coloring agents, therefore, must be added to the gel composition to obtain a desired variety of colors for the product. Some colors are very detrimental to the glow from the phosphorescent particles because the color tends to shield the particles from both absorption and emission of light. Dark colors provide too much shielding of the particles and, therefore, a more pastel color assortment is desired.
The modem shoe, particularly an athletic shoe, is a combination of many elements which have specific functions, all of which must work together for the support and protection of the foot. The design of an athletic shoe has become a highly refined science. Athletic shoes today are varied in both design and purpose. Tennis shoes, basketball shoes, running shoes, walking shoes, etc., are all designed to provide a unique and specific combination of traction, support, and protection to enhance performance. Not only are shoes designed for specific sports, they are also designed to meet the specific characteristics of the user. For example, shoes are designed differently for heavier persons than for lighter persons; differently for wide feet than for narrow feet; differently for high arches than for low arches, etc. Some shoes are designed to correct physical problems, such as over-pronation, while others include devices, such as ankle supports, to prevent physical problems from developing. Other shoes are designed to provide added safety measures, such as a luminescent quality to make them visible in the dark. Prior art describes luminaire-provided footwear, but such prior art luminescent features tend to be cumbersomely located, uncomfortable to the wearer, and difficult to repair or replace. Other prior art describes phosphorescent elastomeric material for use with footwear, but such prior art does not adequately provide sufficient durability or luminescence, or such phosphorescent material is located on the upper part of the shoe, not as a part of the sole.
Generally, a shoe is divided into two parts, an upper and a sole. The upper is designed to snugly and comfortably enclose the foot. The sole is designed to withstand many miles of running and walking while also providing support and comfort to the individual wearing the shoes. To satisfy these goals the sole is generally comprised of three layers, an inner sole, a midsole, and an outer sole. The inner sole provides a comfortable, form-fitting surface for the foot and serves as a transitional layer between the foot and the remainder of the sole. The outer sole must have an extremely durable bottom surface providing good traction when in contact with the ground. However, since such contact may be made with considerable force, protection of the foot and leg demands that the sole also perform a shock-absorbing function. Therefore, the midsole usually comprises a resilient, energy-absorbent material to serve this shock-absorbing purpose. This is particularly true for children's shoes designed to be used by the most active children on all types of surfaces.
Conventionally, it has been attempted that sneakers or sports shoes used as jogging shoes, basketball shoes, tennis shoes or the like are constructed into a multi-layer structure by forming an outer sole, which is a lowermost layer of a shoe sole contacted with the ground or a floor, made of a solid rubber material or a high-density sponge material and laminating at least one sponge sheet of a light-weight material exhibiting satisfactory cushioning properties such as ethylene vinyl acetate (EVA) on the outer sole, to thereby accomplish a decrease in weight and an improvement in shock absorbing properties. The solid rubber or high-density sponge is relatively rigid and exhibits satisfactory ground gripping properties and wear-resistant properties; however, it is increased in weight, and thereby fails to reduce the weight of the shoes.
In view of such a problem, various kinds of techniques of forming a satisfactory shoe sole while improving a material for the shoe sole have been proposed. For example, there is a method wherein a polyurethane resin film like a nonwoven sheet and a liquid polyurethane compound for forming non-slip projections are put in a mold and then subjected to thermal cure, resulting in being integrally bonded. That method is disclosed in Japanese Patent Application Laid-Open Publication No. 310601/1989. Another method comprises the steps of arranging a perforated plate on a nonwoven fabric material to keep both intimately contacted with each other, pouring a polyurethane elastomer material containing a thickening agent into the perforated plate, carrying out a squeezing treatment with respect to the elastomer and heating the elastomer to cure it, resulting in forming an embossed sheet. The method is entitled a "method for manufacturing an embossed sheet" and is disclosed in Japanese Patent Application Laid-Open Publication Unfortunately, an improvement in the material for the shoe sole taught in those methods is insufficient to provide the shoe sole with satisfactory non-slip properties. In order to permit the shoe sole to exhibit increased non-slip properties, it is further required to consider other factors in addition to the material for the shoe sole, such as, for example, a height of a rugged pattern formed on the sole of the sports shoes, an area of the rugged pattern contacted with the ground, a configuration of a surface of the rugged pattern contacted with the ground, arrangement of the pattern and the like. However, consideration of the factors causes a configuration of the rugged pattern to be complicated. Therefore, manufacturing of the shoe sole with the rugged pattern of such a complicated configuration by means of a mold as proposed in Japanese Patent Application Laid-Open Publication No. 310601/1988 causes a manufacturing cost of the mold to be extensively increased.
Also, the above-described method proposed in Japanese Patent Application Laid-Open Publication No. 185922/1992 by the assignee wherein a rugged pattern is formed by the single perforated plate is conveniently applied when a configuration of the rugged pattern is relatively simple, however, it is not suitable for the rugged pattern of such a complicated configuration as described above.
Further, a rugged pattern formed on a sole of sports shoes is generally made of the same material as the sole in a manner to be integral with the sole. It is often desired to locally vary properties of the rugged pattern in order to enhance the non-slip properties and aesthetic properties of the sole. However, the above-described formation of the rugged pattern integral with the sole fails to significantly vary the properties of the rugged pattern.
Extensive clinical evaluation of foot and knee injuries sustained suggests that the most important factors associated with such injuries are shock absorption on impact and lateral foot stability. Based on injury data, these two factors appear to be of about equal importance. Therefore, both factors should be carefully considered in the design of any athletic shoes.
Registration of the upper on the sole is the final step in the manufacture of the shoe. In the shoemaking industry, "cement process" registration is an example of how shoes have been manufactured for some time with prefinished outersoles having either a molded or laminated construction. Such prefinished soles simplify the manufacturing process and introduce certain obvious economies. Their use is predicated upon the accurate registration of the prefinished sole on the upper. Present practices in the shoemaking art provide a sufficient degree of precision in the registration of the shoe components to permit full utilization of the inherent structural features of this type of shoe construction. This process provides a finished shoe which is not only light and very flexible, but also has excellent wearing qualities.
Prior art patents include U.S. Pat. No. 4,640,797 and U.S. Pat. No. 4,629,583, both to Goguen, which disclose phosphorescent polymer containing compositions suitable for use in footwear and phosphorescent shoes, shoe soles, and other molded or extruded shoe pans. A need, however, remains apparent for an improved composition which would provide a longer and brighter phosphorescent glow with an increased degree of abrasion and hardness. The present invention presents such a new and improved composition. In the past, no one has combined the important attributes of hardness, abrasion, and phosphorescence the way the applicant has.
SUMMARY OF THE INVENTION
This invention relates to footwear, and more particularly to a sole for an article of footwear. The invention has applicability to a wide range of footwear, including but not limited to athletic shoes. An object of the invention is to provide a sole for an article of footwear having greater versatility than the soles offered by prior art systems, and to provide a sole which combines the important attributes of hardness, abrasion and phosphorescence in a way which is greatly improved over anything made before.
Another aspect of this invention is directed to a composition comprising between about 40-50% by weight of a rubber substrate, preferably approximately 45.4% by weight; 5-10% by weight of a processing oil, preferably approximately 6.5%; 0-5% by weight of a stabilizer and/or preservative, preferably a mixture of stabilizers all within the same range of weights; and 3-8% by weight of a phosphorescent material, preferably approximately 6.1% by weight of Lumilux® Green phosphorescent material.
Another aspect of the present invention relates to an improved chemical composition for use in producing phosphorescent shoe soles. The present invention provides a greatly improved combination of the significant attributes of hardness, abrasion and phosphorescence.
A further aspect of the present invention relates to phosphorescent articles, in particular, shoes, shoe soles, and other shoe parts made from the above compositions, said articles having the property of glowing in the dark for a period of time following their exposure to light. The foregoing and other objects, features and advantages of this invention will be apparent from the following description of the preferred embodiments of the invention as illustrated in the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
Through example only, the invention will be described in more detail with reference to the accompanying drawings, in which:
FIG. 1 is a side elevation view of a sole in accordance with the present invention;
FIG. 2 is a bottom view of a sole according to the present invention; and
FIG. 3 is a side elevation view of an athletic shoe according to the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to the drawings generally, an article of footwear, such as an athletic shoe, sports shoe, or running shoe, is depicted in accordance with the present invention. Generally, the shoe comprises a sole structure or member and an upper attached thereto. The upper can be of any conventional design, while the sole structure incorporates the novel features of the present invention. The sole structure includes a force absorbing midsole and a flexible, wear resistant outsole. Of course, where appropriate, the midsole and outsole portions can be formed as a single integral unit. The midsole, and partially the outsole, comprises the cushioning element of the shoe.
As used herein, reference to the "lateral edge" refers to the outside peripheral edge of the shoe, the "medial edge" refers to the inside edge of the shoe, the "distal end" refers to that end of the shoe near the toes, and the "proximal end" refers to that end near the heel of the shoe. All components shown in the drawings are for a left shoe, the components for a right shoe being mirror images thereof. Further, it will also be noted that the various cushioning elements of this invention may be repositioned and/or used in various combinations, depending on the various activities for which the shoe is designed and/or targeted costs/selling prices.
Referring now to FIG. 1, the sole 10 comprises a resilient mass of material conforming to the shape of the lower part of an athletic shoe, or outsole 12. The material of the sole 10 is a phosphorescent polybutadiene rubber compound for making shoe soles, especially athletic shoe soles, although the applicability of the invention is not limited to athletic shoes. The outsole 12 comprises a phosphorescent or glow in the dark quality when exposed to a light source for a short period of time.
Referring to FIG. 2, the under surface of the outsole 12 has a conventional pattern of grooves and raised portions 14 in the surface thereof, designed for aesthetic purposes as well as for traction, support and durability. The pattern of grooves and raised portions 14 does not exhibit the phosphorescence or glow in the dark feature of the outsole 12. As may be seen in FIG. 3, the shoe 20 has an upper 22 attached to a midsole 24 which is generally formed of a foam material, has a proximal end 26, a distal end 28, a top surface 30, and a bottom surface 32, and which preferably covers the upper surfaces of the cushioning elements, as well as a major portion of the sides. The midsole 24 is attached to the outsole 12 which is preferably made of material according to the present invention. The outsole 12 has a proximal end 34, a distal end 36, a lateral edge and a medial edge. The bottom is formed into a suitable tread pattern for maximum traction, and minimal wear and tear (see FIG. 2).
The outsole 12 is attached to the bottom surface 32 of the midsole 24 via a suitable means well known in the art, for example an adhesive means, or an anchoring device means. The upper 20 is then attached to the top surface 30 of the midsole 24 along the lower edge of the upper 20. Again such techniques for attachment are well known in the art.
The rubber containing compositions of the present invention preferably comprise one or more of each of the following: rubber, processing and/or extending oils, inorganic additives, stabilizers and preservatives, and phosphorescent (Glow In The Dark ("GID")) compounds. They preferably also comprise modifying polymers, dry blend flow modifiers, and/or reinforcing or extending fillers.
The phosphorescent compounds impart phosphorescence to these compositions and to articles made therefrom. This gives the article it's glowing feature for a period of time (see Table 1 below) following their exposure to light. Such phosphorescence is manifested by a short period of intense glow immediately after exposure of the article to light, followed by a less intense glow that persists for several hours. Upon renewed exposure to light, the material absorbs enough light energy to again demonstrate the glowing quality. The present invention imparts to provide enhanced phosphorescence while maintaining the necessary hardness and abrasion.
TABLE 1______________________________________Glow TestLength of Light Exposure(300 watt sunlamp, e.g., ASTM D-1148)at a distance of 6 inches Length of Intense Glow______________________________________10 sec. 10 min. 1 min. 11 min.10 min. 12 min.30 min. 12 min.______________________________________
Phosphorescence enables the wearers of shoes made from, or having soles made from, the compositions of the present invention to be easily identified at night and avoided by on-coming traffic. Such shoes find particular use by pedestrians and bicyclists. In addition, children are intrigued by the phosphorescence and are inclined to wear phosphorescent and phosphescent soled shoes more than plain shoes and tend to learn how to put them on faster. Further, GID soles enable their owners to locate the shoe more easily in the nighttime to avoid the need to turn on the lights and possibly wake his/her spouse, or to avoid the problem of stubbing a toe while searching for the shoes.
In accordance with the present invention, the phosphorescent material is incorporated throughout the composition. Therefore, it is not removed by abrasion and does not disappear with wear of the shoes. The only interference with the glow that may occur is through a build up of dirt on the phosphorescent part of the sole which, however, can easily be restored with a simple cleaning.
The most preferred phosphorescent compounds suitable for use in this invention are phosphorescent pigments, such as zinc sulfide copper compounds. One such compound is Lumilux® Green supplied by HOECHST branch in Korea. The advantage of using Lumilux Green is that it provides a higher degree of phosphorescence than the phosphorescent pigments used in the prior art.
The rubber material contained in the composition of the present invention provides the elastomeric matrix to which other components are added. Preferably, these polymers are styrenic block copolymers and most preferably butadiene block copolymers. A particularly preferred polystyrene polybutadiene block copolymer is SBR 1502 manufactured by KUM HO Petrochemical Co., Ltd. in Korea. A preferred polybutadiene rubber (BR) is KBR-01, manufactured by KUM HO Petrochemical Co., Ltd. in Korea. Other elastomeric polymers that can be used in accordance with the present invention include but are not limited to EPDM and EPM which enhance the transparency of the final product, and other rubber batching chemicals.
During the conversion of raw synthetic polymers into desired objects, such as shoe soles, various melt-processing procedures are involved, such as extrusion, injection molding, calendaring, blow molding, thermoforming, etc. The inherent viscoelastic properties of each polymer type lead to certain undesirable processing defects, so additives are used to ease these processing-related problems. Heat and light stabilizers, antioxidants, and lubricants are well-defined and well-established additives. Processing aids are another important plastic additive product. Such processing aids can be made of small molecules, oligomers, or high molecular weight polymers.
The processing oil or oils act as viscosity modifiers (plasticizers) of the mixture and facilitate flow and processing. They also act as extenders. Naphthenic hydrocarbon oils, RN-2 and RN-3, are preferred for this purpose, although certain aliphatic oils, RP-1, RP-2 and RP-3, may also be used and are manufactured by MI CHANG Petroleum Ind., Co., Ltd. in Korea.
Modifying polymers are not incorporated into the composition of the present invention. However, modifying polymers can be used without affecting any property of the GID compound, and they usually serve to enhance the melt flow of the composition as well as strength, abrasion resistance, durability and surface finish of the articles made from such compositions. Preferred modifying polymers would be high density polyethylene, ethylene vinylacetate, polybutadiene resins, high styrene resins, poly(alpha-methylstyrene) resin, crystal polystyrene resin, high impact styrene polymers and co-polymers, and mixtures thereof. A particularly preferred mixture would be one containing poly(alpha-methylstyrene), and crystal polystyrene or a high-impact styrene polymer or copolymer (such as a copolymer of styrene and acrylonitrile).
The stabilizers and preservatives incorporated in the present compositions help prevent premature decomposition of the materials during melt-processing (e.g. when making the articles of the present invention), storage, and use. They can include antioxidants, ultraviolet stabilizers, and other stabilizers, preservatives, etc. Any ultraviolet stabilizers must be compatible with the phosphorescent pigment, so that they do not inhibit its light-absorbing ability.
Preferred stabilizers and preservatives are hydroxybenzoate ultraviolet stabilizers, hindered phenolic anti-oxidants, and thioester stabilizers, usually lower alkyl thioesters of carboxylic acids. Particularly preferred as the ultraviolet stabilizer is BIS (2.2, 6.6-tetramethyl-4-piperidiny)sebacate, which is called Tinuvin 770, HALS Sanol LS770i and is manufactured by CIBA-GEIGY Co., Ltd., in Germany. Particularly preferred as the phenolic antioxidant is 2.6-BIS(1.1-dimothyl-ethyl)-4-methylphenol, which is called BHT, manufactured by JIN YANG Chemical Ind. Co., Ltd. in Korea. Preferred would be the thioester stabilizer dilauryl throdipropionate plastic for the plastic batch, but no thioester is used for the GID compound for the shoe outsole. Also preferred as stabilizers are SUNNOC P manufactured by OUCHI SHINKO Chemical Ind. Co., Ltd. in Japan, and Irganox 1010 (antioxidant) 1.3-propanedyl 3.5-BIS (1.1-dimethylethyl)-α-hydroxyxbenene propanoate manufactured by CIBA--GEIGY Co., Ltd. in Switzerland. A combination of an ultraviolet stabilizer, a hindered phenolic anti-oxidant, SUNNOC, and Irganox 1010 is preferred. For the shoe sole compound it is preferable to use the antioxidant BHT for reasons of cost minimization and blooming protection.
Further stabilizers which may be incorporated in the present invention include:
Irganox 245, 259, 565, 1035, 1076, 1098, 3114, and 3125; and
Cyanox 1790, 2246, and 425.
Many other stabilizers not listed here, well-known in the pertinent art, may also be used according to the present invention.
In addition, as a flow modifier known in the art, precipitated finely divided silica is sometimes included to permit easier handling of the mixture during manufacture of the composition by a dry blending process. Polyethylene glycol ("PEG") is mainly used as the flow modifier, but not for the GID composition. In general, 2-3 grams are used for every 100 grams of compound.
Silica and other materials may also be used as fillers. Such fillers typically include limited amounts of sawdust, ground cork, fibrous fillers, such as cellulosic polyester or acrylic fibers. Clay, talc, titanium dioxide, carbon black, calcium carbonate and other pigments commonly used as fillers are not desirable for use in the present invention because they interfere with the intensity of the glow and the length of the afterglow. The content of the present composition in each of the above ingredients is as follows:
polybutadiene rubber: 40-50% by weight; preferably 45.4% by weight;
processing oil: 5-10% by weight; preferably 6.5% by weight;
modifying polymer(s): 0-20% by weight; preferably 0% by weight;
GID: 3-8% by weight; preferably 6.1% by weight;
stabilizer(s): 0-5% by weight; preferably a mixture of stabilizers all within the same weight range;
dry blend flow modifier: 10-30% by weight; preferably 22.7% by weight;
filler: the remainder.
The invention is further described below in particular example, which is intended to illustrate the present invention, but not to limit its scope.
The following ingredients and proportions were used to prepare a phosphorescent rubber compound in accordance with the present invention for use in making shoe soles:
TABLE 2______________________________________GID Sole Recipe GRAM PERCENTCHEMICAL (g) BY WEIGHT______________________________________SMR L (Natural Rubber) 53 g 4.86%SBR 1502 (Polystyrene- 72 g 6.60%butadiene block copolymer)KBR-01 (Polybutadiene rubber) 495 g 45.35%Zeosil (Silica) 248 g 22.72%T-AZO (Activated Zinc oxide) 27 g 2.47%ST/A (Stearic Acid) 6 g 0.55%SUNNOC (Microcrystalline 6 g 0.55%paraffine wax)Processing Oil 71 g 6.51%M (2-Mercaplobenzothiazole) 2.5 g 0.23%DM (2.2-Dithio-bis- 8 g 0.73%benzothiazole)TS (Tetramethylthiuram- 0.9 g 0.08%monosulfide)S (Sulfur) 12 g 1.10%GID (Phosphorescent Pigment) 67 g 6.14%SBR 2003 23 g 2.11%______________________________________
The following ingredients and proportions were used to prepare a non-phosphorescent rubber compound in accordance with the present invention for use in making shoe soles:
TABLE 3______________________________________Regular Sole Recipe GRAM PERCENTCHEMICAL (g) BY WEIGHT______________________________________SMR L (Natural Rubber) 87 g 8.74%NBR 35L (Polyacrylonitrile 87 g 8.74%butadiene rubber)KBR-01 (Polybutadiene rubber) 433 g 43.50%Zeosil (Silica) 260 g 26.12%Processing Oil 35 g 3.52%ZnO (Zinc oxide) 35 g 3.52%PEG (Polyethylene glycol) 24 g 2.41%ST/A (Stearic Acid) 6 g 0.60%SUNNOC (Microcrystalline 6 g 0.60%paraffine wax)M (2-Mercaplobenzothiazole) 1.2 g 0.12%DM (2.2-Dithio-bis- 9 g 0.90%benzothiazole)TS (Tetramethylthiuram- 0.2 g 0.02%monosulfide)S (Sulfur) 12 g 1.21%______________________________________
The compositions of the present invention can be made by well-known and by various methods.
In one dry-blending and/or melt-processing techniques, polybutadiene rubber, in powder form, is charged into a Banbary mixer, or other such kneader, and heated mechanically to about 158°-176° F. Processing oil is added and vigorously mixed into a powder at about 158°-176° F. Polymer modifiers are then added and mixed at a low speed to become uniformly distributed within the blend. Addition of stabilizers and colorants then follows. Flow modifiers are added last to convert the blend to free-flowing finely divided powder. The prepared powder is then melt-mixed as follows: The mixture is heated to melt the ingredients (at about 178°-194° F.). In this step, the solid ingredients are preferably mixed with the melting ingredients as thoroughly as possible. The material is then converted to a form that is suitable for further processing, such as extrusion, injection molding, etc.
A method particularly well known in the art to make shoes and shoe soles is to start with rubber or plastic pellets.
The process of making the sole usually involves a mold to be used in an injection molding machine. The mold determines the dimensional features of the sole, and the injection molding machine melts the thermoplastic rubber and conveys it as a fluid into the mold.
In one method, clear poly-vinyl-chloride ("PVC") outsoles are fabricated either by injection molding directly attached on to the upper portion of the shoe, or the outsole may be separately fabricated and then cemented to the upper portion of the shoe. When such injection molding techniques are used, typically, pellets of PVC, polyurethane or thermo plastic rubber ("TPR"). In this technique, the pellets are melted, and injection molded to form the outsole.
A particularly preferred method for forming the shoe soles in accordance with the present invention is by molding materials that are processed into sheet form. When the preferred compound (polybutadiene rubber) comes out of the Banbary mixer or kneader, it is heated. What comes out of the mixer or kneader is then rolled into a sheet stock. That rolling is accomplished through the use of two rollers disposed proximate to each other, to form a pressing gap. Typically, said sheet stock may be cut into 18 inch wide by 36 inch long sheets. Said sheets are then die cut into pieces, wherein said pieces are more or less the shape of the outsoles. In effect, the sheets and die cut pieces may be sized to minimize waste, as excess material is preferably discarded. By maximizing the die cut sizes (which correspond to the shoe sizes) versus the sheet sizes, the manufacturing process may be optimized, but typically, about six to ten pairs of outsole pieces may be yielded from a single sheet. Then, the die cut pieces are introduced into a steel, high compression mold. The die cut pieces (which are preferably formed of the rubber compound as set forth herein) are then heated to 284°-293° F. for 8 minutes (dwell time) under pressure. Because the die cut pieces are heated within the high compression mold (wherein the mold provides the appropriate gap which corresponds to the desired thickness of the outsole), the rubber compound melts and flows. This melting process accomplishes many objectives, including that any imprints desired (such as treads, designs, etc.) may be molded into the outsole, the outsole may be molded into precisely the correct size and shape (as the molds are based on standard shoe sizes), the rubber may be cured to enhance durability, hardness, abrasion, and other parameters, as desired, etc. Finally, the molded rubber outsoles are pulled from the molds, and are air cooled. If the molded rubber outsoles are left in the mold too long, the pieces may be over cured, and the desired quality lost. The temperature and dwell time may be varied as desired, but as set forth herein, standard temperature and dwell times for any rubber compression molded outsole are set forth.
The mold design is determined primarily by aesthetic considerations, but strength and durability of the sole, and efficiency of the molding process, molding material, and material used to fabricate the mold are all considerations in designing the mold. Mold making materials are metals and composite materials known in the mold design field. Shoe sole molds are preferably machined from aluminum or cast from aluminum.
TABLE 4______________________________________Typical Properties of a Shoe Sole Manufactured in Accordancewith the Present InventionProperty______________________________________Tensile Strength 96 kg/cm.sup.2Elongation Ratio 668%Tear Strength 37 kg/cmHardness 65 ± 2° A-TypeN.B.S. (Abrasion) 228%Specific Gravity 1.14 g/cc.Tensile modulus (or 100% modulus) 17 kg/cm.sup.2300% modulus 36 kg/cm.sup.2______________________________________
The above invention has been described with reference to particular embodiments. In light of the above description, however, it will be obvious to those of ordinary skill in the art that many modifications, additions, and deletions are possible without departing from the scope or the spirit of the present invention as claimed below. | This invention relates to phosphorescent, polymer-containing compositions for use in Glow In The Dark shoe soles, and other molded or extruded shoe parts made from such compositions. One aspect of this invention is directed to a polymeric composition comprising between about 40-50% by weight rubber; 5-10% by weight processing oil; 0-5% by weight stabilizer; and 3-8% by weight phosphorescent material. A sole made according to the present invention for a children's athletic shoe comprises a mass of sole-forming phosphorescent material having peripheral edges and a cushioning element. The `Glow In The Dark` portion of the shoe being visible on both the peripheral edges and underneath surface. | 2 |
BACKGROUND OF THE INVENTION
This invention relates generally to traffic control systems, and more particularly to improvements in monitoring of traffic signal lights for proper operation at controlled roadway intersections.
The present art in the traffic control system uses a controller unit that energizes load switches that drive the signal lamps through a flash transfer relay. In the event that a conflicting signal should arise, a conflict monitor can actuate the relay to transfer the lamp loads to the flasher module.
The conflict monitor measures the traffic signal lamp voltages by converting the AC to DC, enabling a gate which then indicates whether the voltage is present or not. If two signal lamp voltages are ON at the same time in conflicting directions, for instance eastbound and northbound, traffic green signal lights ON, setting up a potential hazard; the conflict monitor will drop or de-energize the flash transfer relay, putting the lamp loads under the control of the flasher, thus putting the intersection into flash.
Prior art has defined a traffic control system as consisting of a traffic controller unit for the purpose of providing 24 volt DC input signals to one or more load switches used to turn traffic signal lamps ON. A conflict monitor device is used to monitor the presence of proper alternating current field wire voltages supplied to power the traffic signal lamps. When improper AC voltages exist, the conflict monitor causes an electro-mechanical relay to transfer, which in turn causes the high current capacity flash transfer relay to remove lamp power from the load switches and to connect the lamp power to a flasher unit, which causes the traffic signal lamps to flash ON and OFF.
In addition to monitoring the AC voltages on the outputs of load switches, the conflict monitor checks for the presence of a 24 volt DC output from the power supplies used by the traffic controller to produce 24 volt DC signals for turning the load switch outputs ON. The 24 volt DC signals supplied from the traffic controller to each of the individual load switch circuits have not previously been monitored within the conflict monitor or the controller unit. A proposed improvement to NEMA traffic control device standards, proposed standard TS2 for future design, would require communication between the traffic controller and the conflict monitor with information sent regarding the programmed traffic controller 24 volt DC signal status, but would not provide a measurement of the 24 volt DC signals actually present at the load switches. U.S. Pat. No. 4,383,240 describes monitoring of DC logic signals, storage, and display of same, along with output status conditions.
There is need for improvements in the control of signal flashing and in the detection and handling of system malfunctions, including that of signal lamps (bulbs), and for simplification of system apparatus and functions.
SUMMARY OF THE INVENTION
It is a major object of the invention to provide an improved system meeting the above needs.
The environment of the invention comprises a traffic control system for use at a roadway intersection, the system including traffic control lights, a light flasher means, and a plurality of load switches electrically coupled with the lights via relay means to which the flasher means is connected, the load switches having inputs, and a controller connected with the load switches for controlling normal operation of the lights and flashing of one or more of the lights by the flasher means in the event of a system malfunction.
In this environment, the invention provides:
a) a microprocessor operatively connected with the load switches and relay means to monitor the system for detecting a malfunction event, for recording the detected malfunction event, and for transmitting the malfunction detection to another location,
b) and verification means at the other locations for
i) receiving the transmitted malfunction detection,
ii) verifying the event, and
iii) initiating malfunction corrective action,
c) whereby the corrective action in the system may be initiated without removing control by the controller of the operation of the traffic control lights at the intersection.
It is another object of the invention to provide means to monitor AC field wire voltages supplied via load switches to power the traffic control lights, and means to monitor DC inputs of the load switches to enable determination, for any load switch, which of three (red, yellow and green signals) DC inputs is ON.
As respects such DC monitoring, the invention provides:
a) a signal monitor means,
b) each load switch having three DC inputs, three corresponding outputs, one output being turned ON in response to application of a DC ground to the corresponding DC input,
c) a voltage summing circuit coupled to the input of each load switch, the circuit including three interconnected resistors respectively in series with the DC inputs, and the circuit coupled to the signal monitor means,
d) the voltage summing circuit including three diodes respectively connected in series with the three resistors to prevent the DC inputs from feeding energy to the signal monitor means when the inputs are in off-state,
e) the signal monitor means including an additional resistor coupled to a stable reference voltage,
f) the additional resistor and the three resistors in the voltage summing circuit forming a voltage divider when a DC input to the load switch is selected by the controller, to allow determination of which DC input is ON, at a particular load switch.
As respects the reference to AC voltage monitoring, it is an object of the invention to provide conflict monitor means to sequentially compare the AC voltages with reference voltage in the monitor, the monitor also operating to provide DC signal monitoring, as referred to. Thus, the conflict monitor may comprise a module coupled to the input and output side of each load switch, to function as described.
It is another object to provide input monitor means with circuit means for transferring traffic signal lamp loads from the load switches to the flasher means under substantially no-load conditions whereby arcing at the flash transfer relay means is suppressed.
These and other objects and advantages of the invention, as well as the details of an illustrative embodiment, will be more fully understood from the following specification and drawings, in which:
DRAWING DESCRIPTION
FIG. 1 is a system block diagram;
FIG. 2 is a block diagram showing AC field wire voltage monitoring;
FIG. 3 is a block diagram showing monitoring of DC voltage input levels to load switches;
FIG. 3a is a circuit diagram;
FIG. 4 is a flasher circuit diagram;
FIG. 5 is a load switch circuit diagram;
FIG. 6 is an analog board circuit diagram;
FIG. 7 is a block diagram showing details of the conflict monitor seen in FIG. 1;
FIG. 8 is a "hold-off" circuit diagram;
FIG. 9 is a circuit diagram showing analog board coupling between load switch inputs and the conflict monitor;
FIG. 10 is a circuit diagram showing use of saturable care reactors in the load switches;
FIGS. 11(a), 11(b), and 11(c) are wave forms;
FIG. 11(d) is a circuit diagram showing integration of circuit sensor signals, as represented in FIG. 11 (c);
FIGS. 12(a), 12(b), and 12(c) are wave forms; and 12(d) is a comparator circuit; and
FIGS. 13(a), 13(b),and 13(c) are wave form diagrams, and 13(d)is a comparator circuit.
DETAILED DESCRIPTION
In FIG. 1, a traffic controller is indicated at 10, as having output at 11, connected at 12-16 with load switches 17-20. Such switches have outputs at 21-24 connected at 25-29 with flash transfer relay means 30, which is in turn connected at 31-36 with traffic control light units 37-40. The latter are normally located at different corners of a roadway intersection. When a system malfunction occurs, red lights in units 37-40 are placed in a flashing mode. This is accomplished by the high current capacity relay means 30, which receives a flash initiating signal from a conflict monitor 41, via connection 42. The relay removes power transmission from the load switches to the lights (the four load switches normally connected via the relay to the respective four lights), and connects power transmission from the flasher circuit 43 to all light units.
The conflict monitor 41 is shown as operatively connected with the load switches 17-20, as via bus 44, Load Management System (LMS) analog board 45, bus 56 and connections 47-50, whereby the monitor 41 measures the presence or absence of predetermined or selected AC field wire voltages at the outputs of the switches 17-20, for example appropriate level AC voltage level supply to the light units from the load switches. Also, the conflict monitor 41 monitors the DC voltage from the controller that is used to turn each load switch output ON. If the DC voltage from the controller is not selected, but the output from the load switch is ON or vice versa, the conflict monitor determines that a malfunction has occurred and initiates corrective action.
Such measurements by the conflict monitor may effectively be made by comparing the AC voltage level with a selected level, as in a comparator; and by comparing the DC voltage level with a selected (24 volt) level, as in a comparator. Such measurements are made by the conflict monitor while measuring the current actually drawn by the signal lamp loads at the light units as via bus 44 connected with output leads 25-28. Bus 44 provides DC voltage status of the load switches 17-20 to the monitor 41; whereas bus 52 provides AC voltage information to the monitor.
LMS circuit 44 is not only connected at 47-50 and via board 45 with the load switches, but also with the flasher circuit 43 via connector 55. The LMS and conflict monitor 41 respond to a malfunction, such as dropping of the AC output voltage from a load switch below a threshold, to cause the relay means 30 to decouple from the load switches, and couple to the flasher unit, at a non-load condition during the AC cycle. This is extremely beneficial, as the electro-mechanical flash transfer relays used at 30 for load switching normally are required to transfer relatively high electrical currents; and if switching is done with random timing during the AC cycle, arcing can likely occur, causing damage to the load switches 17-20, to the flasher circuit 33, and other devices. Note also that the monitor 41 enables malfunctioning corrective action to be initiated without removing control by controller 10 of operating of the traffic signal lights 37-40. This allows the traffic intersection to be operated (by the lights) in a highly efficient manner, to enable increased vehicular traffic flow and correspondingly reduced vehicle fuel consumption.
FIG. 2 shows in further detail the manner in which the conflict monitor measures the output voltages from the load switches and compares these with a reference. Load switch 17 has connections 25a, 25b and 25c with relay switches 30a, 30b and 30c; and the latter are connected at 33a, 33b and 33c with the red, yellow and green lights of light units 37, as shown. Likewise, load switch 18 has connections 26a, 26b and 26c with relay switches 30d, 30e and 30f; and the latter are connected at 38a, 38b and 38c with the red, yellow and green lights of light unit 38. Typically, one relay 30 is used (see one armature 30k solenoid controlled at 30j. In one position, it allows connections from 25a, 25b, and 25c to light inputs at 37a, 37b, and 37c, as shown; in another position of 30k, it connects only red light inputs 37a, 38a, etc., with the flasher 43, as via leads 43d and 43e.
Outputs from lines 25a-25c are connected via lines 47a, 47b and 47c with a multiplexer amplifier 60, via attenuator 61, in monitor 41 (which may be considered to include LMS board 45); and outputs from lines 26a-26c are connected via lines 48a, 48b and 48c with 60 and 61. The multiplexer applies the voltages on 47a-47c and 48a-48c, one at a time to the comparator 62, where they are compared with a reference voltage applied at 63 to the comparator. That reference voltage is supplied and controlled via CPU 64, as via isolator 65 and digital to analog converter 66. The comparator output at 67 is fed via isolator 68 to the CPU, for processing to determine whether it exceeds (for any of the AC inputs at 47a-47c and 48a-48c) a selected threshold level, thereby indicating a malfunction. Attenuator 61 is controlled by the CPU via line 69 and isolator 70 (buffer). A "watch dog" signal is transmitted at 71 by the CPU to monitor proper operation of the CPU.
The conflict monitor CPU may be programmed to monitor for occurrence of malfunctions and to react to them as a fault as has traditionally been the practice in the industry where the intersection is removed from actuated control by the controller 10 and put into flashed control by the flasher 43, or to react to malfunctions as a message where the occurrence of the malfunction is recorded, stored, and, if desired, transmitted to other equipment without removing control of traffic from the traffic controller 10. The benefits of this are increased traffic flow, reduced congestion, reduced fuel consumption, and reduced vehicle emissions (pollution). Separate memory records may be used for the purpose of storing faults and messages. See record means 64a.
The LMS also logs into a memory record the occurrence of user-inputted and traffic control system-initiated changes in the operation of the load management system. This information is recorded and stored in a memory record, as at 64b, which may be separate from the fault and message memory records. Information logged relates to times and dates, and nature of changes in the monitoring operation, and to the information stored in other memory records, such as fault memory and message memory.
Referring now to FIGS. 3 and 5, the means to monitor the DC circuit levels at the inputs to the load switches will now be described. Each load switch has three inputs, as well as three outputs, previously referred to, as at 25a-25c and 26a-26c. FIGS. 3 and 5 show load switch 17 DC inputs at 80a-80c, and analog channel 80d connected to 80a-80c, and also connected to the LMS, including analog board 45 and multiplexer 83. The latter delivers those three analog circuit levels, serially, via connector 84 to an A to D converter 85 in monitor 41. FIG. 6 illustrates such a board 45 in greater detail. (Parallel delivery of circuit levels could be employed.)
Refer now to FIGS. 3a and 5 showing the three DC input levels A, B and C fed to the converter 85 (in 41) via the three resistors 86, 87 and 88, to summing junction 89, the resistors having different values. See FIG. 3a for representative values. Three diodes 90-92 are in series with the respective resistors to prevent DC inputs from feeding energy into the board 45 and monitor 41. Inside the monitor 41 the analog DC signal obtained is tied at 93 to a stable reference voltage 94, through a resistor 95. The latter, plus the three resistors 86-88 in the load switch 17, form a voltage divider when a DC input from the load switch is selected by the controller. A filter comparator is shown at 96. By converting the analog DC status signal to a digital signal, the signal monitoring unit can determine which resistor (86, or 87, or 88) in the load switch is included in the divider network; and this in turn allows determination by the monitor of which DC input (80a, 80b or 80c) is ON, at a particular load switch. See also the detailed circuitry in FIG. 9.
As described, the load switch has three associated signals: DC input A, DC input B, and DC input C which represent three inputs from the controller unit to the corresponding DC inputs A, B and C. To turn on an output, the corresponding input requires a DC low voltage. When nothing is selected or when there is no connection between the conflict monitor and the load switch, the pull-up resistor, R4, at 95, sets the A to D value to 5 volts DC (assuming that voltage reference is 5 volts). When an input is selected, the corresponding resistor inside the load switch and resistor 95 form a divider network. This network will give different A to D values depending on which resistor is included in the network. The table below shows the different A to D values based on the different input selected. Voltage reference is assumed to be 5 volts DC.
______________________________________INPUTSELECTED RESISTORS IN NETWORK A TO D VALUE______________________________________None R4 5.00 voltsA R1, R4 1.56 voltsB R2, R4 2.38 voltsC R3, R4 3.23 voltsA, B R1, R2, R4 1.16 voltsA, C R1, R3, R4 1.33 voltsB, C R2, R3, R4 1.88 voltsA, B, C R1, R2, R3, R4 1.03 volts______________________________________
Referring to FIG. 7, it shows in more detail the functional blocks of the conflict monitor for measuring AC signal voltages supplied to the signal lights or lamps, and also as referred to above. It incorporates for each light channel (red, yellow and green) use of a reference voltage, as at 63 (for example) that can be changed by the DAC 66, under control of the microprocessor CPU 64.
The invention enables changing of input circuitry to measure traffic signal lamp voltages using different microprocessor set thresholds at different times. In doing this, several benefits are achieved:
a) By setting the reference to 0 volts, the input circuitry becomes a zero crossover detector which can be used to verify that the measured traffic signal voltage is in phase with the AC line voltage and is not shorted to another phase voltage (for instance street lights).
b) Setting the reference to a negative voltage allows the measurement of only the negative one half cycle. This then allows the microprocessor to determine if the negative half cycle of traffic signal voltage is present and of sufficient amplitude to drive the traffic signal lamp.
c) Setting the reference to a positive voltage allows for the measurement of only the positive half cycle. This then allows the microprocessor to determine if the positive half cycle of traffic signal voltage is present and of sufficient amplitude to drive the lamp.
d) The determination or knowledge of the presence of a half wave signal will allow the microprocessor to set different references for half wave than for full wave traffic signal voltages. This is important because conservation of power is often achieved by providing half wave rectified voltages to traffic signals.
e) This technique is also used to measure the load resistance during the OFF time, thus giving the microprocessor a method of testing for the presence of, and for the amount of, the load. This provides a method for measuring current which does not require the use of additional current sensor loops.
The above additional information provided to the microprocessor can be used to record when a malfunction occurs and to report to a central office without having to put the intersection into flash. This makes it possible for increased traffic flow, reduced fuel consumption and reduced down time.
In FIGS. 12 (a)-(d), the microprocessor first sets up the reference to 0 volts DC and waits until a change of state occurs from 0 to 1 at the output of the comparator 137. See 12(b). At the time the state changes, the input is at 0° in FIG. 12(a). Then the microprocessor sets up the D to A for a reference into the comparator equal to the required threshold of the positive half cycle. At this time, the output of the comparator will change from 1 to 0. The microprocessor continues to monitor the output for a state change from 0 to 1 within a time period that does not exceed 1/2 the cycle time. If the states does change from 0 to 1, the positive threshold was reached. The microprocessor then sets up the reference to 0 volts DC and waits until it sees a change of state from 1 to 0 at the output of the comparator. At the time the state changes, the input is at 180°. Then, the microprocessor sets up the D to A for a reference into the comparator equal to the required threshold of the negative half cycle. At this time, the output of the comparator will change from 0 to 1. The microprocessor continues to monitor the output of the comparator for a state change from 1 to 0 within a time period that does not exceed 1/2 the cycle time. If the state does b change from 1 to 0, the negative threshold was reached. If it does not occur in less than 1/2 cycle time, the threshold was not reached. At this time, the microprocessor will set the D to A to 0 volts DC and repeat this process all over again looking for the 0° point.
Should the positive or negative thresholds not be reached, the input is not present. There will, however, always be a zero crossover due to leakage current of the surge protection circuitry in the load switch. During the time that there is no input present to a load switch circuit, the load for the corresponding output can be measured by switching the input attenuator OFF with an analog switch. This gives the effect of changing the range.
In FIG. 13(a) to 13(d), the microprocessor sets up the reference to 0 volts DC and waits until it sees a change of state from 0 to 1 at the output of the comparator 141. At the time the state changes, the input is at 0°. Following this state change of 0 to 1, the microprocessor then steps up the D to A for a reference into the comparator and looks for the next state change from 1 to 0. At the time the state change from 1 to 0 occurs, the reference is greater than the input. Then, the microprocessor continues to monitor the output of the comparator until the state changes from 0 to 1. If the time has not passed 1/4 cycle time, the microprocessor steps up the D to A for a reference into the comparator 141, and looks for a state change from 0 to 1 just as before until 1/4 cycle time has passed. At this time, the peak voltage is reached and the voltage measured is proportional to the load resistance. This measurement can be made every time that the load switch is turned OFF and can be compared to the previous measurement, thereby permitting detection of load changes, such as can be caused due to burning out of signal lamps.
This technique is especially beneficial because it can automatically measure out-of-phase AC voltages. By gradually changing the reference voltage and looking for the state changes at the output of the comparator, the conflict monitor can determine where the peak of an input is, and in turn, determines the out-of-phase angle of the input from the AC line reference.
Referring to FIG. 8, it shows hold-off circuitry associated with each load switch, also seen in FIG. 5, as referred to above.
As shown, at the time that a conflict is sensed and just before the flash transfer relay is dropped, a signal is sent at 95 to the load switches 17-20 and flasher 43. This signal will momentarily turn them OFF (hold off), as via circuits 110, during the time that the flash transfer relay is dropped. This will prevent the flash transfer relay from burning its contacts and possibly sticking, ensuring safe operation of the intersection and ensuring the reliable operation of the flash transfer relay.
Note connector at 95 (in the analog board) between monitor transistor 96 and current source means 97-99 in the load switch circuits 17, 18, and 19, for this purpose.
The flasher circuitry 43 seen in FIGS. 1 and 8 is shown in detail in FIG. 4.
In FIG. 4, the driver logic supply 103, alternately selects either the triac 104 or 105 to generate an output 104a or 105a. These outputs then feed through the inputs of the opto-isolators 106 and 107. Two resistors of different values 110 and 111 are connected to the respective outputs from the opto-isolators 106 and 107, respectively. Resistors 108 and 109 provide pull-up to Vcc. When the output of triac 104 is turned ON, the corresponding opto-isolator 106 is also turned ON. The resistors 109, 111, and 110 form a network divider with analog channel out 112 being measured through an A to D converter 116 with the pull-down resistor 113 and a filter capacitor 114. When triac 105 is turned ON, opto-isolator 107 is turned ON. Resistors 108, 110, and 111 form a different network divider and give a different value of analog channel out 112. By monitoring the analog channel out 112, the conflict monitor 41 can detect that the flasher 43 is operating by observing the analog channel out 112 switching from one level of voltage to another.
In FIG. 2, the relay armature 30k is connected to all the switch arms, to simultaneously switch their positions in response to energization of solenoid 30j. That solenoid is operated, via line 182, by a driver associated with the CPU of monitor 41, when a malfunction event occurs, thereby to cause disconnection of the load switches from the traffic lights (as at 37 and 38), and to connect the flasher circuit 43 with the traffic signal red lights, as is clear from FIG. 2. The same operation of the relay 30, to produce red light flashing, occurs in the event the microprocessor CPU itself malfunctions; for example, interruption of CPU clock signals delivered at 186 to the watch dog circuit 71 causing the latter to operate the solenoid 30j via line 183, to effect red light flashing in the manner referred to.
In FIG. 4, the A and B outputs are fed to the relay 30, as via each of lines 43d and 43e, seen in FIG. 2. The opto-isolator circuit 190 in FIG. 4 is also referred to in connection with the description of FIG. 8.
Each load switch and flasher contains a 0° phase angle driver. Simply stated, by using the load switch and flasher to switch the power, damage due to current in-rush surges is brought to a minimum. This is accomplished by sending a positive signal to all of the load switches and flashers (FIGS. 4, 5 and 8) through the analog board before the flash transfer relay is de-energized. In the load switch (FIG. 5), this signal is capacitively coupled to a current regulator and for a short, controlled period of time (one to five AC line cycles) the current regulator is changed from a 20 ma current regulator to a 0 ma current regulator. This current is not adequate to drive the opto-isolator, used within the load switch to supply power to the signal lamps, and, in turn, for that period of time will shut down of all the load switches. The flasher (FIG. 4) at the same time receives the same hold-off signal. It is driven through an opto-isolator where, on the AC line side, it is capacitively coupled to a blinking input on internal logic; or it may instead be capacitively coupled to a transistor that momentarily shorts the flasher DC supply voltage that runs the internal logic. Either circuit will work, with the end result being that the flash transfer relay and the load switches and flasher are all saved from excessive current in-rush by ensuring that all switching is done at the zero crossover time. This aspect of the invention has applicability in fields other than traffic control, where solid state relays are used in conjunction with electro-mechanical relays or magnetic contactors.
The invention also enables circuit measurement in a simple, effective manner through use of a saturable core reactor, or reactors, as shown at 100 in FIGS. 5, 10, and 11(d).
The illustrated reactor 100 is a toroid that is driven into saturation by the current to be measured, i.e., the current being supplied to the load. See line 25a. This approach is different and unique from traditional current transformers in that current transformers are not driven into saturation. The counter EMF generated by the saturable reactor of this invention is then rectified at 110a and integrated at 101 to represent the current for a resistive load and supplied at 102 as an analog circuit to the LMS. These integrated voltages are not linear with respect to the current and more sensitive for small loads than for large loads. The present invention does not require that a linear measurement be made and provides increased sensitivity at lower currents. This invention can be employed to detect a partial or a complete loss in load, such as the loss of a traffic signal lamp from a parallel string of lamps. A lamp out detection may be accomplished by detecting a sudden drop in the current supplied to the load.
A corresponding reactor 100' is used in the flasher for measurement of current supplied to loading during flasher operation. See 101' and 102' as in FIG. 4.
Considering the above, note that
Volt source=volt load+volt inductor
Voltage total=(R×I)=(L×di/dt)
with the voltage across the inductor equal to
V=L×di/dt,
where
V=voltage,
L=inductance,
di=change in current
dt=change in time
Ampere's Law
I=0.795×H×1×I/N,
where
I=peak magnetizing current in Amperes 0.795=1/(pi×0.4),
H=magnetizing force in Oersteds,
l=mean magnetic path length in cm,
N=number of turns in primary.
Simply stated from these equations, di is a constant derived from the fact that H in Ampere's Law reaches a maximum value at the saturation of the magnetic core. Therefore, the current I reaches a maximum value as well. This I maximum defines di in the previous equation. Consider the case of a small load where the applied voltage is a sine wave (FIG. 2). Some amount of time, dt, is required in the case of a larger load. As dt increases, voltage decreases. As dt decreases, voltage will increase. This voltage is stepped up on the secondary winding of the toroid and is rectified and integrated in order to be read as an analog voltage representing the current drawn by the load.
There are several advantages:
1. Electrical isolation from the load is maintained.
2. The voltage measurement is non-linear, making it more sensitive at lower currents. This has the effect of automatically changing the range of the current measurement.
3. The current sensor does not have a voltage drop after the magnetic core is saturated, resulting in less power loss from the load to the magnetic core than with other techniques.
4. Surge protection is provided by this circuit because the maximum energy that can be coupled to the secondary is the energy that is stored in the core. The nature of this invention is that small amounts of energy are stored. This assumes good isolation from the load.
5. Reduced size and cost from other current measurement techniques is achieved due to the fact that a small core is required in order to saturate the core.
This approach works well in applications requiring measurement of changes in resistive load current, such as for detecting tungsten lamp outages in traffic signal displays. Another advantage of this invention is that manual calibration is not required. A microprocessor can be used without the need to know what the actual value of the current is; it is only necessary to know if the current has changed. This fact is extremely useful in automatic measurement and reporting of load current changes such as light bulb burn-out occurrences.
Faraday's Law:
B=(E×100,000,000)/(4.4×A×N×f),
where
B=maximum flux density in gauss,
E=voltage across core in volts,
A=core cross sectional area in cm squared,
N=number of turns on the primary,
f=frequency in hertz.
L=(0.4×pi×u×N×N×A)/(1×10,000,000),
where
L=inductance,
u=core permeability (u=B/H),
B=maximum flux density in gauss,
H=magnetizing force in Oersteds,
N=number of turns in primary,
A=core cross sectional area in cm squared,
l=means magnetic path length in cm.
The constants A, l and u are fixed in the selection of the core to be used.
Faraday's Law is used in determining a suitable core, and it is desirable in the application of detecting traffic signal lamp losses to use a tape wound core as opposed to other types for the following reasons:
1. The tape wound core does not have a distributive gap. A distributive gap prevents saturation of the core.
2. Higher gauss levels (magnetic flux density) can be achieved. This results in much more accurate measurement because the signal strength is many times higher than with other types of toroid cores.
3. This application requires load current measurements on an alternating current line. This is a low frequency application (50-60H z ) making it ideal for the tape-wound core which works well at lower frequencies than other types of toroid core. Not nearly as many urns around the tape-wound core are required to yield the same measured voltage, E, as would be required using cores, other materials and construction.
SUMMARY
The LMS herein is used in traffic controller assemblies to monitor and ensure the safety of intersection operation. The LMS incorporates the signal monitor unit, which measures load currents to know when signal lamps fail; monitors and compares controller 24 volt DC driver signals with load switch outputs to identify precisely which equipment fails; continuously monitors flasher unit outputs before "flash" operation of the intersection is required to verify that the flasher unit will perform when the lamp loads are transferred to it; and eliminates electrical voltage and current transients from being generated by flash transfer relays to prevent their destruction as well as that of other cabinet electronics.
Special load sensing switches measure load current permitting detection of the loss of solid state and fiberoptic signals as well as field wire shorts. Load current measurements are sent to the monitor using a simple harness and no cabinet rewiring or modification is necessary. With the harnessing, the signal monitor unit is also provided with controller 24 volt DC driver signal status, which is compared with load switch outputs to confirm proper operation of traffic signals. This permits identification of equipment which malfunctions saving valuable maintenance personnel and service equipment time. The simple harnessing used also connects the SMU (i.e., monitor) with the flasher units so that their outputs may be continuously monitored for proper operation before they need to control the intersection. Failure of flasher units as well as all other information stored in the SMU can be communicated to another location via modem or RS232 connections or retained within internal memory for retrieval when a field service person arrives. A convenient "MESSAGE" indicator 64c calls attention to changes in recorded information and to needed maintenance.
When flash transfer relays are required to transfer signal lamp loads to flasher units, generation of high voltage and high current transients caused by arcing of contacts is avoided. This prevents damage to electronic equipment within the controller assembly and to flash transfer relay contacts such that their replacement is virtually eliminated.
Sensing of load currents and 24 volt DC driver signals can be performed outside of the load switches and flashers, such that the simple harnessing described to connect load switches to the monitor is eliminated. The sensing of load currents and 24 volt DC signals may be performed within another device, such as the traffic controller, an interface unit, or at the field wire termination panel itself, and processed and compared with AC voltage measurements within the conflict monitor or another device, such as the traffic controller or a remotely located computer. | A traffic control system for use at a roadway intersection, the system including traffic control lights, a light flasher structure, and a plurality of load switches electrically coupled with the lights via relay structure to which the flasher structure is connected, the load switches having inputs, and a controller connected with the load switches for controlling normal operation of the lights and flashing of one or more of the lights by the flasher structure in the event of a system malfunction comprising a microprocessor operatively connected with the load switches, flasher, and relay structure to monitor the system for detecting a malfunction event, for recording the detected malfunction event, and for transmitting the malfunction detection to another location; and verification structure at the other locations for i) receiving the transmitted malfunction detection, ii) verifying the event, and iii) initiating malfunction corrective action; whereby the corrective action in the system may be initiated without removing control by the controller of the operation of the traffic control lights at the intersection. | 6 |
FIELD OF THE INVENTION
The present invention relates to tetraamido macrocyclic ligands that form complexes with transition metals, and more particularly to an improved synthesis of such macrocycles as exemplified by 5,6-Benzo-3,8,11,13-tetraoxo-2,2,9,9-tetramethyl-12,12-diethyl-1,4,7,10-tetraazacyclotridecane, H 4 .
BACKGROUND OF THE INVENTION
The use of transition metal chelates as catalysts for bleaching agents is well known in the art. For example, U.S. Pat. No. 4,119,557, issued to Postlethwaite, discloses the use of iron-polycarboxyamine complexes with hydrogen peroxide releasing substances to clean fabrics. Similarly, U.S. Pat. No. 5,244,594 (Favre et al.), U.S. Pat. No. 5,246,621 (Favre et al.), U.S. Pat. No. 5,194,416 (Jureller et al.), and U.S. Pat. No. 5,314,635 (Hage et al.) describe the use of manganese complexes of nitrogen- (or other heteroatom-) coordinated macrocycles as catalysts for peroxy compounds.
The utility of compounds of this type has motivated researchers to develop new ligands that both stabilize the catalyst complex and that are able to withstand an oxidative environment. Promising ligands in this respect are the tetraamido macrocycles represented by structure 10 shown in FIG. 1 which, when complexed with a transition metal such as iron, afford particularly good dye transfer inhibition capabilities.
An azide-based, four-step synthesis of the macrocycle is described by Collins et al. in J. Am. Chem. Soc., vol. 113, No. 22, page 8419 (1991). A problem with this synthesis is that it produces the tetraamido macrocycle in yields of only about 12% (starting from 1,2-phenylenediamine, as shown in the scheme at page 8422 of the article) and employs isolation techniques which cannot be adapted to large scale production. An alternative synthesis described in U.S. Pat. No. 5,853,428, issued also to Collins, employs a ring forming strategy that is the reverse of the earlier published synthesis. This later synthesis, described by Collins as now being his preferred synthesis, and in what is clearly an effort to overcome the shortcomings of the prior synthetic method, provides the macrocycle structure in two steps and in an improved overall yield of about 18% (starting from diethyl malonyl dichloride, as shown in the general scheme at col. 15 of the patent). However, the first step, a double coupling, is said to require 72-144 hours for completion, while the second step, a ring closure, requires 48-110 hours. Further, the use of large amounts of anhydrous pyridine as solvent are apparently required in both steps, which is commercially prohibitive. For commercial purposes, a much more efficient synthesis of the tetraamido macrocycle is required than is provided by either of the two heretofore known syntheses.
SUMMARY OF THE INVENTION
Briefly, the present invention comprises an improved, azide-based synthesis of tetraamido-macrocyclic ligands as exemplified by 5,6-Benzo-3,8,11,13-tetraoxo-2,2,9,9-tetramethyl-12,12-diethyl-1,4,7,10-tetraazacyclotridecane, H 4 in which the synthesis is made very amenable to commercial production and in which the overall yield of the macrocycle is remarkably increased from 12% (Collins et al.) to approximately 50-60% starting from 1,2-phenylenediamine. The improvement in methodology and yield results primarily from the modification of two steps in the synthesis compared to the method of the prior art as follows:
First, the 1,2-phenylenediamine starting material and 2-bromoisobutyryl bromide are reacted in tetrahydrofuran (THF) as opposed to the methylene chloride used in the prior art. The use of THF as solvent is an important improvement over the prior art synthesis because the intermediate reaction product, 1,2-bis(2-bromo-2-methylpropan-amido)benzene, is caused to precipitate directly out of the reaction mixture. The product then only requires filtration for its isolation, thus allowing a much more practical, and commercially very viable method of separation and purification to be used. The method of Collins et al., by contrast, requires that the reaction mixture be extracted multiple sequential times with aqueous hydrobromic acid and aqueous sodium carbonate, a process which is very impractical for large scale synthesis. Additionally, the use of THF as solvent results in a product of increased purity compared to the method reported by Collins et al. (in addition to a small improvement in yield). The increase in purity may further facilitate an increase in yields for the subsequent steps.
Second, in the final cyclization step, in which diethylmalonyl dichloride is reacted with 1,2-bis(2-amino-2-methylpropanamido)benzene to form the macrocycle, this reaction is carried out in (refluxing) ethyl acetate as the solvent as opposed to the methylene chloride used in the prior art. This again allows for a much simplified method of isolation of the macrocycle reaction product because pure product is caused to precipitate out as the reaction progresses. The method also reduces the required addition time of the reactants from many hours to thirty minutes or less. Moreover, the reaction conditions employing ethyl acetate remarkably increase the yield of the macrocycle from about 24%, as obtained for this one step in the prior art, to approximately 60-70% with the method of the present invention. It may be that this surprising increase in yield is effected at least in part by the driving force afforded by the precipitation of the product according to Le Chatelier's principle. It may also be that the formed product is less subject to unwanted side reactions once precipitated. It may further be that use of a higher temperature (i.e., refluxing ethyl acetate versus room temperature methylene chloride) in combination with ethyl acetate as solvent results in a more favorable reaction pathway. In any event, no other solvent investigated afforded this multifold increase in yield and ease of isolation of the product.
The combination of the two improved steps as described above results in the approximately four- to fivefold improvement in overall yield over the method of the prior art and provides, for the first time, a commercially viable synthesis of macrocyclic ligands as denoted by structure 10 in FIG. 1.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a flowchart illustrating the improved synthesis of the tetraamido macrocycle and its precursors according to the present invention.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 illustrates a reaction sequence using industrial-compatible isolation processes for preparing the tetraamido macrocycle 10 in higher yields than was previously possible on any scale. In the preferred reaction sequence, 1,2-phenylenediamine (phenylenediamine 12) and triethylamine are dissolved in anhydrous THF. 2-Bromoisobutyryl bromide (14) (R 1 =R 2 =methyl) is dissolved separately in THF and added dropwise to a solution of the phenylenediamine 12 at room temperature. After addition is complete, the mixture is stirred at room temperature overnight. Preferably, the mixture should be stirred for at least six hours. The mixture is then filtered to remove the crude product, 1,2-bis(2-bromo-2-methylpropanamido)benzene (dibromide 16) plus triethylamine hydrobromide. The filtered material is washed with an aqueous solution (preferably pure water) to remove the triethylamine hydrobromide from the crude dibromide 16. If further purification is desired, crude dibromide 16 can be recrystallized from ethanol to give the purified dibromide 16 in 95% yield. The isolation and purification techniques are well-suited for the large scale production of dibromide 16 in order to prepare macrocycle 10 in commercially relevant amounts. The use of THE as solvent, from which the dibromide 16 precipitates in a substantially pure form (after simple washing), allows filtration to be used for isolation, which is commercially very favored. Also, the THF can be distilled and recycled. As noted previously, the relatively pure condition of the product also likely enhances the yields of the remaining steps.
In the next step of the improved reaction sequence, the dibromide 16 from the previous step is dissolved in hot ethanol and brought to reflux. An aqueous solution of sodium azide is then added dropwise to the refluxing ethanol solution. The reaction is allowed to proceed at reflux for at least six hours, and preferably for 16 hours, and is then cooled to room temperature. The progress of this reaction is easily monitored, e.g., by thin layer chromatography. The solution is reduced in volume by about 80% by evaporation (e.g., on a rotary evaporator) and additional water is added to help precipitate the product, 1,2-bis(2-azido-2-methylpropanamido)benzene (diazide 18). The mixture is cooled and filtered to isolate diazide 18 as a water-wet solid, which is then washed well with water to remove any remaining sodium azide. This very industry favorable procedure for isolating the azido-intermediate by forced precipitation with water and filtration results in a very pure product and eliminates the need to perform the methylene chloride extractions reported in the procedure of Collins et al. In addition, the method of precipitating the diazide 18 with water also contributes to the increase in yield.
Wet diazide 18 is then dissolved in ethanol and hydrogenated using palladium on charcoal as the catalyst. The reaction is monitored by IR spectroscopy to verify complete reduction of the azido groups. After hydrogenation is complete, the catalyst is filtered off and the filtrate is dried on a rotary evaporator and under high vacuum to give 1,2-bis(2-amino-2-methylpropanamido)benzene (diamine 20) in 100% crude yield (95% purity by NMR=95% yield) from dibromide 16. This product may be used as is, or may be purified by recrystallization from isopropyl alcohol to obtain an analytical sample. In contrast, Collins et al. report a 57% yield for the comparable sequence of the two steps of azide formation and hydrogenation for their synthesis. As indicated earlier, the substantial increase in yield for this two step sequence may be due to the relatively high purity of the dibromide 16 used, which is a direct result of the use of THF as a precipitate-forcing solvent during formation of the dibromide 16. It will be apparent to those with ordinary skill in the art that methods other than hydrogenation with a platinum group metal, e.g., reduction with ammonium sulfide, might be employed for reduction of the azido groups.
Diamine 20 prepared in the previous step is dissolved in an organic solvent which is preferably a mixture of methylene chloride and ethyl acetate. The minimum amount of methylene chloride is used to maintain the diamine 20 in solution. Diethylmalonyl dichloride (dichloride 22) (R 3 =R 4 =ethyl) is dissolved separately in ethyl acetate. Both solutions are pumped simultaneously into a large reaction vessel containing refluxing ethyl acetate and triethylamine (2-3 molar equivalents). The triethylamine acts to scavenge the hydrogen chloride generated in the reaction. Other tertiary amino hydrogen chloride scavengers can be substituted for the triethylamine.
The addition of the two solutions into the reaction vessel is done over a time period of about 20-30 minutes. After the addition is complete, the reaction mixture is refluxed for another eight hours and then reduced in volume by distilling off some of the solvent. The reaction is allowed to cool and the product 5,6-benzo-3,8,11,13-tetraoxo-2,2,9,9-tetramethyl-12,12-diethyl-1,4,7,10-tetraazacyclotridecane, H 4 , macrocycle 10, and triethylamine hydrochloride are filtered and washed with a little ethyl acetate. The solid collected by filtration is washed again with water to remove the triethylamine hydrochloride and the remaining solid is dried in a vacuum oven to give the macrocycle 10 in very good purity and in 60-70% yield from diamine 20, versus a yield of 24% obtained by Collins et al.
In addition to the superior yield, the methodology used by the present invention for synthesis of the macrocycle 10 from diamine 20 is also much simpler to perform than that described by Collins et al. In the method of Collins et al., diamine 20 and dichloride 22 are added in four separate portions at three hour intervals and the resulting mixture is then stirred for 12 hours. The reaction solution must then be extracted repeatedly with aqueous solutions of HBr and Na 2 CO 3 and the final product must be purified by column chromatography in which portions of the eluted column are "sliced" and the sliced portions extracted, a process which is commercially highly unsuitable. The cumbersome process and poor yield of Collins et al. makes the preparation of commercially useful quantities of the macrocycle 10 very burdensome. In contrast, by the use of ethyl acetate as solvent and with the methodology described, the improved synthesis of the present invention provides that the addition of reactants is completed in twenty to thirty minutes, that the product macrocycle 10 is formed in good yield, and that the macrocycle 10 is caused to precipitate out of solution, thereby allowing its collection by industry favored filtration. Further, the ethyl acetate can be distilled and recycled.
The overall yield of macrocycle 10 starting from phenylenediamine 12 is about 50-60%, which is 4-5 times better than the overall yield of 12% obtained using the synthesis described by Collins et al. Also, the isolation and purification methods of the present invention allow practical production of commercial quantities of the macrocycle 10 for the first time.
It will be apparent to those with ordinary skill in the art that the synthesis which has been described can easily be adapted for the preparation of tetraamido macrocyclic ligands having substituents other than that of the exemplified macrocycle 10. For example, reacting in the first step of the synthesis a 1,2-phenylenediamine having substituents at any or all of the 3-, 4-, 5- and 6-positions of the phenyl ring with a bromoacid bromide (or compound with equivalent acylating and leaving groups) having R 1 and/or R 2 other than dimethyl can yield, after azide treatment and reduction, any number of what can generically be referred to as 1,2-bis(2-aminoalkanamido)benzenes. Likewise, a malonyl dihalide can be used in the last step in which R 3 and/or R 4 are other than diethyl. Thus, and referring to FIG. 1 one last time, R 1 , R 2 , R 3 and R 4 may be any of a wide variety of different substituents such as hydrogen, alkyl (including short and long chains), alkenyl, aryl (including benzyl), halo, etc., and the phenyl ring can be substituted with any of a number of substituents such as nitro, methoxy, halo, etc., as are all well known in the art, in order to make a number of differently substituted macrocycles 10.
Therefore, although the present invention has been described in terms of a presently preferred embodiment, it is to be understood that such disclosure is not to be interpreted as limiting. Various alterations and modifications in addition to those just described will no doubt become apparent to those skilled in the art after having read the above disclosure. Accordingly, it is intended that the appended claims be interpreted as covering all alterations and modifications as fall within the true spirit and scope of the invention.
The following three examples illustrate the preferred methods for preparing compounds 16, 20 and 10 according to the present invention:
EXAMPLE 1
Preparation of 1,2-Bis(2-bromo-2-methylpropanamido)benzene (16)
To a large Morton flask is added solid phenylenediamine (27 grams, 0.25 moles), THF (250 mL), and triethylamine (78 mL). To an addition flask is added 2-bromoisobutyryl bromide (70 mL, 0.57 moles) and THF (55 mL). The acid bromide solution is then added dropwise to the phenylenediamine solution over a period of about 2 hours. The resulting mixture is stirred overnight at room temperature. The resulting solid suspension is filtered and washed with THF. The collected solid is washed with water to remove any triethylamine salts and the remaining solid is dried in a vacuum oven to give 107 grams (107% yield) of "semi-crude" product. This material is recrystallized from ethanol to give 94 grams (94% yield) of essentially product, as determined by 13 C-NMR spectroscopy.
EXAMPLE 2
Preparation of 1,2-Bis(2-amino-2-methylpropanamido)benzene (20)
To a large round-bottom flask is placed 1,2-Bis(2-bromo-2-methylpropanamido)benzene (92.9 grams, 0.228 moles). Absolute ethanol (1.2 L) is added and the resulting solution is heated under reflux. A solution of sodium azide (33.9 grams, 0.521 moles) in water (100 mL) is added dropwise via an addition funnel and the resulting homogeneous solution is refluxed overnight. The reaction mixture is cooled to room temperature and reduced in volume about 80% on a rotary evaporator. Cold water is added to the reaction mixture and, upon further stirring, crude 1,2-bis(2-azido-2-methylpropanamido)benzene precipitates as a white solid. The crude diazide is isolated as the water-wet solid by filtration and washing with water. The diazide is then dissolved in warm ethanol (800 mL) and hydrogenated using 5% palladium-on-carbon catalyst until the azido peak is no longer detected by IR. The resulting solution is filtered to remove the catalyst and evaporated to dryness on a rotary evaporator to yield the desired product as a pale-yellow solid (63.8 grams, 100% yield). The product is pure enough to be used as-is, or can be recrystallized from isopropyl alcohol to obtain an analytical sample.
EXAMPLE 3
Preparation of 5,6-Benzo-3,8,11,13-tetraoxo-2,2,9,9-tetramethyl-12,12-diethyl-1,4.7,10-tetraazacyclotridecane, H 1 (10)
A 1 L three-neck round-bottom flask was equipped with a reflux condenser and two 250 mL addition funnels. 1,2-Bis(2-amino-2-methylpropanamido)benzene (10 g, 35.9 mmol) was dissolved in a methylene chloride/ethyl acetate solution (5:1, 180 mL) and transferred into one of the addition funnels. Diethylmalonyl dichloride (6.8 mL, 39.5 mmol) was dissolved in ethyl acetate (180 mL) and transferred to the other addition funnel. A stirring solution of ethyl acetate (180 mL) and triethylamine (11 mL, 79 mmol) was brought to reflux. Over a 20 minute period, the solutions in the two addition funnels were added simultaneously to the refluxing reaction, resulting in a cloudy white, heterogeneous mixture. After the additions were complete, the reaction was allowed to reflux an additional 8 hours. The solvents were then concentrated in vacuo and the remaining white solid was transferred to a vacuum filter. The crude solid was washed with ethyl acetate (15 mL) and water (50 mL). The resulting white solid was dried in a vacuum oven (10.2 g, 71%) and was pure by NMR analysis. | An improved synthesis for preparing a tetraamido-macrocyclic ligand, such as 5,6-Benzo-3,8,11,13-tetraoxo-2,2,9,9-tetramethyl-12,12-diethyl-1,4,7,10-tetraazacyclotridecane, H 4 , in greatly improved yield and in a commercially viable manner, comprising the steps of dissolving a quantity of a 1,2-bis(2-aminoalkanamido)benzene in a solution comprised of ethyl acetate and methylene chloride to yield a first reaction solution; dissolving a quantity of a malonyl dihalide in an ethyl acetate solution to yield a second reaction solution; adding the first reaction solution and the second reaction solution to a reaction vessel containing a third reaction solution comprised of refluxing ethyl acetate solution and an acid scavenger to form a reaction mixture; and isolating a solid product comprised of the tetraamido-macrocycle directly from the reaction mixture by filtration. | 2 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a nonwoven fabric containing a blend of hard and elastic staple fibers. In particular the invention concerns an improved process for making such a fabric in the form of a heat-treated, spunlaced structure which has improved physical and aesthetic characteristics.
2. Description of the Prior Art
Nonwoven fabrics made by hydraulic entanglement techniques are well known in the art, as for example, from U.S. Pat. Nos. 3,485,706 (Evans), 3,493,462 (Bunting et al.), 3,494,821 (Evans) and 3,560,326 (Bunting et al.). These patents disclose the impingement of fine columnar jets of liquid onto a fibrous batt supported on a foraminous member. This treatment entangles the fibers and converts the batt into a strong nonwoven fabric. Adhesive binders or self-bonding fibers are not necessary to hold the fibers together. Such fabrics have been referred to in commercial use, as well as in the technical literature, as spunlaced fabrics.
Fibers suitable for use in the starting batts of these spunlaced fabrics can be of one or more types and compositions. A wide range of fiber lengths is useful, from very short to substantially continuous. The resultant hydraulically entangled fabrics can be nonpatterned or have a repeating pattern of entangled fiber regions and interconnecting fiber regions, with or without a repeating pattern of apertures. It has also been suggested that by combining fibers of different compositions, melting or softening points, deniers, lengths or cross-sections, tactile aesthetics and physical properties of the fabric can be altered.
Many useful spunlaced fabrics have been prepared by the above-described hydraulic entanglement techniques. Numerous blends of different types of fibers have been found suitable for making a wide variety of spunlaced fabrics. Such fabrics have found application in a wide variety of uses and products. However, improvements in the stretch, resilience, crease resistance and other aesthetic characteristics of these fabrics would greatly enhance their utility and versatility. For example, strong, stretchable and resilient nonwoven fabrics are desired as substrates for use in vinyl-coated upholstery mterial. Nonwovens with such improved characteristics also would improve their utility in nonwoven industrial garments and increase their life in limited wear garments. The surface characteristics as well as the stretch, resilience and strength characteristics of spunlaced fabrics are of great importance to synthetic leather manufacturers and improvements in several of these characteristics would improve the usefulness of the substrate, as for example, in the manufacture of synthetic leather gloves, shoe uppers, and bags.
U.S. Pat. No. 3,485,706, Example 56, item "e," illustrates the fabrication of a bulky, puckered, spunlaced fabric having high elasticity in one direction. The structure is made up of two layers of polyester staple fibers, between which is a warp of spandex yarns of 70-denier, coalesced multifilaments. During the hydraulic entanglement step of the fabrication, the spandex yarns are prestretched 200%. The patent further suggests that any elastic fibers and/or yarns may be used in a tensioned warp or cross warp and that any fiber may be used in the surface layers to obtain a warp-reinforced spunlaced nonwoven fabric. Although such structures are technically feasible, the introduction of pretensioned warps into the hydraulic entanglement process results in technical complications and additional costs. Furthermore, well known spandex filaments or yarns which might be used in such fabrics generally are of high denier and lead to irregularities or "show through" of the pretensioned warps in the final product.
U.S. Pat. No. 3,007,227 (Moler) suggests that improved yarns, fabrics and other textile materials can be made with blends of intermingled fibers of staple length comprised of a major portion by weight of hard inelastic staple fibers and a minor portion of essentially straight elastomeric staple fibers. The patent discloses nonwoven fabrics can be made from such blends in the form of carded webs, Rando-Webber batts and mechanically needled felts. A felt made by mechanically needling a 75/25 blend of rabbit fur and synthetic elastomeric fibers is exemplified in Example VIII, wherein the elastic fiber is reported to increase the hardness and compactness of the felt, as well as its resistance to delamination, in comparison to a felt made of 100% rabbit fur.
The purpose of the present invention is to provide an improved process for preparing nonwoven fabrics containing elastic fibers and to provide an improved spunlaced nonwoven fabric thereby.
SUMMARY OF THE INVENTION
The present invention provides an improved process for making a nonwoven fabric. The process is of the general type wherein a batt composed of at least two types of staple fibers is subjected to a hydraulic entanglement treatment to form a spunlaced nonwoven fabric. For the purpose of imparting greater stretch and resilience to the fabric, the process improvement comprises forming the batt of hard fibers and potentially elastic elastomeric fibers and after the hydraulic entanglement treatment, heat-treating the thusly produced fabric to develop elastic characteristics in the elastomeric fibers. The preferred polymer for the elastomeric fibers is poly(butylene terephthalate)-co-poly-(tetramethyleneoxy)terephthalate.
The present invention also includes novel spunlaced nonwoven fabrics made by the above-described process.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
In accordance with this invention, the process requires the basic steps of forming a batt of blended staple fibers, hydraulically entangling the batt fibers to form a spunlaced fabric and heat-treating and spunlaced fabric. Although each of these basic steps is known in the art, the use of these steps with the particular blends of staple fibers required in the present process, is novel and leads to unexpectedly large improvements in various physical and aesthetic characteristics of the final product.
In the first step of the process of the invention, a batt is formed from at least two types of staple fibers; namely, hard fibers and elastomeric fibers that are "potentially elastic." The fibers, which are substantially uniformly intermixed in the batt, may have been blended by conventional methods prior to batt formation or may have been blended in the batt-forming step itself.
The hard fiber may be of any staple length or denier suitable for processing on conventional batt-making equipment, such as cards, Rando-Webbers, or air-laydown equipment such as that disclosed in U.S. Pat. No. 3,797,074 (Zafiroglu). The hard fibers may be of any synthetic fiber-forming material, such as polyesters, polyamides, acrylic polymers and copolymers, vinyl polymers, cellulose derivatives, glass, and the like, as well as any natural fiber such as cotton, wool, silk, paper, and the like, or a blend of two or more hard fibers. These hard fibers generally have low stretch characteristics as compared to the stretch characteristics of the elastic fibers described hereinafter.
The term "elastic" as used herein has the meaning usually given to that term in the art and is intended herein to describe a fiber that can elongate at least 100% before breaking. When elastic characteristics are developed in the heat-treatment step, the elastomeric fibers suitable for use in the present invention have break elongations of at least 100% and preferably greater than 150%, but usually less than 500%. Generally, these elastic fibers have a modulus of less than about 1 gram per denier and preferably less than about 1/2 gram per denier. This is in contrast to the hard fibers which generally have a modulus in the range of about 18 to 85 grams per denier and usually elongate no more than about 20 to 40% before breaking.
The term "potentially elastic" refers to the elastomeric fibers in the blend, which have the ability to be handled like hard fibers on conventional batt-making equipment but are capable of exhibiting elastic characteristics upon being subjected to a suitable heat treatment.
The potentially elastic fibers utilized in the staple fiber blends of the present invention are generally made of synthetic elastomeric polymer which has been extruded into filaments, drawn and cut to form staple fibers having a denier in the range of about 1 to about 30 and a staple length of about 1/2 to about 6 inches. The potentially elastic fibers of the present invention may be selected from several classes of elastomeric polymer compositions, among which are the classes described in column 6, line 70 through column 7, line 56 of U.S. Pat. No. 3,007,227, which portion of text is incorporated herein by reference. A simple test for determining which of such polymers from potentially elastic elastomeric fibers is to spin a candidate polymer into filaments, draw the filaments (e.g., at a draw ratio of at least 2:1), and then measure the tenacity, elongation and modulus before and after a relaxed heat treatment (e.g., of 3 minutes at 150° C.). Comparison of the before and after treatment properties immediately reveals which polymers are suitable for making the elastomeric fibers required by the present invention.
A class of elastomeric compositions which has shown particular utility in the present invention is the polyetheresters and more specifically, poly(butylene terephthalate)-co-poly(tetramethyleneoxy)terephthalates, such as those disclosed in U.S. Pat. Nos. 3,651,014, 3,766,143 and 3,763,109 (Witsiepe). In these polymers, the poly(butylene terephthalate) units comprise the hard segments of the polymer chain and poly(tetramethyleneoxy)terephthalate comprises the soft segments. Generally, for use in the present invention, these polymers contain by weight 15 to 60% of soft segments and 85-40% of hard segments. The preferred amount of soft segment is usually in the range of 20-55% by weight and the most preferred amount is in the range of 45-55%. It should be noted that within these polymers, the segments of poly(tetramethyleneoxy)terephthalate are usually derived from a corresponding glycol which generally has a number average molecular weight in the range of 600 to 3000, preferably in the range of 1500 to 2500, and most preferably in the range of 1800 to 2200.
In the following table, physical properties are listed for two potentially elastic elastomeric fibers suitable for use in the present invention. The properties are reported for these fibers before and after a 180° C., 3-minute, relaxed heat treatment. The fibers were made by melt-extruding poly(butyleneterephthalate)-co-poly(tetramethyleneoxy)terephthalate into filaments and then drawing the the filaments at a draw ratio of 2.2:1, as described in greater detail in the Example below. The polymers used were Hytrel® polyester elastomers manufactured by E. I. du Pont de Nemours and Company of Wilmington, Del. Note the large differences in tenacity, elongation and modulus that result from the heat treatment.
TABLE______________________________________Polymer A B______________________________________Soft-to-Hard Segment 41/59 52/48Weight RatioSoft segment molecular 1000 2000weightTex per filament 0.32 0.27Melting point, °C. 208 213______________________________________Heat Treated No Yes No Yes______________________________________Tenacity, dN/tex 3.0 1.5 1.9 1.5Elongation, % 45 157 104 245Modulus, dN/tex 3.0 1.0 1.1 0.6______________________________________
It should be noted that the melt-spun, potentially elastic, elastomeric filaments are usually drawn at a draw ratio of at least 2:1 to provide drawn filaments having a tenacity of at least about 1 gpd (0.9 dN/tex) and an elongation at break of less than about 125%, preferably less than 100%, so that the fibers can be handled readily on conventional batt-forming equipment.
Generally, the staple fiber blends used in the process of the present invention comprise by weight of the total blend, no less than 5% and no more than 40% of elastomeric fibers. Usually, the elastomeric fibers make up less than 30% of the blend and preferably amount to between 10 and 25%. The fraction of elastomeric fibers selected for the blend depends on the amount of elastic character desired in the final product and the elastic properties that can be developed by heat treatment of the potentially elastomeric fibers. The temperture of the heat treatment also affects the elastic properties that can be developed. The following tabulation shows the effect of the temperature of a 3-minute, relaxed heat treatment on the break elongation developed in drawn filaments of the Hytrel® polyester elastomer that was identified as "B" above.
______________________________________Temperature Elongation°C. %______________________________________ 75 170100 200150 220180 245200 380______________________________________
After the fiber batt has been formed, the batt is given a hydraulic entanglement treatment in accordance with the general procedures disclosed in U.S. Pat. Nos. 3,485,706, 3,493,462, 3,494,821, 3,560,326 and more recently 4,069,563. The batt is treated while supported on a foraminous member. Generally, the support will be in the form of a woven wire screen having a mesh of 60 (i.e., 23.6 wires/cm) or less in at least one direction and an open area of at least 20%. Alternatively, an apertured plate having a corresponding number of openings and open area can be used.
The supported batt is treated by fine, columnar streams of water, preferably supplied at a gauge pressure of at least 200 psi (1379 kPa) from a row or rows of small-diameter (e.g., 0.003 to 0.007 inch [0.076-0.178 mm]) orifices evenly spaced at 10 to 60 per inch (3.9 to 23.6/cm) in each row. The fine columnar streams supply an energy flux at the web of at least 23,000 ft-poundals/in 2 sec (9000 Joules/cm 2 min) to provide a total energy of impingement of at least 0.1 Hp-hr/lb (0.59×10 6 J/kg) of fabric. Usually pressures of greater than 2000 psi (13,790 kPa) are not necessary.
The weight of the web is selected with regard to the use intended for the fabric. Generally, the unit weight of the spunlaced fabric is in the range of 0.5 to 10 oz/yd 2 (17 to 340 g/m 2 ).
After the hydraulic treatment has formed the spunlaced fabric, the fabric is heat-treated to develop the elastic properties. It is preferred that the fabric be heat-treated in a relaxed condition. Any conventional heating device, oven, tenter, or the like, can be used for the treatment. The temperature of the heat treatment usually depends on the particular fibers in the blend. Usually the heat treatment is carried out at a temperature in the range of 100° to 200° C., for a time sufficient to develop the elastic characteristics of the potentially elastic elastomeric fibers. A preferred treatment consists of heating the fabric to a temperature of about 180° C. When the heat treatment is carried out with the fabric in a relaxed condition, significant shrinking and bulking of the fabric can occur. In addition, as a result of the above-described process, the final spunlaced and heat-treated nonwoven fabric exhibits physical and aesthetic characteristics that are suprisingly superior to those of a similarly hydraulically entangled batt that did not include the elastic fibers. In particular, the effects on the elongation, resilience and resistance to disentanglement of the fabric of the invention appear to be far in excess of and disproportionate to the small fraction of elastic fiber contained in the fabric.
The present invention also includes novel fabrics prepared by the process of the present invention. In particular, the products of the present invention comprise spunlaced fabrics that contain blends of at least two types of staple fibers; one type being conventional hard staple fibers and the other type being elastic staple fibers. Generally, the elastic staple fibers comprise more than 5% and less than 40% by weight of all the fibers, and preferably 10 to 25%. It is also preferred that the elastic staple fibers of the spunlaced fabric be of a melt-spun and drawn polymer of poly(butylene terephthalate)-co-poly-(tetramethyleneoxy)terephthalate.
The following test procedures provide data on various characteristics of the fibers used and the nonwoven fabrics produced in the practice of the present invention. Unless stated otherwise, these tests were used for obtaining the values reported herein.
Fiber tensile, elongation and modulus are measured by ASTM Method D-2653-72.
Disentanglement resistance of fabric is measured in cycles by the Alternate Extension Test (AET) described by M. M. Johns & L. A. Auspos, "The Measurement of the Resistance to Disentanglement of Spunlaced Fabrics," Symposium Papers, Technical Symposium, Nonwoven Technology--Its Impact on the 80's, INDA, New Orleans, La., 158-174 (March 1979).
Grab tensile strength of the fabric is reported for 1-inch (2.54-cm) wide strips of fabric. Machine direction (MD) and crossmachine direction (XD) measurements are made with an Instron machine by ASTM Method D-1682-64 with a clamping system having a 1×3 inch (2.54×7.62 cm) back face with the 2.54 cm dimension in the vertical or pulling direction) and a 1.5×1 inch (3.81×2.54 cm) front face (with the 3.81 cm dimension in the vertical or pulling direction) to provide a clamping area of 2.54×2.54 cm. A 4×6 inch (10.16×15.24 cm) sample is tested with its long direction in the pulling direction and mounting between 2 sets of clamps at a 3-inch (7.62 cm) gauge length (i.e., length of sample between clamped areas). The average of the MD and XD values are reported. Break elongation values are measured at the same time and reported in the same manner. The same size of samples and the same equipment can be used to measure the recovery properties of the fabrics.
Bending rigidity, which can be used as an indication of the liveliness or resilience of a fabric (i.e., the ability of a fabric to return to its original state after removal of a deforming force) can be measured as described by Sueo Kawabata, "The Standardization and Analysis of Hand Evaluation," 2nd Ed., The Textile Machinery Society of Japan, Osaka, Japan, 30-31 (1980).
EXAMPLE
A batch of poly(butylene terephthalate)-co-poly(tetramethyleneoxy)terephthalate polymer flake (Hytrel® 5664 polyester elastomer) was dried at 100° C. for 6 hours in a forced air oven and then fed to a single-screw melt-extruder which had three successive heating zones maintained at 192°, 235° and 245° C., respectively. The polymer was extruded through sixty-eight 0.015-inch (0.038-cm) diameter orifices having a 5:1 length-to-diameter ratio located in a spinneret maintained at 240° C. A screw pressure of 750 psi (517 kPa) and a total flow of 20.7 grams per minute was maintained. The resultant filaments were quenched by air at room temperature and a magnesium-stearate-in-silicone-oil textile finish was applied to the filaments. The filaments were withdrawn by a feed roll operating at 1000 meters per minute, then drawn at a draw ratio of 2.2:1 with a draw roll operating at 2200 meters/min and then wound up at 1900 meters/min. Between the draw and final windup rolls, the filaments were permitted to relax. Drawing and relaxation were performed at room temperature.
The 68 filaments formed a 102 denier (11.3 tex) yarn which exhibited a tenacity of 2.2 grams per denier (1.9 dN/tex), an elongation of 108% and a modulus of 1.6 gpd (1.4 dN/tex) when tested on an Instron tester at a strain rate of 250% per minute. These filaments were to form the potentially elastic, elastomeric fiber portion of the starting fiber blend. A sample of these filaments was heat-treated in a relaxed state for three minutes at 200° C. The heat-treated filaments had a tenacity of 0.8 gpd (0.7 dN/tex), an elongation of 380%, and a modulus of 0.5 gpd (0.4 dN/tex).
The as-spun and drawn filaments were creeled, formed into a 60,000 denier (6,670 tex) tow, cold stuffer-box crimped and cut with a Lummus cutter into staple fibers of 1.5-inch (3.8-cm) length. These fibers were blended by hand with 3.0 dpf (0.33 tex per filament), 41/2 inch (11.4-cm) long polyester fibers of 4.2 gpd (3.7 dN/tex) tenacity and 41% break elongation. The blend contained 80% by weight polyester fibers and 20% polyester elastomer fibers. This blend was then formed into a 1.5-oz/yd 2 (50.9-g/m 2 ) batt on a Garnett card.
Three layers of Garnett batt were then hydraulically entangled. The batts were wet with water while being supported on a 72×62 mesh (28.3 wires/cm by 24.4 wires/cm) screen and then passed beneath a bank of orifices from which streams of water emerged in the form of columnar jets having a divergence angle of less than about one degree. The orifices, which were 0.005 inch (0.013 cm) in diameter, were arranged in two staggered rows perpendicular to the length of the batt and one inch (2.5 cm) above the surface of the batt. The orifices in each row were spaced 0.05 inch (0.13 cm) apart center to center and the rows were 0.04 inch (0.10 cm) apart. Seven passes, at a speed of 26 yards/min (24 m/min) were made beneath these orifices which operated at a water pressure of 600 psi (4,130 kPa) in the first pass, 1400 psi (9,650 kPa) in the second pass and at 2000 psi (13,780 kPa) in the last five passes. The resultant spunlaced fabric was dried at 66° C. The dry fabric weighed 3.6 oz/yd 2 (122 g/m 2 ).
The spunlaced fabric was then heat-treated under zero tension at 180° C. for 5 minutes and then heat-set on a frame at 210° C. for two minutes. The final weight of fabric was 4.8 oz/yd 2 (163 g/m 2 ). The fabric exhibited desirable strength, stretch, resilience and surface characteristics.
The heat-treated, heat-set spunlaced fabric was laminated to a 19-oz/yd 2 (644-g/m 2 ) vinyl film by means of a Plastisol® vinyl adhesive. A laboratory press, operating at a temperature of 165.5° C. and a pressure of 5 psi (35 kPa) for one minute, was used for the lamination. A control spunlaced fabric composed 100% of polyester staple fibers and weighing 5 oz/yd 2 (170 g/m 2 ) [Sontara® Type 062 manufactured by E. I. du Pont de Nemours and Company] was laminated in the same manner.
The thusly prepared laminated fabrics were tested for stretch and recovery. A three-inch (7.6-cm) wide strip of each coated fabric was subjected to a load of 27 pounds (12.3 kg) for 30 minutes; the load was then removed; and the fabric was maintained under no load for another 30 minutes. The length of the fabric was measured before loading, under load and 30 minutes after removal of the load. The following data were derived:
______________________________________ Sample of Control Invention Sample______________________________________Total Unit WeightOz/yd.sup.2 23.8 23.0(g/m.sup.2) (807) (780)Machine Direction Stretch, % 24 5.4% Recovery from Stretch 97.4 99.0______________________________________
The laminated fabric of the invention, with its 24% stretch, its greater-than-95% recovery and its excellent conformability, was judged to be well suited for vinyl-coated upholstery. In contrast, the lack of adequate stretch and conformability in the control sample made the control completely unsuited for use in such upholstery. | Novel hydraulically entangled spunlaced fabrics and an improved process for making such fabrics composed of at least two types of staple fibers are provided. Elastomeric staple fibers which behave as ordinary staple fibers until heat treated are included in the hydraulically entangled fabric. Upon heat treatment, the elastomeric fibers become elastic and impart improved stretch and resilience properties to the fabric. | 3 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention involves integrated optical circuits (“IOC”) formed of moldable materials, such as thermal plastic, and tools for making such IOCs.
2. Description of Related Art
An integrated optical circuit (IOC) is a collection of one or more miniature optical waveguides on a substrate that provides optically transmitting paths for connection between optical components. Typically, such optical components include lasers, optical amplifiers, optical modulators, and optical detectors. Usually IOCs are similar in size to electronic integrated circuits, with areas ranging between 1 and 625 square millimeters.
Some IOCs are formed by compression-molding a material that is optically transparent. The molded material may be a polymer, a thermoplastic, or another moldable plastic. As is typical in compression-molding, a molding die is shaped as a “negative copy” of the IOC. The molding die is pressed into the moldable material, and the die forms the moldable material into a “positive copy” of the IOC, a copy identical in shape to the desired waveguide.
Demand for IOCs is increasing due to increased usage of fiber optics and optical chips. Accordingly, methods and tools capable of making IOCs in efficient and cost effective manner are need.
SUMMARY OF THE INVENTION
The present invention provides tools and methods for economically making IOCs including one or more waveguides using conventional moldable materials.
One embodiment of a tool within the present invention includes a molding die. The molding die includes a substrate having a topographically patterned first surface. A conformal protective film is provided over said first surface. The film has an outer second surface that forms a negative copy of the IOC to be molded using the molding die.
In one method of making the molding die, a silicon or gallium arsenide wafer is provided. The wafer may be used to form a plurality of the molding dies simultaneously. The wafer is patterned to form the patterned first surface, which typically includes trenches and/or ridges. The patterning may be done using methods common to semiconductor manufacturing, such as plasma etching through a photoresist mask. The protective film may be any hard, durable material compatible with the material of the substrate. For example, the film may be metal, aluminum oxide, or diamond, among other possibilities. The film may be deposited on the wafer by plating or sputter deposition, among other possibilities. Finally, the wafer is cut into various pieces, with each piece comprising one of the molding dies or a strip of the molding dies. If desired, a backing plate may be attached to the substrate opposite the first surface to lend support to the substrate.
An alternative embodiment of a tool for molding such an IOC includes a roller having the shape of a cylinder with a curved outer surface. One or more of the novel molding dies described above (or one or more conventional molding dies) are applied to the curved outer surface of the roller. The molding dies may be bent so as to conform to the curved outer surface of the roller.
The present invention also includes methods of compression molding one or more IOCs. An exemplary method includes providing a molding die and a moldable first material. The molding die includes a substrate with a topographically patterned first surface, and a hard protective film over the first surface. The exposed outer surface of the film is the molding surface of the molding die. The first material is positioned on a holding substrate. One or both of the molding die and the first material are heated to a selected molding temperature. The molding surface of the molding die is pressed into the first material at a selected pressure, thereby molding a patterned IOC surface in the first material. The first material is then cured.
In one embodiment, a molded IOC surface includes a plurality of channels. The channels are filled with a second moldable material that is optically transmissive, thereby forming a waveguide. The first and second materials are cured simultaneously or in separate steps.
An alternative method within the invention for compression-molding an IOC includes providing a molding tool having one or more molding dies mounted on a roller. A tape of a moldable first material also is provided. The molding tool and/or the tape are heated. The tape is fed under the rolling molding tool, which presses its molding die(s) into the tape of the first material, thereby molding a patterned IOC surface. The tape is then cured, and individual IOCs are singulated from the tape using a saw or some other severing device.
Another method within the present invention for molding an IOC includes providing a mold having a cavity defined by an interior surface. A molding die is mounted on the interior surface of the cavity. The molding die includes a substrate with a topographically patterned first surface, and a hard protective film over the first surface. The exposed outer surface of the film is the molding surface of the molding die. A moldable first material is injected into the cavity so that the first material contacts and conforms to the molding surface of the die, thereby molding a patterned IOC surface. The first material is cured, and removed from the mold.
These and other aspects of the present invention may be better appreciated in view of the attached drawings and the following detailed description.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 depicts a cross-sectional side view of a molding die 1 with a patterned lsubstrate 10 and protective film 20 .
FIG. 2 depicts a cross-sectional side view of a molding die 2 with a patterned substrate 10 , protective film 20 , and curved molding surface 35 .
FIG. 3 depicts a cross-sectional side view of a molding die 3 with a patterned substrate 10 , protective film 20 , and curved molding surface 35 .
FIG. 4 a depicts a molding tool 4 including a roller 40 and multiple molding dies 44 applied to an outer surface 42 of roller 40 .
FIG. 4 b is a cross-sectional side view of molding tool 4 of FIG. 4 a.
FIG. 5 a depicts a molding tool 5 including a roller 40 and multiple molding dies 44 that are applied to and bent around outer surface 42 of roller 40 .
FIG. 5 b is a cross-sectional side view of molding tool 5 of FIG. 5 a.
FIG. 6 a is a flow chart of an exemplary method 50 of compression-molding an IOC.
FIG. 6 b is a cross-sectional side view of molding die 1 of FIG. 1 being used according to method 50 of FIG. 6 a.
FIG. 6 c is a cross-sectional side view of an alternative IOC that was molded according to method 50 of FIG. 6 a.
FIG. 6 d is a cross-sectional side view of a further alternative IOC that was molded according to method 50 of FIG. 6 a.
FIG. 7 depicts molding tool 5 of FIG. 5 a being used in accordance with an exemplary molding method 70 of compression-molding an IOC.
FIG. 8 is a cross-sectional side view of a molding die 44 being used according to an exemplary method 80 of injection-molding an IOC.
In the drawings, where the different embodiments have similar structures, the same reference numbers are usually used.
DETAILED DESCRIPTION
FIG. 1 depicts a cross-sectional side view of a molding die 1 in accordance with one embodiment of the present invention. Molding die 1 includes a substrate 10 that has a patterned first surface 12 and an opposite back surface 14 . A hard protective film 20 is superimposed over first surface 12 . Film 20 has a contact surface 25 that is applied over first surface 12 and an opposite, exposed second surface 30 .
Substrate 10 may be made of silicon, gallium arsenide, silicon nitride, or silicon carbide or any other material compatible with the very fine manufacturing techniques that are commonly used in the semiconductor industry, such as plasma etching, sputter etching, sputter deposition, and plating. For the sake of example, assume that substrate 10 is silicon unless otherwise specified.
During fabrication, molding die 1 typically will be is fabricated on a wafer, e.g., a silicon wafer, using conventional semiconductor manufacturing processes. Typically, a plurality of molding dies 1 will be made in a matrix form on a single wafer, similar to how integrated circuit chips are made on a wafer. Subsequently, the individual molding dies may be singulated from the wafer by a conventional wafer sawing method. Alternatively, the wafer may be sawn so that an array of molding dies are in a single, monolithic strip (e.g., a one by five array of molding dies).
Protective film 20 may be made of any hard and durable material that is compatible with being applied on a wafer of material of the types listed above, e.g., silicon, and is compatible with molding processes, such as are provided below. Exemplary materials include nickel, titanium, aluminum oxide, and diamond, among other possibilities.
First surface 12 of substrate 10 is topographically patterned to include one or more trenches, ridges or both, which are subsequently coated by film 20 . For example, in FIG. 1 , substrate 10 includes a plurality of film-coated trenches 16 . Each trench 16 has vertical sidewalls and a bottom. A film-coated ridge 18 is between two trenches 16 . Each ridge 18 has vertical sidewalls and a top. A trench 16 in molding die 1 may be used to mold a ridge in an optically transmissive material so as to form an optical waveguide of an IOC. Alternatively, a ridge 18 on molding die 1 may be used to mold a trench in a first material that may be filled in with a second material to form an optical waveguide of an IOC. Typically, the first material would have a higher index of refraction that the second material, as discussed below.
First surface 12 may be patterned by any fine patterning method compatible with the materials used for substrate 10 . For example, where substrate 10 is silicon or gallium arsenide, techniques such as plasma etching, chemical etching, or e-beam milling may be used, typically in conjunction with a photoresist mask or other type of mask, to pattern first surface 12 . Film 20 may be applied over first surface 12 by any method compatible with substrate 10 and the materials of film 20 . For example, where substrate 10 is silicon and film 20 is metal, such as nickel, then sputtering, electroplating, or electrodeless plating may be used to apply film 20 over first surface 12 of substrate 10 .
In an exemplary embodiment of the present invention, molding die 1 includes substrate 10 that is made of silicon and is 1-2 mm thick. First surface 12 is patterned by plasma etching to include a plurality of trenches 16 . Film 20 is nickel, is 0.4-0.8 mm thick, and is applied by electrodeless plating. A metal backing plate may applied to opposing second surface 14 of substrate 10 to lend support to substrate 10 .
When film 20 is applied over first surface 12 of substrate 10 , lower contact surface 25 of film 20 conforms to the shape of first surface 12 . However, the thickness of film 20 causes the shape of the opposing upper second surface 30 of film 20 to be slightly different from the shape of first surface 12 . For example, the thickness of film 20 on opposing sidewalls of a trench in first surface 12 causes the film-coated trench 16 to be narrower than the underlying trench in first surface 12 of substrate 10 . Applying film 20 over first surface 12 may also cause the shape of second surface 30 to differ from the shape etched into first surface 12 of substrate 10 . Accordingly, first surface 12 of substrate 10 is patterned so that, after film 20 is applied over first surface 12 , second surface 30 is a negative copy of the desired IOC, i.e., a surface that can be used to mold the IOC.
FIG. 2 depicts a cross-sectional side view of an alternative embodiment of a molding die within the present invention. Molding die 2 includes a substrate 10 , first surface 12 , and film 20 similar to those of molding die 1 of FIG. 1 . However, in molding die 2 , first surface 12 of substrate 10 is patterned such that the vertical sidewalls of the trenches include intermediate steps 17 between the top and the bottom of the trench. Accordingly, second surface 30 of film 20 will have a vertically curved surface 35 within trench 16 . During molding of the IOC, curved surface 35 will act to produce a molded optical waveguide with a matching curved outer surface.
FIG. 3 depicts a cross-sectional side view of a further alternative embodiment of a molding die 3 within the present invention. Molding die 3 of FIG. 3 is similar to molding die 2 of FIG. 2 , except that substrate 10 is patterned with steps 17 that extend further up the sidewall of the trench toward first surface 12 . Accordingly, second surface 30 forms curved surfaces 35 at both the top and the bottom of trench 16 with no sharp vertical corners. A ridge formed in a moldable material by curved surface 35 of FIG. 3 will have a matching curved surface.
The elimination of sharp vertical corners in molding dies 2 and 3 reduces the stress on the molding die during molding. Therefore, the durability of the molding die is increased and the tendency for the molding die to crack during molding is decreased over that of a similar molding die that has sharper vertical corners. The embodiment of FIG. 3 has fewer sharp corners than that of FIG. 2 .
FIG. 4 a depicts a molding tool 4 in accordance with another embodiment of the present invention. Molding tool 4 includes a roller 40 that is cylindrically shaped. Roller 40 may be made of any material, such as steel, that is durable and consistent with rolling and applying pressure to a moldable material. FIG. 4 b depicts a cross-sectional side view of molding tool 4 .
One or more molding dies 44 each having a topographically patterned surface 30 is applied to the curved outer surface 42 of roller 40 . Patterned surface 32 faces outwards from roller 40 . Dies 44 may be any of dies 1 , 2 , or 3 of FIGS. 1 , 2 or 3 . Alternatively, another die (e.g., a conventional die) may be used as die 44 . Typically, a plurality of molding dies 44 are applied fully around outer surface 42 of roller 40 , as depicted in FIG. 4 a . A narrow space may be allowed between the molding dies 44 . Molding dies 44 may be attached to outer surface 42 by any method compatible with the material of substrate 10 , such as soldering, brazing, or bonding with an epoxy or other adhesive.
FIG. 5 a depicts a further alternative embodiment of a molding tool 5 within the present invention. Roller 40 and outer surface 42 of molding tool 5 are similar to those of molding tool 4 of FIGS. 4 a , 4 b . However, in molding tool 5 , molding dies 44 are bent around the curvature of surface 42 as they are applied to surface 42 . FIG. 5 b depicts a cross-sectional side view of molding tool 5 . Molding dies 44 may be thinned to increase its flexibility for bending around the curvature of surface 42 . With such an embodiment, excess spacing between the dies 44 may be eliminated, and the molded IOCs may have a straighter alignment.
Molding die 44 may be thinned using any method compatible with the material of the die. For example, where die 44 is one of dies 1 , 2 or 3 of FIGS. 1 , 2 , and 3 , respectively, and substrate 10 is made from a silicon wafer, then substrate 10 may be thinned using conventional polishing or etching techniques. The amount of thinning done will typically be the amount necessary to obtain the flexibility necessary to allow substrate 10 to be bent around curved outer surface 42 of roller 40 .
For example, a conventional silicon wafer is 0.5 mm thick. After patterning, the unpatterned back surface 14 of the wafer may be polished to reduce the thickness of the wafer to 50 microns or less, which allows silicon substrate 10 to be flexibly bent around a roller 40 that has a radius of curvature of 10 mm. Subsequently, strips of molding dies 1 , 2 , or 3 may be sawed from the wafer, with each strip including a plurality of molding dies 1 , 2 , or 3 . The strips are then applied over outer surface 42 and attached thereto, so as to form a continuous ring of molding dies 1 , 2 , or 3 .
FIG. 6 a is a flow chart of an exemplary method 50 of compression-molding an IOC that includes at least one optical waveguide. The order of the steps may vary.
In step 52 , a molding die 44 is provided, such as molding dies 1 , 2 , and 3 of FIGS. 1 , 2 , or 3 respectively. As mentioned above, each of molding dies 1 , 2 , and 3 includes a substrate 10 , a patterned first surface 12 , a film 20 over first surface 12 , and an exposed second surface 30 of film 20 .
In step 54 , moldable first material 64 is positioned on a top surface of a holding substrate 62 , as depicted in FIG. 6 b . First material 64 may be any material suitable for compression molding, such as thermosetting polymer, thermoplastic, photopolymer, or polycarbonate.
In step 56 , first material 64 , and molding die 1 are heated to selected temperatures. In step 57 , second surface 30 of molding die 1 is pressed into first material 64 with a selected pressure. FIG. 6 b depicts second surface 30 of molding die 1 being pressed into first material 64 in accordance with step 57 of FIG. 5 . In one embodiment, first material 64 and molding die 1 are heated to a temperature that is near, but below, the glass transition temperature (Tg) of first material 64 . Typically, the viscosity of first material 64 is high enough to require considerable pressure to force first material 64 into the contours of molding die 1 .
In step 58 of FIG. 5 , molding die 1 is removed from first material 64 . In step 59 , first material 64 is cured according to methods specific to first material 64 , e.g., by exposing first material 64 to a change in temperature, exposing first material 64 to ultraviolet light, or simply waiting for the passage of a selected time period. For example, if first material 64 is a thermosetting polymer, curing may be accomplished by further increasing the temperature of first material 64 to a selected curing temperature (e.g., 150-170° C.) and waiting for a selected curing time (e.g., 5 to 60 minutes). As another example, if first material 64 is a thermoplastic, curing may be accomplished by reducing the temperature of first material 64 . As a further example, if first material 64 is a photopolymer, curing may be accomplished by exposing first material 64 to ultraviolet light to the gel point and then heating as above.
According to one embodiment of the present invention, first material 64 of FIG. 6 b is optically transparent and is molded to form at least one ridge-channel 66 in the IOC that is an optical waveguide. In this instance, a plurality of ridge channels 66 are formed, with each being a separate waveguide of the IOC. First material 64 also includes intervening areas 65 of the IOC where there is no ridge-channel 66 (e.g., between the ridge channels 66 ). In this embodiment, first material 64 is molded to be sufficiently thin in the intervening areas 65 (e.g. two microns thick) that optical signals traveling in a ridge-channel 66 are confined to the ridge-channel 66 and do not leak into intervening areas 65 or into other ridge-channels 66 .
Alternatively, as is shown in FIG. 6 c , first material 64 may include a plurality of layers of different materials, e.g., a topmost, exposed surface layer 63 and lower, optical confinement layer 67 . Optical confinement layer 67 is beneath surface layer 63 and has an optical index of refraction that is lower than that of surface layer 63 . In this embodiment, confinement layer 67 may be of any thickness as long as surface layer 63 is sufficiently thin in the intervening areas 65 (e.g. two microns thick) that an optical signal traveling in a ridge-channel 66 is confined to the ridge-channel 66 .
FIG. 6 d depicts a cross-sectional side view of an alternative IOC produced by an alternative method within the present invention. As above, first material 64 is compression molded to form one or more channels 68 . A moldable second material 69 is inserted in channels 68 so as to substantially fill channels 68 . Second material 69 is cured, forming an optical waveguide. In this embodiment, second material 69 must be optically transparent and must have an optical index of refraction that is higher than that of first material 64 . Neither an optical confinement layer 63 nor thin intervening areas 65 are required, as in FIGS. 6 b , 6 c . In FIG. 6 d , the topographical pattern of second surface 30 of dies 1 , 2 , or 3 is not a negative copy of the IOC but rather is a positive copy of the IOC.
FIG. 7 depicts a method 70 of using a roller to compression-mold an IOC in accordance with the present invention. Molding tool 5 of FIGS. 5 a , 5 b is provided and includes roller 40 and one or more molding dies 44 . Molding dies 44 have a topographically patterned surface 32 and are applied to roller 40 with patterned surface 32 facing outwards from roller 40 . Again, molding die 44 may be dies 1 , 2 , or 3 of FIGS. 1-3 , respectively, or some other type of molding die.
A tape 46 of optically transparent and moldable material is provided. Subsequently, tape 46 , roller 40 , and a backing-roller 48 are heated, as in method 50 of FIGS. 6 a , 6 b . As tape 46 is conveyed past roller 40 , roller 40 and backing-roller 48 cooperatively turn and apply pressure to tape 46 . This pressure forces top surface 30 of the molding dies 44 of roller 40 into tape 46 to mold the IOC. Roller 40 , backing-roller 48 , and tape 46 may be continually operated to form a continuous tape containing multiple replications of the IOC.
Tape 46 of FIG. 7 is subsequently cured, such as by heating tape 46 , cooling tape 46 , exposing tape 46 to ultraviolet light, or waiting for the passage of a selected time period, as in method 50 of FIGS. 6 a , 6 b . For example, if tape 46 is a thermosetting polymer, curing may be accomplished by further increasing the temperature of tape 46 to a selected curing temperature (e.g., 150-170° C.) and waiting for a selected curing time (e.g., 5-60 minutes). As another example, if tape 46 is a thermoplastic, curing may be accomplished by reducing the temperature of tape 46 . Tape 46 may be heated or cooled by passing tape 46 over additional rollers that are at selected temperatures, or by using heat lamps that shine on tape 46 . As a further example, if tape 46 is a photopolymer, curing may be accomplished by exposing tape 46 to ultraviolet light. After curing, individual IOCs on tape 46 may be singulated through methods common to high-precision cutting of polymers or plastics, such as sawing or scribing and breaking.
In an alternative method in accordance with the present invention, each molding die 44 of tool 5 of FIG. 7 may be used to form one or more channels 68 in tape 46 , similar to method 55 of FIG. 6 c . (Again, die 44 may be one of dies 1 , 2 , or 3 .) Subsequently, a moldable second material 69 is inserted so as to substantially fill each channel 68 , thereby forming an optical waveguide in each channel 68 . The material of tape 46 and the second material 69 may be cured in separate steps or simultaneously. In this instance, the topographical pattern of molding die 44 is not a negative copy of the IOC but rather is a positive copy of the IOC. In such an embodiment, tape 46 may or may not be optically transparent, as long as second material 69 is optically transparent and has an optical index of refraction that is higher than that of tape 46 .
FIG. 8 depicts an alternative method 80 of molding an IOC in accordance with the present invention. A mold having a top half 82 , a bottom half 83 , an interior cavity therebetween, an interior surface 84 , and an injection port 86 is provided. A molding die 44 (e.g., molding die 1 , 2 , or 3 of FIGS. 1 , 2 , and 3 ) with a topographically patterned surface 32 is provided. Molding die 44 is fixed to interior surface 84 of top half 82 , with patterned surface 32 facing toward the interior of the mold cavity. Molding die 44 is placed so that injection port 86 has clear access to the interior cavity. An optically transparent and moldable first material 88 is provided into the interior of cavity 82 through injection port 86 so that first material 88 contacts and conforms to the pattern of surface 32 . An injection molding technique will typically be used. Transfer molding may also be used. First material 88 is subsequently cured by methods common to injection molding or transfer molding. The mold is then opened and first material 88 is removed.
As an example of an alternative method in accordance with the present invention, injection-molding may be used as in method 80 of FIG. 8 to form at least one channel 68 in first material 88 , similar to that done in method 55 of FIG. 6 c . Subsequently, a moldable second material 69 is inserted so as to substantially fill each channel 68 and thereby forming optical waveguides. In this embodiment, the topographical pattern of molding die 44 is not a negative copy of the IOC but rather is a positive copy of the IOC. Tape 46 may or may not be optically transparent, as long as second material 69 is optically transparent and has an optical index of refraction that is higher than that of first material 88 . First material 88 and second material 69 may be cured separately or simultaneously.
The embodiments described above are merely examples of the present invention. Practitioners will recognize that variations of the embodiments herein are possible within the equitable scope of the appended claims. | Tools and methods for making molded an optical integrated circuit including one or more waveguides are disclosed. In one embodiment, a molding die is provided that includes a substrate that has a topographically patterned first surface. A conformal protective film is provided over the first surface of the substrate. The substrate may be formed of silicon or gallium arsenide, and may be patterned using conventional semiconductor patterning techniques, such as plasma etching. The protective film may be metal (e.g., nickel or titanium), diamond, or some other hard material. Typically, a plurality of such molding dies are formed from a wafer of the substrate material. The die is pressed into a moldable material, such as thermal plastic, to form the wave guide(s) of the optical integrated circuit. A plurality of the dies may be mounted around the curved surface of a heated roller, and a heated tape of the waveguide material may be fed under the roller in a mass production process. Alternatively, the die may be mounted in an injection molding cavity, and the IOC may be formed by an injection molding process. | 1 |
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The invention relates to a device for clamping a fluidic component, particularly a nozzle, particularly in the high pressure region. Of particular interest are holders for micro-engineered components, particularly micro-engineered nozzles which are to be produced by micro-engineering. Such nozzles are used for example in nebulizers for producing propellant-free medicinal aerosols used for inhalation.
[0003] The aim of the invention is to further improve the clamping of a fluidic component consisting of a wear-resistant, hard, and generally brittle material, and to increase the reliability of the holder.
[0004] 2. Brief Description of the Prior Art
[0005] Micro-engineered nozzles having for example a nozzle aperture of less than 10 μm are described for example in WO 94/07607 and WO 99/16530. The inhalable droplets produced thereby have a mean diameter of about 5 μm, when the pressure of the liquid to be nebulized is from 5 MPa (50 bar) to 40 MPa (400 bar). The nozzles may for example be made from thin sheets of silicon and glass. The external dimensions of the nozzles are in the millimeter range. A typical nozzle consists for example of a cuboid with sides measuring 1.1 mm, 1.5 mm and 2.0 mm, made up of two sheets. Nebulizers for producing propellant-free aerosols in which the device according to the invention for clamping a fluidic component can be used are known from WO 91/14468 or WO 97/12687.
[0006] The term fluidic component denotes a component which is exposed to a pressurized fluid, and the pressure is also present inside the component, for example in a nozzle bore. Such a component may be kept pressure-tight for example by pressing into a holder of hard material if the material of the component can withstand mechanical forces without collapsing or deforming to an unacceptable degree. At high pressures, seals of deformable material, e.g. copper, or hard material which can be pressed in with great force are used. In the case of components made of brittle material the known processes for pressure-tight clamping of the component require considerable effort and great care. It is impossible to predict with any reliability the service life of a fluidic component clamped in this way.
[0007] U.S. Pat. No. 3,997,111 describes a fluid jet cutting device with which a high-speed fluid jet is produced which is used for cutting, drilling or machining material. The nozzle body is cylindrical and consists e.g. of sapphire or corundum. The setting ring is pressed into an annular recess in the nozzle carrier and seals off the nozzle body against the nozzle carrier.
[0008] U.S. Pat. No. 4,313,570 describes a nozzle holder for a water jet cutting device wherein the nozzle body is surrounded by a ring of elastomeric material which is in turn mounted in a recess in the holder. The recess is in the form of a straight cylinder. The cross-section of the ring is rectangular. The outer surface of the recess and the outer and inner surfaces of the ring are arranged concentrically to the axis of the nozzle body and run parallel to one another and to the axis of the nozzle body.
[0009] WO 97/12683 discloses a device for clamping a fluidic component which is subjected to fluid pressure, which is suitable for components consisting of a wear-resistant, hard and hence generally brittle material, and which does not produce any excessively great local material tensions in the component. The fluidic component is arranged in a holder which makes contact with the fluidic component on its low pressure side. The fluidic component is surrounded by an elastomeric shaped part the outer contour of which is adapted to the inner contour of the holder and the inner contour of which is adapted to the outer contour of the fluidic component. The elastomeric component surrounds the entire circumference of the fluidic component. At least one free surface of the elastomeric component is exposed to the pressurized fluid. The holder may have a projection on the inside underneath which the elastomeric shaped part is pushed. It has proved difficult to generate internal tension in the elastomeric shaped part which is sufficiently great, even at low fluid pressures, and which is spatially roughly uniformly distributed in the elastomeric shaped part.
[0010] This known device has proved pressure-tight when subjected substantially constantly to moderate and high fluid pressures. When subjected to alternating fluid pressures fluctuating between a high peak value and a very low value, the known device is in need of improvement for long-term use.
[0011] The problem thus arises of providing a device for clamping a fluidic component which is reliably leak-tight even when subjected to alternating loading from a sharply fluctuating fluid pressure in long-term use. The components needed should be cheap to manufacture and should also be capable of being assembled with relative ease.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] FIG. 1 a is a cross-sectional, elevational view of a pot-shaped holder ( 1 ).
[0013] FIG. 1 b is a cross-sectional, elevational view of an elastomeric shaped part ( 4 ) and a cuboid, fluidic component ( 5 ).
[0014] FIG. 1 c is a cross-sectional, elevational view of a mating part ( 9 ) with a bore ( 10 ) and an annular projection ( 11 ).
[0015] FIG. 2 is an elevational view of the underside of the mating part ( 9 ).
[0016] FIGS. 3 a , 4 a , and 5 a show the elastomeric shaped part viewed perpendicularly.
[0017] FIGS. 3 b , 4 b , and 5 b , are cross-sections through the elastomeric shaped part.
[0018] FIG. 6 shows a cross section through the assembled holder which is mounted on a container for a fluid.
[0019] FIGS. 7 a , 7 b and 7 c show the holder according to the invention in cross-hatched cross-section.
[0020] FIGS. 8 a , 8 b , and 8 c show a prior-art embodiment.
SUMMARY OF THE INVENTION
[0021] This problem is solved according to the invention by a device for clamping a fluidic component which is subjected to alternating fluid pressure and which comprises a holder within which the fluidic component is arranged. The holder makes contact with the fluidic component at its low pressure end. The device comprises an elastomeric shaped part which surrounds the fluidic component over its entire circumference. The outer contour of the elastomeric shaped part is adapted to the inner contour of the holder and the inner contour of the elastomeric shaped part is adapted to the outer contour of the fluidic component. The elastomeric shaped part has at least one free surface which is exposed to the pressurised fluid. The holder is secured at the high pressure end to a mating part, and
before the assembly of the device the elastomeric shaped part is chamfered towards the fluidic component on its side facing the fluid pressure, and the mating part is provided with an annular projection the outer contour of which is adapted to the inner contour of the holder; after the assembly of the holder with the mating part the projection projects into the holder and deforms the elastomeric shaped part, as a result of which a uniformly distributed internal tension is generated in the elastomeric shaped part, and the volume of the projection on the mating part is adapted to the volume that is missing from the elastomeric shaped part in the region of the chamfer, and the elastomeric shaped part which is deformed and subjected to internal tension after the assembly of the holder with the mating part almost totally fills the space up to the mating part.
[0026] The elastomeric shaped part is chamfered into a recess at its high pressure end. The chamfer begins in the outer surface of the high pressure end of the elastomeric shaped part at a solid line which may be, for example, circular, elliptical, or rectangular. The chamfer may, for example, have a constant angle of inclination, or the angle of inclination may vary in the azimuthal direction. In the latter case, it is preferably smaller along the longer side of a cuboid, fluidic component than along the shorter side of the cuboid, fluidic component. The line of intersection of the chamfer with the recess in the elastomeric shaped part may extend at a constant level, or the line of intersection may be curved.
[0027] The projection on the mating part may preferably be annular and of constant width. The outer contour of the projection is preferably adapted to the inner contour of the holder. Moreover, the inner contour of the projection may be adapted to the outer contour of the fluidic component. The projection on the mating part may have a constant width and have a constant height on its circumference, or the projection may vary in width and/or height; it may, for example, be higher in the two areas located opposite the two longer sides of a cuboid, fluidic component than in the two areas located opposite the two shorter sides of a cuboid, fluidic component. In this way, the elastomeric shaped part may deform to different degrees in some areas when the holder and mating part are put together and influence the spatial distribution of the internal tension in the elastomeric shaped part. The internal tension in the elastomeric shaped part is produced substantially by the deformation of the elastomeric shaped part, not by its compression. The deformation of the elastomeric shaped part and the distribution of the tension in the elastomeric shaped part can be determined by the finite elements method (FEM).
[0028] The elastomeric shaped part is preferably constructed as an injection-molded part. The pre-elastomer is poured without bubbles into a mould that is adapted to the contours of the holder and the fluidic component. An elastomeric shaped part of this kind behaves somewhat like an incompressible fluid. It fits precisely into the holder and fluidic component. The elastomeric shaped part is only exposed to fluid pressure at the pressure end, not at the sides where it abuts on the holder and on the fluidic component. The elastomeric shaped part allows pressure compensation on the fluidic component. The elastomeric shaped part has no free surface towards the low pressure side. The elastomeric shaped part may consist, for example, of natural rubber or synthetic rubber, such as silicon rubber, polyurethane, ethene-propene rubber (EPDM), fluorine rubber (FKM) or nitrile-butadiene rubber (NBR) or of a corresponding rubber.
[0029] The fluidic component may consist of a wear-resistant, hard and hence generally brittle material (such as silicon, glass, ceramics, gemstone, e.g., sapphire, ruby, diamond) or of a ductile material with a wear-resistant hard surface (such as plastics, chemically metallized plastics, copper, hard chromium-plated copper, brass, aluminum, steel, steel with a hardened surface, wear-resistant surfaces produced by physical vapor deposition (PVD) or chemical vapor deposition (CVD), for example, titanium nitride (TiN) or polycrystalline diamond on metal and/or plastics. The fluidic component may be made in one piece or composed of a number of pieces, while the pieces may consist of different materials. The fluidic component may contain cavities, voids or channel structures. In the voids there may be microstructures which act as filters or anti-evaporation means, for example. The channels may be nozzle channels for an atomizer nozzle. An atomizer nozzle may contain one or more nozzle channels the axes of which may extend parallel to one another or be inclined relative to one another. If, for example, there are two nozzle channels the axes of which are located in one plane and which intersect outside the nozzle, the two fluid jets that emerge meet at the point of intersection of the axes and the fluid is atomized.
[0030] The holder may consist of virtually any desired material, preferably metal or plastics, and may be a body of revolution or a body of any other shape. The holder may, for example, be a pot-shaped body of revolution which contains a rotationally symmetrical recess, starting from its lid end, the axis of which coincides with the axis of the body of revolution. This recess may be cylindrical or in the shape of a truncated cone, the end of the truncated cone with the larger diameter being located at the lid end of the holder. The outer surface of the recess forms the inner contour of the holder. It may be produced as a molding, as a casting or by processing to remove material (e.g., by machining, etching, erosion, elision).
[0031] The mating part may consist of metal or plastics.
[0032] The holder which contains the elastomeric molding and the fluidic component is assembled with the mating part. The side of the elastomeric shaped part which contains the chamfer faces towards the mating part. The edge of the holder rests on the mating part. The fluidic component may be pushed into the elastomeric shaped part, preferably before the elastomeric shaped part is inserted in the recess in the holder. The holder may be attached to the mating part by screwing, gluing, welding, crimping, casting or press-fitting or snap-fitting onto the mating part. The holder may preferably be secured to the mating part by a union nut.
[0033] In a preferred embodiment the mating part is formed as a body of revolution in the area where it is connected to the holder. The fluid which is under high pressure is conducted to the holder through a channel in the mating part which is coaxial, for example. The fluid enters the channel structure in the fluidic component and leaves the fluidic component at the low pressure end thereof in the region of the base of the holder. The fluid pressure acts within the dead volume on the elastomeric shaped part.
[0034] The device according to the invention has the following advantages:
The tension within the elastomeric shaped part is spatially more uniformly distributed than the tension which may be produced in the known embodiment of the holder by an annular projection formed on the inside of the holder, underneath which the elastomeric shaped part is pushed during assembly. The tension within the elastomeric shaped part may be adjusted, not only by the material properties of the shaped part itself, but by the ratio of the volume of the projection on the mating part to the volume which is absent from the tensionless elastomeric shaped part as a result of the chamfer. The fluidic component is surrounded to its full height by the elastomeric shaped part which is under tension. The device according to the invention is pressuretight in long-term use at fluctuating pressures with a large difference between the maximum pressure (40 Mpa or more) and the minimum pressure (about 0.1 Mpa). The dead volume between the deformed elastomeric shaped part subjected to internal tension and the side of the mating part facing the holder can be kept small. It serves at the same time to equalise the tolerances when the holder is joined to the mating part. The controlled deformation of the elastomeric shaped part during the joining of the holder to the mating part prevents the elastomeric shaped part from swelling out through the opening in the fluidic component.
[0041] The device according to the invention for clamping a fluidic component is used, for example, in a miniaturized high pressure atomizer (e.g., according to WO 91/12687), in a needle-less injector (e.g., according to WO 01/64268) or in an applicator for opthalmologic, medicinal formulations (e.g., according to WO 03/002045). A medicinal fluid administered with a device of this kind may contain a pharmaceutical substance dissolved in a solvent. Suitable solvents include for example water, ethanol, or mixtures thereof. Examples of the pharmaceutical substances include berotec (fenoterol-hydrobromide, atrovent (ipratropium bromide), berodual (combination of fenoterol-hydrobromide and ipratropium bromide), salbutamol (or albuterol), 1-(3,5-dihydroxy-phenyl)-2-[[1-(4-hydroxy-benzyl)-ethyl]-amino]-ethanol-hydrobromide), combivent, oxivent (oxitropium-bromide), Ba 679 (tiotropium bromide), BEA 2180 (di-(2-thienyl)glycolic acid-tropenolester), flunisolide, budesonide and others. Examples may be found in WO 97/01329 or WO 98/27959.
DESCRIPTION OF THE INVENTION
[0042] The device according to the invention is explained more fully with reference to the Figures:
[0043] FIG. 1 a shows in cross-section and diagonal elevation a pot-shaped holder ( 1 ) provided with a recess ( 2 ). An opening ( 3 ) is provided in the base of the holder.
[0044] FIG. 1 b shows in cross-section and diagonal elevation an elastomeric shaped part ( 4 ) and a cuboid, fluidic component ( 5 ), which is made up of two parts and which has been inserted in the elastomeric shaped part. In the contact surface of the two parts a nozzle structure is provided which extends as far as the nozzle aperture ( 6 ). The top surface of the elastomeric shaped part ( 4 ) at the high pressure end stands in the annular region ( 7 ) perpendicular to the axis of the elastomeric shaped part. The chamfer ( 8 ) of the elastomeric shaped part begins on the top surface of the elastomeric shaped part and extends as far as the outer surface of the fluidic component.
[0045] FIG. 1 c shows in cross section and in diagonal elevation a mating part ( 9 ) with a bore ( 10 ) and an annular projection ( 11 ) on its side facing the elastomeric shaped part.
[0046] FIG. 2 shows another embodiment of the projection ( 11 ) on the mating part ( 21 ) in diagonal elevation. The projection ( 11 ) is higher in the two diametrically opposite regions ( 22 a , 22 b ) than in the two diametrically opposite regions ( 23 a , 23 b ). When the holder is joined to the mating part the higher regions ( 22 a , 22 b ) of the projection ( 11 ) deform the elastomeric shaped part more than the regions ( 23 a , 23 b ).
[0047] FIGS. 3 a , 4 a , and 5 a show the elastomeric shaped part viewed perpendicularly. FIGS. 3 b , 4 b and 4 b show cross-sections through the elastomeric shaped part.
[0048] The elastomeric shaped part contains a cuboid recess ( 31 ) for a cuboid fluidic component. The cross-section in FIG. 3 a runs along the line A-A in FIG. 3 a ; the line A-A runs perpendicularly to the longer side of the recess ( 31 ). The cross section in FIG. 4 b runs along the line B-B in FIG. 4 a ; the line B-B runs perpendicularly to the shorter side of the recess ( 31 ). The cross section in FIG. 5 b runs along the line C-C in FIG. 5 a ; the line C-C runs diagonally to the recess ( 31 ). The line of intersection ( 32 ) of the chamfer ( 8 ) with the recess ( 31 ) runs at a constant level. The angle of inclination (measured from the main axis of the component) of the chamfer ( 8 ) is at its greatest in FIG. 3 b and at its smallest in FIG. 5 b , and in FIG. 4 b the angle of inclination has an intermediate value.
[0049] FIG. 6 shows a cross section through the assembled holder which is mounted on a container for a fluid. The holder ( 1 ) contains in its recess an elastomeric shaped part ( 4 ) with the fluidic component ( 5 ). A mating part ( 9 ) is located on the edge of the holder. The projection ( 11 ) on the mating part ( 9 ) projects into the recess in the holder ( 1 ) and has deformed the elastomeric shaped part ( 4 ). The side ( 61 ) of the elastomeric shaped part exposed to the fluid is convex, but the deformed elastomer does not extend right up to the nozzle structure in the fluidic component. The dotted lines ( 64 a ) and ( 64 b ) indicate the contour of the chamfered shaped part ( 4 ) before the assembly of the holder. The dead volume ( 63 ) serves to equalize the tolerances during the assembly of the holder; it has been reduced to the minimum. The holder is secured to the mating part ( 9 ) and to the housing ( 65 ) for the fluid by a union nut ( 62 ). The direction of flow of the fluid is indicated by arrows. The low pressure end of the holder is located in the surface which contains the nozzle aperture ( 6 ). The high pressure in the fluid acts in the channel structure within the fluidic component ( 5 ), within the dead volume ( 63 ), within the bore ( 10 ) in the mating part ( 9 ) and within the housing that contains the fluid.
[0050] FIGS. 7 a , 7 b , 7 c show the holder according to the invention in cross-hatched cross-section and FIGS. 8 a , 8 b , and 8 c compare it with the embodiment in the cross-hatched cross section according to the prior art.
[0051] FIG. 7 a shows a chamfered elastomeric shaped part ( 4 a ) with a fluidic component ( 5 ) inserted therein before the assembly of the holder according to the invention. The elastomeric shaped part is almost as high as the fluidic component at its outer edge but lower in the area of contact with the fluidic component at the recess. The elastomeric shaped part is still un-deformed and is not yet under internal tension. FIG. 7 b shows the situation after the insertion of a ring ( 71 ), causing the elastomeric shaped part ( 4 b ) to be deformed and internal tension to be produced inside the elastomeric shaped part. The deformed elastomeric shaped part ( 4 b ) extends over the fluidic component as far as its upper edge. The convexity of the elastomeric shaped part scarcely projects beyond the height of the fluidic component. FIG. 7 c shows the deformed elastomeric shaped part ( 4 c ) after the assembly of the holder. The inserted projection ( 11 ) has deformed the elastomeric shaped part ( 4 c ). A small dead volume ( 63 ) is present between the deformed elastomeric shaped part ( 4 c ) and the base of the mating part.
[0052] FIG. 8 a shows a (non-chamfered) elastomeric shaped part ( 74 a ) with a fluidic component ( 5 ) inserted therein before the assembly of the holder according to the prior art. The elastomeric shaped part is lower than the fluidic component. The elastomeric shaped part is un-deformed and is not under internal tension. FIG. 8 b shows the situation after the addition of a ring ( 71 ) which prevents the elastomeric shaped part ( 74 b ) from falling out of the holder or from sliding inside the holder but does not deform the elastomeric shaped part. FIG. 8 c shows the un-deformed elastomeric shaped part ( 74 c ) after the assembly of the holder using a mating part ( 9 ), on which an annular projection ( 11 ) is provided. The dead volume ( 75 ) in FIG. 8 c is larger than the dead volume ( 63 ) in FIG. 7 c.
Example
Mount for an Atomizer Nozzle of Miniature Construction
[0053] This device consists of a cylindrical holder made of steel with an external diameter of 6.0 mm and a height of 2.6 mm. It contains a truncated cone-shaped recess with an internal diameter of 4.0 mm at the base of the truncated cone. The base of the holder contains a bore 0.8 mm in diameter. The base of the holder is 0.4 mm thick in the vicinity of the bore.
[0054] The outer contour of the elastomeric shaped part made of silicon rubber is cylindrical. Before it is inserted in the holder the cylinder has a diameter of 4.2 mm and is 2.1 mm high on its outer surface. It contains a symmetrically arranged recess 1.3 mm wide and 2.8 mm long which passes axially through the elastomeric shaped part.
[0055] The elastomeric shaped part is chamfered towards the recess at its high pressure end. The chamfer begins in the cover surface of the cylinder over a circle with a diameter of 3.2 mm. The chamfer runs at different inclinations towards the rectangular recess to a constant depth of 0.7 mm at the line of intersection with the recess.
[0056] The fluidic component is constructed as an atomizer nozzle. The nozzle is a cuboid made up of two sheets of silicon and is 1.4 mm wide, 2.7 mm long, and 2.1 mm high. In the contact surface of the sheets the nozzle contains a recess which is provided with a micro-engineered filter and a micro-engineered evaporation device. On the side of the nozzle where the fluid leaves the nozzle, the recess merges into two channels each of which is 8 μm wide, 6 μm deep, and about 200 μm long. The axes of the two channels are located in one plane and are inclined at about 90 degrees to one another. The two nozzle apertures are spaced from one another by about 100 μm on the outside of the atomizer nozzle.
[0057] The essentially cylindrical mating part is provided with an annular projection on its side facing the holder. The projection has an external diameter of 3.15 mm, an internal diameter of 2.9 mm, and a constant height of 0.6 mm. The mating part contains an axial bore 0.4 mm in diameter.
[0058] The device is secured to the mating part by means of a union nut. The mating part is part of a container which contains the liquid to be atomized. The liquid is conveyed from the container to the atomizer nozzle by means of a miniaturized high pressure piston pump in amounts of about 15 microliters.
[0059] The peak value of the fluid pressure inside the atomizer nozzle is about 65 MPa (650 bar) and falls back to virtually normal air pressure (about 0.1 MPa) after the end of the atomization. | A fluidic component is arranged in an elastomeric shaped part the contour of which is matched to the outer contour of the component and to the inner contour of a holder. The elastomeric shaped part is chamfered towards the fluidic component on its pressure side. When the holder is assembled the elastomeric shaped part is deformed by a projection provided on a mating part and is put under uniformly distributed internal tension, after which the elastomeric shaped part surrounds the fluidic component to its full height. | 8 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a process and apparatus for removing chemical contaminants from soil, and more particularly to a process and apparatus in which vacuum extraction is used to remove contaminants in both liquid and gaseous phases. The invention relates to a process and apparatus for (1) the removal from soil of volatile organic compounds, (2) continuous and simultaneous remediation of the treated soil and (3) the removal of ground water and suspended or dissolved contaminants.
Contaminants may exist in subsurface soil in the liquid or vapor phase as discrete substances and mixed with and/or dissolved in ground water and soil gases. Such contaminants may be found and dealt with in accordance with this invention in the vadose (unsaturated) zone found between the surface of the earth and the water table, at the interface between the vadose zone and the water table, and in the saturated zone below the water table.
2. Description of the Prior Art
At many industrial and commercial facilities and at waste handling and disposal sites, soil and ground water are contaminated with suspended or water-soluble chemicals, or both.
A variety of techniques have been used for removal of soil contaminants and remediation of affected soil. One common technique involves the excavation and off-site treatment of the soil. Another technique involves saturating the contaminated soil with water in situ, causing the contaminants to be slowly leached from the soil by the water. The contaminated water can then be removed.
Techniques have also been proposed for removing volatile organic contaminants from soil by vacuum extraction. For example, in U.S. Pat. No. 4,323,122, it was proposed that a vacuum be applied in a borehole at the level of the water table, the assumption being that a contaminant such as gasoline, which is lighter than water for example, would float on the water table and present a layer which could be drawn off by vacuum applied to the liquid at or around that level.
Others have suggested the possibility of venting soil above the water table (i.e., in the vadose zone) to cause vaporization of the contaminant in the soil, and then drawing off the contaminant in the vapor phase. Thus, conventional vacuum extraction systems are designed to clean the vadose zone by applying vacuum to draw air through the soil through wells having screening which does not extend below the water table. Ground water requiring treatment is in such processes conventionally removed by pumping from separate conventional water wells. In situations in which water does flow into vacuum extraction wells, it has been suggested that a second, liquid phase pump be placed either in the well or at the surface to remove the water through a second conduit. Thus, conventionally, water wells separate and apart from vacuum extraction wells may be required at a given site, and water pumps in addition to vacuum generation devices may be employed. In accordance with the present invention, which exploits two phase vacuum extraction, a single vacuum device removes contaminants in both the water and the soil gases by way of a single conduit formed by the well casing.
SUMMARY OF THE INVENTION
The present invention involves a process and apparatus for two phase removal of contaminants from the soil, in which contaminants are typically present in the vadose zone and below the water table. The process involves the steps of providing a borehole in the contaminated area; placing in the borehole a riser pipe, the riser pipe preferably being so constructed as to admit fluids both from the vadose zone and from below the natural water table; applying a vacuum to the riser pipe so as to draw soil gases and entrained liquid into the riser pipe and to transport both the gases and the liquid to the surface; separating the liquid and the gases, and separately subjecting the separated liquid and gases to appropriate treatment. Treated water may be returned to the soil or disposed of in conventional ways. In one embodiment of the invention (which constitutes the best mode contemplated for carrying the invention into effect), the well casing is constructed with perforations (screening) extending below the natural water table and also upward into the unsaturated (vadose) zone. The unsaturated zone may be the natural vadose zone lying above the natural water table, or an expanded "artificial" vadose zone created when removal of the ground water through the extraction well causes local lowering of the water table. Placing of the screening so that it extends into the vadose zone allows soil gases, including contaminants in the vapor phase, to be drawn into the well under the influence of a vacuum generator. The gases, it has been found, entrain the liquid phase, so that both phases may be transported to the surface together in a common stream. At the surface, the two phases are separated in a vapor-liquid disengaging vessel, such as a cyclone separator, knock-out pot or other suitable component, and after separation the phases may individually be routed to systems for contaminant removal by further treatment steps. Suitable processes for contaminant removal include filtration, adsorption, air stripping, settling, flocculation, precipitation, scrubbing and the like.
As an alternative, the treatment well may be constructed so that screening is at all times is below the water table, even in the situation in which removal of water causes local depression of the water table. In such an arrangement, the fluid transported to the surface would predominantly be in the liquid phase, although it may still be necessary to provide vapor-liquid separation and individual phase treatment at the surface to deal with phase transformation which may occur as a result of turbulence and pressure reduction at the suction side of the vacuum device.
Two phase vacuum extraction in accordance with the present invention improves over known soil and ground water remediation vacuum extraction techniques by simplifying equipment requirements and increasing the rate of recovery of ground water. Unlike the prior art, water wells and pumps distinct from the extraction well are not required. A single vacuum device serves to remove contaminants in both the vapor and liquid phases, using a single conduit.
BRIEF DESCRIPTION OF THE DRAWINGS
There is seen in the drawings a form of the invention which is presently preferred (and which represents the best mode contemplated for carrying the invention into effect), but it should be understood that the invention is not limited to the precise arrangements and instrumentalities illustrated.
FIG. 1 is a side elevation view, in cross-section, illustrating somewhat schematically an arrangement for two phase vacuum extraction for removal of contaminants from a contaminated area of the ground.
FIG. 2 is a schematic view of apparatus for the handling and treating of materials removed from the ground by two phase vacuum extraction.
FIG. 3 is a cross-sectional view, in side elevation, of an extraction well which may be used with the apparatus of FIG. 1.
FIG. 4 is a cross-sectional view, also in side elevation of, an air inlet well intended for use in the present invention.
DETAILED DESCRIPTION
Referring now to FIG. 1, there is seen schematically a system, designated generally by the reference numeral 10, for two phase vacuum extraction and treatment in accordance with the invention. Seen in FIG. 1 is a source 12 of volatile contaminants, creating a plume 14 of absorbed or suspended contaminants in the soil 16 of the vadose (unsaturated) zone. The contaminants making up the plume 14 tend to leach or percolate downwardly toward the natural water table 18. Components lighter than water and not dissolved are depicted by the reference numeral 20, and tend to float at the top of the water table. Dissolved contaminants and free-phase contaminants lighter than water tend to percolate downwardly in a plume 22 below the water table 18, and free-phase components 24 heavier than water tend to migrate downwardly to the aquitard 26.
An extraction well, designated generally by the reference numeral 28, and which will be described in greater detail shortly, is sunk in the area of the plume 14 and extends through the vadose zone and below the natural water table 18. Spaced from the extraction well 28 are air inlet wells, designated by the reference numeral 30, and which will also be described in greater detail. Air inlet wells 30, it will be understood, are best disposed at spaced locations around the perimeter of the plume 14. Those skilled in the art will appreciate that the number and spacing of the air inlet wells 30 with respect to the plume 14 and extraction well 28 will depend upon the size of the plume 14, as well as the composition and permeability of the soil to be treated.
Associated with the extraction well 28 is a vacuum extraction system, designated by the reference numeral 32. Gases removed by the vacuum extraction system 32 may be vented to atmosphere at 34 if within acceptable environmental limits, or further processed such as by being incinerated or passed to a condenser, granular activated carbon filter, or other such component 36. The component 36 serves to remove contaminants from the extracted gases. Water extracted by the process may be treated by passing it through conventional systems for metals removal, volatile organic compound removal, or other steps of purification. The treated and purified water, if it is of sufficient purity at this stage, may be returned to a sewer or directly to the ground as indicated at 38. Contaminants may be stored in drums 40 for eventual destruction or further processing.
Referring now to FIG. 3, the extraction well 28 will be described in greater detail. The extraction well 28 in the illustrated form of the invention includes an elongated borehole 42, into which there is placed a riser pipe 44. The riser pipe 44 includes an inperforate upper portion 46 and a perforate (screened) lower portion 48. In one operative example, the riser pipe 44 is of four inch diameter PVC, capped at the bottom, and the screen consists of 0.010 inch slots. In the operative example, the riser pipe 44 was approximately twenty feet in length, with the lower fifteen feet comprising the slotted lower portion 48 and the upper five feet the imperforate upper portion 46. The upper end of the riser pipe 44 is here shown to be is associated with a concrete floor or deck, and is provided with a suitable pipe fitting 52, enabling the riser pipe 44 to be coupled in fluid communication to the remainder of the vacuum extraction system 32 (not seen in FIG. 3). The upper portion 46 of the riser pipe 44 is surrounded by a low permeability grout, such as bentonite cement 54, and below the grout 54 by a bentonite seal 56. The area within the borehole 42 surrounding the slotted lower portion 48 of the riser pipe 44 and part of the upper portion 46 above the slotted lower portion 48 is packed with fine screened sand, to facilitate the flow of gas and liquid from the surrounding soil into the riser pipe 44. In a preferred form of the invention, the extraction well 28 is constructed so that the screened lower portion 48 extends below the natural water table and upwardly into the vadose zone. The vadose zone into which the screened lower portion 48 extends may be the natural water table 18, or the expanded artificial vadose zone created when prolonged removal of ground water through the extraction well causes local lowering of the water table as indicated by the reference numeral 18' in FIG. 3. Placement of the screened lower portion 48 of the riser pipe 44 as indicated above allows soil gases (the vapor phase) to be drawn into the well under the influence of vacuum created by the extraction system 32 and to entrain the liquid phase so that both phases may be transported to the surface together. As will be explained, at the surface, the two phases may be separated and differently treated.
Alternatively, the extraction well 28 may be so constructed that the screening of the lower portion 48 is entirely submerged, i.e., disposed below the natural or actual water table, even after withdrawal of water from the aquifer under the influence of the vacuum extraction system 32. In the latter case, the fluid transported to the surface would be predominantly in the liquid phase.
Referring now to FIG. 4, there is seen an example of an air inlet well 30. The air inlet well 30 comprises a borehole 58, which receives a pipe 60. The pipe 60 in one operative embodiment comprises a four inch diameter PVC pipe, capped at the bottom, and having a screen of 0.010 inch slots. The pipe 60 is surrounded at its upper end by a cement collar 62, extending to the ground surface 64. Suitable caps 66 and covers 68 may be provided in association with the collar 62 to selectively cap or cover the injection well as desired. Surrounding a medial portion 70 of the pipe 60 within the borehole 58 is a bentonite slurry 72, which provides a gas-tight seal between the pipe 60 and the borehole 58. The slotted lower portion 74 of the pipe 60 is surrounded by gas-permeable packed sand 76. As will now be apparent, the pipe 60 facilitates the injection of air into the zone surrounding the plume 16.
Referring now to FIG. 2, the vacuum extraction system 32 and the steps and apparatus for treating extracted material will now be described in greater detail. Referring to FIG. 2, a vacuum pump 78, driven by electric motor 80, is in fluid communication through a pipe 82, knock-out pot 84 and pipe 86 with the extraction well 28. The knock-out pot 84 may be of conventional design, familiar to those skilled in the art.
The knock-out pot 84 serves to separate the two phases emerging from the extraction well 28, enabling them to be subjected to appropriate further processing. In this regard, a pipe 88 is provided in association with the knock-out pot 84, to conduct effluent in the liquid phase through filtration and stripping steps. Filtration is provided in the illustrated embodiment by parallel bag filters 90 and 92 which may alternately or simultaneously be used in a conventional manner. Cut-off valves, omitted in the drawings for clarity permit either filter 90, 92 to be isolated, and each bag removed, cleaned or replaced. Suitable pressure guages, not shown may be placed on the suction and discharge sides of the bag filters 90 and 92 to indicate bag loading. In one operative embodiment, the bag filters 90 and 92 were 50 micron nylon filters, sold by Rosedale Products, Incorporated, capable of passing 222 gpm at 150 psi. Other equivalent separation techniques and apparatus may be used.
A pump 94, for erosion resistance preferably of the single stage progressive cavity (screw) type, serves to draw off the liquid phase effluent of the knock-out pot 84. One suitable pump is sold by the Nemo Pump Division of Netzsch Incorporated, of Exton, Pa., Model Ne-30A. Here, too, other suitable apparatus may be used.
In the illustrated embodiment, the liquid phase is fed from the pump 94 through a pipe 96 to an air stripper assembly 98, the function of which is to remove from the effluent volatile organic compounds. A blower 100 associated with the air stripper assembly 98 delivers a flow of warm air through the housing of the air stripper assembly 98, carrying off the volatile organic compounds through the vent 102 to atmosphere or further processing (not shown). A transfer pump 104, discharging to a pipe 106, serves to transport liquid from the sump of the air stripper assembly 98 for further processing. The transfer pump 104 may be turned off in response to a low level switch 108 associated with the air stripper assembly 98. A high level switch 110 associated with the air stripper assembly 98 controls the pump 94 in response to high water level in the air stripper assembly 98. The air stripper assembly 98 may be a conventional "off-the-shelf" unit, familiar to those skilled in the art.
The air stripper assembly 98 may, if desired, be omitted, and the effluent of the pipe 96 joined with the effluent of the pipe 120. In one pilot installation, it was found that the reduction in the concentration of volatile organic contaminants between the local ground water and the effluent of the pipe 96 is significant, approximately 98.7%, thus rendering the air stripper assembly unnecessary. It is hypothesized that the intimate mixing of the air and water during extraction (at which time ground water is extracted in a low pressure air stream) allows the volatile compounds to come out of solution, thus obviating the need for later air stripping.
Avoidance of the need for an air stripper assembly 98 also reduces the total volume of air streams bearing volatile organic compounds. In situations in which air emissions must be controlled, this is a distinct advantage. Another advantage of the two-phase vapor extraction process, as practiced without additional air stripping, is that due to the low pressure at which the vapor/liquid mixing and separation are accomplished, there is no less oxygenation of the water than would result from conventional air stripping. It is to be expected that lower dissolved oxygen levels will result in less corrosion and fouling of downstream components of the apparatus.
Referring again to FIG. 2, the processing of the vapor phase effluent from the knock-out pot 84 will now be described.
As indicated above, under the influence of the vacuum pump 78, the vapors separated from the two-phase effluent from the extraction well 28 (not seen in FIG. 2) are drawn through the pipe 82 to the vacuum pump 78. In the illustrated form of the invention, the vacuum pump 78 is of the liquid ring type, and is provided with a make up water line 112, served by a domestic supply. The make up water line 112 is provided with a solenoid actuated valve 114 responsive to the high water level switch 110 of air stripper assembly 98.
The pump 78 exhausts to a vapor/liquid separator 116, the vapor effluent of which is conducted to atmosphere, or if appropriate to further processing through a pipe 118. The bulk of the liquid effluent from the vapor liquid separator 116 passes through a pipe 120 to a sump 122, where it joins the effluent of the pipe 106, the liquid output of the air stripper assembly 98. A fraction or all of the liquid effluent of the vapor liquid separator 116 may be drawn off through a line 124 to join the flow in the make up water line 112 servicing the liquid ring pump 78.
A pump 126, controlled by a low level cut-off switch 128, draws liquid from the sump 122 and propels it through a pipe 130 for further processing. In the illustrated embodiment, the liquid is passed in two stages through cannisters 132 and 134 containing granular activated carbon. Other contaminant removal steps or techniques may be used. The treated water emerges through a pipe 136 and is of sufficient purity to allow its return to the soil or a sewer without further treatment.
As was mentioned above, a major advantage of the application of two phase vacuum extraction in accordance with the present invention is that the rate of production of groundwater may be significantly increased over conventional single phase flow rates. By applying vacuum to the subsurface using the extraction well 28 and vacuum extraction system 32 as described above, water is drawn from the soil by the fluid dynamic effects of sweeping air and soil gases over the aquifer surface toward the well and also by the artificial creation of a low head (water pressure) inside the riser pipe 44. The low head in the riser pipe 44 makes it, in effect, a low point in the hydraulic system so that water in the surrounding soil readily flows to it.
Artificially increasing the rate of production of groundwater over what can be achieved with conventional pumps is especially beneficial in subsurface formations through which natural recharge is slow. In addition to increasing the size of the groundwater capture zone around the extraction well 28, operation of the above-described apparatus 10 depresses the natural water table, thereby increasing the volume of the vadose zone which is subject to clean up by the vapor extraction mechanism generated by the apparatus 10. Tangible benefits are shortening of the duration of the treatment time and reduction of the cost of the overall contaminant removal effort.
In one pilot installation, over a four month trial period, operation of the apparatus 10 caused the local water table to be lowered by over twelve feet while the pressure in the immediate vicinity of the extraction well 28 dropped over 18 in. Hg. The yield of ground water from this well was found to be 3.3 GPM, an improvement over a yield of 0.3 GPM using conventional pumping from the same well. In this installation, which employed a riser pipe 44 of four inches in diameter and a perforated length of approximately 20 feet, average daily mass flow of contaminants TCE and 1,2-DCE was approximately 4.4 lbs. in the vapor phase. Simultaneously, approximately 23 lbs. per day of TCE and 1,2-DCE were removed from the recovered groundwater when pumping at a volume of 3.3 GPM.
Soil sampling adjacent to the three air inlet wells 30 used showed a decrease in the concentration of volatile organic compounds from 3.44×10 4 ug/kg to 3.65×10 2 ug/kg. This decrease in contamination was observed at depths of 5-7 feet. It was also found that the drawn down in the overburden aquifer ranged from 0.1-9.37 feet below static water level, further evidence of the influence of the apparatus 10, while the radius of the cone of depression around the extraction well 28 approximated 100 feet. Draw downs in the bedrock aquifer were found to be neglible during the same period. The capture zone in the overburden aquifer was demonstrated to extend approximately 200 feet radially crossgradient of natural groundwater flow and 125 feet downgradient.
The present invention may be embodied in other specific forms without departing from its spirit and essential attributes. Accordingly, reference should be made to the appended claims rather than the foregoing specification as indicating the scope of the invention. | A process for two phase vacuum extraction of contaminants from the ground involves vacuum withdrawal of liquid and gaseous phases as a common stream, separation of the liquid and gaseous phases, and subsequent treatment of the separated liquid and gases to produce clean effluents. Two phase vacuum extraction employs a single vacuum generating device to remove contaminants in both the liquid stream and soil gases through a single well casing. | 4 |
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates generally to gas compressors. More particularly, the present invention relates to a clutch assembly for a gas compressor of the type having eccentric drives.
2. Disclosure Information
A conventional rotary compressor is constructed so that a crankshaft having an eccentric part is driven in a cylinder by a motor. A rolling piston fitted to the eccentric part compresses refrigerant gas inducted into the cylinder. A compression chamber is formed inside the cylinder between its axial ends and a vane, which is slidably held in the cylinder and has an end portion contacting the outer surface of the rolling piston. Rotary compressors of this general type are well known in the art.
A scroll-type gas compressor is described in U.S. Pat. No. 4,781,549. This compressor includes symmetrical scroll members encircling one another in one wrap. The ends of the wrapped members provide continued sealing between the scroll members.
As is also well known in the art, each of these compressors includes a crankshaft drivably connected to a power source, such as the vehicle engine. Typically, an endless belt connects the crankshaft of the compressor to the automotive engine so that the crankshaft of the compressor produces torque which drives the orbiting or rotating elements of the compressor. In order to prevent continuous transmittal of torque through the compressor, friction clutches have long been proposed which selectively enable the transmission of torque from the vehicle engine to the crankshaft of the compressor. These friction clutches, typically involving an electromagnetic clutch assembly which engages the crankshaft of the compressor upon the need for air conditioning in the vehicle are well known in the art. However, these electromagnetic friction clutches are often noisy, complex and add cost and weight to the compressor. It would, therefore, be desirable to find an alternative type of clutch assembly for transmitting torque from the vehicle engine through to the orbiting elements of the compressor.
SUMMARY OF THE INVENTION
The present invention overcomes the disadvantages of the prior art by providing a clutch apparatus for a compressor of an air conditioning system in an automotive vehicle. The clutch apparatus of the present invention comprises a crankshaft drivably connected to a power source at one end thereof and defining a chamber at an opposite end thereof and an eccentric operative to engage an orbiting ring within the compressor so as to cause rotation of the ring. The eccentric is rotatable relative to the crankshaft and is slidably received in the chamber of the crankshaft. The eccentric defines a blind bore of predetermined shape at one end thereof. The clutch apparatus further includes a plunger disposed within the crankshaft, the plunger including a head portion and a shaft portion. The head portion is disposed in the chamber of the crankshaft and matingly engages the bore in the eccentric. The plunger shaft is axially reciprocal in the crankshaft. The clutch apparatus further includes means for axially reciprocating the plunger shaft in the crankshaft so as to cause engagement and disengagement of the plunger head portion into the blind bore of the eccentric. In this manner, the crankshaft transmits torque to the eccentric to rotate the orbiting ring upon engagement of the head portion into the blind bore upon actuation of said means and the crankshaft rotates freely relative to eccentric upon de-actuation of the means for axially reciprocating the plunger shaft.
In one embodiment, the means for axially reciprocating the plunger shaft portion in the crankshaft includes a linkage assembly connected to the plunger shaft. The linkage assembly is operatively associated with a coil of current-carrying wire disposed in the crankshaft and electrically connected to an electrical power source such that under a current from an electrical power source in the vehicle, such as the vehicle battery, the coil causes the linkage assembly to reciprocate, which in turn causes the plunger head to axially move relative to the crankshaft to engage the blind bore of the eccentric.
It is an advantage of the present invention to provide a clutch apparatus for a rotary compressor which has simple construction, is more compact and is quieter than previously known friction drive clutches. These and other objects, features and advantages of the present invention will become apparent from the following drawings, detailed description and claims.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an exploded, perspective view of a compressor structured in accord with the principles of the present invention.
FIG. 2 is a perspective view of a clutch apparatus of the present invention.
FIGS. 3A-C are cross-sectional views of the clutch apparatus of FIG. 2 in various stages of operation in accordance with the principles of the present invention.
FIG. 4 is a cross-sectional view taken along line 4--4 of FIG. 3A.
FIG. 5 is a cross-sectional view of an alternative embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The clutch apparatus of the present invention can be utilized with any type of drive mechanism for causing relative motion between a driving and driven member, the drive mechanism having an eccentric offset from the axis of its crankshaft. The present invention has particular utility in a rotary or scroll type compressor having an eccentric with an axis offset from the axis of the crankshaft, especially in the rotary compressor described in U.S. Pat. No. 5,135,368, assigned to the assignee of the present invention and to which the description of the present invention pertains. It should be apparent that the present invention is not meant to be limited solely to the rotary compressor described herein, but applies equally to other types of compressors as well.
Referring first to FIG. 1, the housing of a gas compressor includes a front head 10, center housing 12, rear gasket 16 and rear head 18. These components and rear plate 14 are mutually connected by passing tension bolts 20 through four aligned bolt holes formed in each of the components and by engaging threads tapped in the rear head. Dowel pins 22, 23 located within alignment holes 24, 25 establish and maintain the angular position of the front head relative to the center housing. Dowel pins 26, 27 located within holes 28, 29 in the rear face of the center housing, the rear plate gasket and front face of the rear head establish and maintain the angular relative position among these components. While dowel pins are described for locating the components relative to one another, other means for locating components are well within the knowledge of one of ordinary skill in the art.
The front head includes a cylindrical bore 30 having a small diameter sized to receive a hydraulic seal 32 and a larger diameter sized to receive roller bearing 34. The bearing rotatably supports a crankshaft 36, which includes a splined surface 38 for drivably connecting the crankshaft to the sheave of a drivebelt assembly, a cylindrical shoulder 40 fitted within the bearing concentric with axis A--A, eccentric 42 having a cylindrical surface whose axis B--B is offset radially from axis A-A, and a large cylindrical surface coaxial with A--A.
An orbiting ring 46 includes a cylindrical outer surface 48 coaxial with B--B, a cylindrical boss joined by a web to the outer surface defines a central bore 54 concentric with axis B--B. Bushing 56 is fitted within bore 54 and rotatably supports eccentric 42 on the orbiting ring. Other types of bearings are also possible for rotatably and axially supporting the crankshaft and the orbiting ring.
The compressor also includes a center housing 12 having a cylindrical inner surface 58 on which the outer cylindrical surface 48 of the orbiting ring rolls, a suction passage 62 through which incoming low pressure gas flows, and outer vane slots 64, 66 in which vanes 74, 76 slide into contact with the outer surface of the orbiting ring. Inlet passages 68, 70, communicating respectively with passages 62, 63, carry refrigerant at suction pressure to inlet pockets 72, 73 formed on the lateral, inner faces of the outer vanes 74, 76, respectively.
The rear plate 14 of the compressor includes a post 78 having an outer cylindrical surface 80 coaxial with axis A--A, sized to fit within the orbiting ring and located within center housing 12. The post contains a transverse diametric slot 82, within which internal vanes 84, 86 are mounted for sliding radially directed movement into contact with the inner surface of the orbiting ring. The rear plate also includes a suction passage 88 aligned with passage 62, first stage-discharge passages 90, 92, intermediate or second-stage inlet passages 94, 96, and second stage discharge passages 98, 100.
A valve plate 102, formed of spring steel, seats within a circular recess formed on the rear face of head 14 and defines four reed valves: first and second first stage discharge valves 104, 106 for opening and closing passages 90, 92; and first and second second stage discharge valves 108, 110 for opening and closing passages 98, 100. The reed valves operate on the basis of pressure difference across the valves to open and close corresponding passages. The valves open by bending valve tabs 104, 106, 108, 110 through their thicknesses of the spring steel sheet. As the pressure difference across the valve declines, the degree to which the corresponding passages are opened by the valve decreases due to resilience of the steel sheet and its tendency to close the corresponding passage when the pressure difference is removed.
Located between the adjacent faces of the rear head and rear plate, gasket 16 seals the periphery of the four tension bolt holes, and two dowel holes and the passages opened and closed by the four reed valves, viz. the intermediate pressure passage and inlet or suction passages.
The rear head 18 also includes a suction port 112, a suction passage (not shown) aligned and communicating with suction passage 88 and 62, and discharge port 116 communicating with the interior waist of the cylinder integrally cast with the body of the rear head. As fully explained in the '368 patent, the disclosure of which is hereby incorporated by reference, first stage discharge pressure gas flows through passages defined by the waist of cylinder. These passages are aligned with intermediate pressure passages 94, 96 formed through the thickness of rear plate 14 and the length of post 78, through which gas compressed in the first stage is carried to and enters the second stage. The interior volume of cylinder 118 is divided by the baffle into two portions, each portion communicating with second stage discharge passages 98, 100. The slots in the baffle provide means for passages 98, 100 to maintain communication with discharge port 116 through which gas at discharge pressure leaves the compressor as is more fully explained in the '368 patent.
Referring now to FIGS. 2 and 3A, the clutch assembly of the present invention includes crankshaft 36 having a splined or keyed surface 38 at one end thereof which is drivably engageable with the vehicle engine such as through a pulley and endless belt arrangement as is known in the art. The crankshaft 36 includes a generally cylindrical bore 122 disposed therethrough which terminates in a chamber 124 at an end of the crankshaft opposite the splined surface end. The chamber is a generally cylindrical area which houses the eccentric 42 therein. The eccentric 42 can move axially within the chamber either due to gas compression in the orbiting ring component of the compressor or due to other vibratory motions of the compressor. As can be seen, the axis of rotation of the eccentric, B--B is offset from the axis of rotation of the crankshaft (A--A).
Disposed within the cylindrical bore 122 of the crankshaft 36 is a plunger 126 and a secondary shaft 128. The secondary shaft 128 has a terminating end 129 which extends a predetermined distance from the terminating end of the splined surface portion of the crankshaft when the secondary shaft is in the position indicated in FIG. 3A. This is a position of non-engagement such that the crankshaft 36 rotates freely relative to the eccentric 42 and transmits no torque therebetween. The plunger 126 includes a head portion 130 and a shaft portion 132. The shaft portion 132 contacts the secondary shaft 128 upon actuation of the clutch assembly. The head portion 130 of the plunger 126 is frusto-conical-shaped and configured to matingly engage a frusto-conical-shaped blind bore 134 in the eccentric 42. The benefits of this shape will be described in greater detail below.
The clutch assembly further includes means for axially reciprocating the plunger shaft in the crankshaft to cause engagement of the plunger head 130 into the eccentric blind bore 134. In the embodiment shown in FIGS. 3A-C, the means includes a coil of current carrying wire 136 circumferentially surrounding the crankshaft 36, into which a generally cylindrical linkage assembly 140 projects. As shown in FIG. 4, the coil assembly 136 includes a fixed inner coil 137 and a fixed outer coil 139 which define a gap 141 therebetween. The linkage assembly 140 is disposed in gap 141 and interconnects the coil assembly with a terminating end 129 of the secondary shaft 128 disposed within the cylindrical bore 122 of the crankshaft 36. The linkage assembly is connected to the pulley 144 which in turn is connected to the crankshaft at 142 in a known manner. The linkage 140 also includes a plate member 146 which connects the terminating end 129 of the secondary shaft to the coil assembly 136. The coil assembly 136 is electrically connected to an electric power source, such as the vehicle battery 138 such that upon energization of the coil assembly 136, the linkage assembly is pulled into the coil assembly and thereby forcing the secondary shaft 128 into the cylindrical bore 122 of the crankshaft 36. When a current is not applied to the coil assembly 136, the crankshaft 36, pulley 144 and linkage assembly 140 rotate freely relative to the eccentric.
FIGS. 3A-C show the progressive steps of the engagement of the clutch assembly to transmit torque from the vehicle engine to the eccentric to cause rotation of the ring and subsequent compression of the gas within the compressor. FIG. A shows non-engagement of the clutch assembly relative to the eccentric 42. During the operation of the vehicle, when the compressor is not engaged, the eccentric 42 may shift axially within the chamber 124 due to gas pressure developed in the compressor such that the axis of rotation of the eccentric 42 (B--B) moves axially closer to the axis of rotation of the crankshaft (A--A). When air conditioning is needed within the vehicle, and the operation of the compressor is necessary, the power source 138 sends an electrical signal to coil 136 to energize the clutch assembly. Upon energization of the coil, the linkage assembly pushes the secondary shaft 128 into engagement with the shaft portion 132 of the plunger 126. As shown in FIG. 3B, the frusto-conical surface of the head portion 130 of the plunger contacts a side of the blind bore 134 of the eccentric and because of the ramped mating surfaces between the plunger head portion and the blind bore, the eccentric is forced into its design position as the plunger 126 is forced further into the blind bore 134. As shown in FIG. 3C, the plunger head portion 130 is fully engaged into the blind bore 134 of the eccentric and torque can now be transmitted from the crankshaft 36 to the eccentric 42 for operation of the compressor to compress the gas as has been described above. Appropriate seals may be placed between the moving portions of the clutch assembly to prevent leakage of gas therethrough.
FIG. 5 shows an alternative embodiment of the clutch apparatus of the present invention. In FIG. 5 like elements will be given like reference numerals. In this embodiment, the coil of current carrying wire 154 circumferentially surrounds the crankshaft 36 of the clutch apparatus. The plunger 126 and/or secondary shaft 128 are made from a magnetically responsive material such that energization of the wound wire coil causes the secondary shaft to engage the plunger (or the plunger itself if no secondary shaft is provided) to engage the frusto-conical shaped blind bore 134 in the eccentric. When current is interrupted to the wire coil, a return spring 150 and/or eccentric reaction forces causes the plunger 126 to retract into the crankshaft and the eccentric moves in the chamber 124 resulting in no load transmission through the shaft. A bearing member 152 is circumferentially disposed between the wound coil wire 136 and the crankshaft 36.
Various other modifications and alterations of the present invention will no doubt occur to those skilled in the art. For example, the pulley utilized for interconnecting the vehicle engine to the crankshaft could be sized smaller for better packaging such that the pulley would be disposed interior of the linkage assembly. The linkage assembly and coil assembly could be fixed relative to the rotating crankshaft such as to a portion of the compressor housing to reduce the number of rotating members within the compressor. Furthermore, it is contemplated that other means may be utilized to actuate the plunger into the eccentric. These include hydraulic pressure, gas pressure, cam actuation or direct mechanical actuation. Also, the shape of the plunger head may take any number of shapes known in the art. Those skilled in the art, in view of the present disclosure, will appreciate that numerous other alternative embodiments of the invention are within the scope of the following claims. | A clutch apparatus for a rotary compressor for an air conditioning system is disclosed including a crankshaft, an eccentric for engaging an orbiting ring within the compressor, and a plunger disposed within the crankshaft. The apparatus further includes a device for axially reciprocating the plunger in the crankshaft so as to cause engagement and disengagement of the plunger into the eccentric whereby the crankshaft transmits torque to the eccentric to rotate the orbiting ring within the compressor. | 5 |
Subsets and Splits
No community queries yet
The top public SQL queries from the community will appear here once available.